1 Firmware Update SIMATIC S7-1500

Unspecified Hardware Configuration

2
with SIMATIC S7-1500
Decentral Hardware configuration with
3 SIMATIC S7-1500 and ET 200SP via
PROFINET
Basics of FC Programming
4
with SIMATIC S7-1500

Basics of FB Programming
5
with SIMATIC S7-1500

SIMATIC S7 6
IEC Timers and IEC Counters
Multi-instances for SIMATIC S7-1500

Basics of Diagnostics with SIMATIC S7-

TIA Portal 7
1500
Programming
Diagnostics via the Web
8
with SIMATIC S7-1500

Analog Values
9
for SIMATIC S7-1500

Global Data Blocks

10
for the SIMATIC S7-1500

WinCC Advanced with

11
TP700 Comfort and SIMATIC S7-1500

PID Controller
12
for SIMATIC S7-1200/1500
Name:
Frequency converter G120 on
13
Course from: to: PROFINET with SIMATIC S7-1500

Instructor:
14
Location:

15

16
Training Document TIA Portal Version
 TIA Portal Module 001

Training Curriculum

TIA Portal Module 001

Firmware Update SIMATIC S7-1500

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 TIA Portal Module 001

Table of contents
1 Goal .......................................................................................................................................... 4

2 Requirement ............................................................................................................................. 4

3 Required hardware and software .............................................................................................. 4

4 Theory ...................................................................................................................................... 5

4.1 SIMATIC S7-1500 automation system ................................................................................. 5

4.2 Operator control and display elements of the CPU 1516F-3 PN/DP ........................................ 6

4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display ........................................... 6

4.2.2 Status and error displays ...................................................................................................... 6

4.2.3 Operator control and connection elements of the CPU 1516F-3 PN/DP behind the front
flap ........................................................................................................................................ 7

4.2.4 SIMATIC Memory Card (MC) ............................................................................................... 8

4.2.5 Mode selector ....................................................................................................................... 8

4.3 SIMATIC STEP 7 Professional V1X (TIA Portal V1X) programming software..................... 9

4.3.1 Basic settings for the TIA Portal ........................................................................................... 9

4.3.2 Setting the IP address on the programming device............................................................ 10

4.3.3 Setting the IP address in the CPU ...................................................................................... 14

Formatting the memory card in the CPU ............................................................................................ 16

4.3.4 Restoring the factory settings of the CPU .......................................................................... 17

Downloading a firmware update from the SIEMENS Support website .............................................. 18

Firmware update of the CPU .............................................................................................................. 25

4.3.5 Firmware update of the display........................................................................................... 29

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 TIA Portal Module 001

Firmware Update – SIMATIC S7-1500

1 Goal
This chapter will show how the firmware version of the CPU of a SIMATIC S7-1500 can be
checked and upgraded using the TIA Portal.

2 Requirement
No prerequisites have to be met for successful completion of this chapter.

3 Required hardware and software

1 Engineering station: requirements for hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVD)

2 SIMATIC STEP 7 Professional software in TIA Portal – V1X or higher

3 SIMATIC S7-1500 controller, e.g. CPU 1516F-3 PN/DP – Firmware V1.6 or higher
with memory card

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
1 Engineering station Professional (TIA Portal)
V14 or higher

4 Ethernet connection

3 SIMATIC S7-1500 controller

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 TIA Portal Module 001

4 Theory
4.1 SIMATIC S7-1500 automation system
The SIMATIC S7-1500 automation system is a modular controller system for the middle to upper
performance range.

A comprehensive range of modules is available to optimally adapt the system to the automation
task.

SIMATIC S7-1500 is the next generation of the SIMATIC S7-300 and S7-400 automation systems
with the following new performance features:

- Increased system performance

- Integrated motion control functionality

- PROFINET IO IRT

- Integrated display for machine-level operation and diagnostics

- STEP 7 language innovations while maintaining proven functions

The S7-1500 controller consists of a power supply ①, a CPU with integrated display ② and input
and output modules for digital and analog signals ③. The modules are mounted on a mounting
rail with integrated DIN rail profile ④. If necessary, communications processors and function
modules for special tasks such as stepper motor control are also used.

④
②
②
③
①
①

The system is programmed with the STEP 7 Professional software.

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 TIA Portal Module 001

4.2 Operator control and display elements of the CPU 1516F-3 PN/DP
The figure below shows the operator control and display elements of a CPU 1516F-3 PN/DP.

The arrangement and number of elements differ from this figure for other CPUs.

4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display

1) LED displays for the current operating mode and diagnostic status of the CPU
2) Display
3) Control keys

4.2.2 Status and error displays

The CPU comes with the following LED displays:

1) RUN/STOP LED (yellow/green LED)

2) ERROR LED (red LED)
3) MAINT LED (yellow LED)
4) LINK RX/TX LED for port X1 P1 (yellow/green LED)
5) LINK RX/TX LED for port X1 P2 (yellow/green LED)
6) LINK RX/TX LED for port X1 P1 (yellow/green LED)

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4.2.3 Operator control and connection elements of the CPU 1516F-3 PN/DP
behind the front flap

1) LED displays for the current operating mode and diagnostic status of the CPU

2) Display connection

3) Slot for the SIMATIC memory card

4) Mode selector

5) LED displays for the 3 ports of PROFINET interfaces X1 and X2

6) MAC addresses of the interfaces

7) Display connection

8) Slot for the SIMATIC Memory Card

9) Mode selector

10 LED displays for the 3 ports of PROFINET interfaces X1 and X2

11) MAC addresses of the interfaces

Note: The hinged front cover with the display can be removed and inserted during operation.

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4.2.4 SIMATIC Memory Card (MC)

A SIMATIC Micro Memory Card (MC) is used as the memory module for the CPUs. This is a
preformatted memory card that is compatible with the Windows file system. It is available with
various storage capacities and can be used for the following purposes:
- Transportable data storage medium

- Program card

- Firmware update card

For operation of the CPU, the MMC must be inserted because the CPUs have no integrated load
memory. A commercially available SD card reader is needed to write/read the SIMATIC memory
card with the programming device or PC. This allows files to be copied directly to the SIMATIC
memory card using Windows Explorer, for example.
Note: It is recommended that the SIMATIC Memory Card only be removed or inserted when the
CPU is in the POWER OFF state.

4.2.5 Mode selector

The mode selector allows you to set the operating mode of the CPU. The mode selector is
designed as a toggle switch with three switch positions.

Position Meaning Explanation

RUN RUN mode The CPU is executing the user program

STOP STOP mode The CPU is not executing the user program

MRES Memory reset Position for the memory reset of the CPU

You can also use the button on the CPU operator panel of the SIMATIC STEP 7
Professional V1X software in Online & Diagnostics to switch the operating mode (STOP or RUN).
The operator panel also contains an MRES button for performing a memory reset and displays
the status LEDs of the CPU.

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4.3 SIMATIC STEP 7 Professional V1X (TIA Portal V1X) programming

software
The SIMATIC STEP 7 Professional (TIA Portal) software is the programming tool for the following
automation systems:

- SIMATIC S7-1500

- SIMATIC S7-1200

- SIMATIC S7-300

- SIMATIC S7-400

- SIMATIC WinAC

SIMATIC STEP 7 Professional provides the following functions for plant automation:

- Configuration and parameter assignment of the hardware

- Specification of the communication

- Programming

- Testing, commissioning and service with operational/diagnostic functions

- Documentation

- Creation of visualizations for SIMATIC Basic Panels with the integrated

WinCC Basic software

- Visualization solutions for PCs and other panels can also be created with other WinCC
software packages

Support is provided for all functions through detailed online help.

4.3.1 Basic settings for the TIA Portal

® Users can specify their own default settings for certain settings in the TIA Portal. A few
important settings are shown here.

® In the project view, select the ® "Options" menu and then ® "Settings".

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 TIA Portal Module 001

® One basic setting is the selection of the user interface language and the language for the
program display. In the curriculums to follow, "English" will be used for both settings.

® Under ® "General" in "Settings", select "User interface language ® English" and "Mnemonic
® International".

Note: These settings can always be changed.

4.3.2 Setting the IP address on the programming device

You need a TCP/IP connection in order to upgrade the CPU of a SIMATIC S7-1500 controller
from the PC, the programming device or a laptop.
It is important that the IP addresses of both devices match for the computer and SIMATIC
S7-1500 to communicate with each other via TCP/IP.
First, we will show you how to set the IP address of a computer with the Windows 10 operating
system.

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 TIA Portal Module 001

® Select the network icon in the taskbar at the bottom and click ® "Network settings".

® In the network settings window that opens, click ® "Ethernet" and then on ® "Change
adapter options".

® Select the desired ® "LAN Connection" that you want to use to connect to the controller and
click ® "Properties".

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 TIA Portal Module 001

® Select ® "Properties" for ® "Internet Protocol Version 4 (TCP/IPv4)".

® You can now use the following IP address, for example ® IP address: 192.168.0.99 and enter
the following ® subnet mask 255.255.255.0. Accept the settings. (® "OK" )

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TIA Portal Module 001

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4.3.3 Setting the IP address in the CPU

Before a firmware update of the CPU can be performed, set the IP address of the
SIMATIC S7-1500 correctly so that the programming device can reach the CPU via TCP
(IP communication). The IP address of the SIMATIC S7-1500 is set as follows.

® Double-click the Totally Integrated Automation Portal to select it. ( ® TIA Portal V1X)

® Click ® "Online & Diagnostics" and open ® "Project view".

In the project tree under ® "Online access", select the network adapter that was set previously. If you
click ® "Update accessible devices", you will see the IP address (if previously set) or the MAC address (if
IP address not yet assigned) of the connected SIMATIC S7-1500. Select ® "Online & Diagnostics".

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 TIA Portal Module 001

® Under ® "Functions", you now find the ® "Assign IP address" item. Enter the following IP
address here (example): ® IP address: 192.168.0.1 ® Subnet mask 255.255.255.0. Next,
click ® "Assign IP address" and this new address will be assigned to your SIMATIC S7-1500.

® If the IP address was not successfully assigned, you will receive a message in the ® "Info"
window under ® "General".

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 TIA Portal Module 001

Formatting the memory card in the CPU

If the IP address could not be assigned, the program data on the CPU must be deleted. This is
accomplished in two steps: ® "Format memory card" and ® "Reset to factory settings".

® First, select the ® "Format memory card" function and press the ® "Format" button.

® Confirm the prompt asking if you really want to format the memory card with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

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 TIA Portal Module 001

4.3.4 Restoring the factory settings of the CPU

® Before you can reset the CPU, you must wait until the formatting of the CPU has finished.
Afterwards, you must select ® "Update accessible devices" and ® "Online & Diagnostics" of
your CPU again. To reset the controller, select the ® "Reset to factory settings" function and
then ® "Delete IP address" and click ® "Reset".

® Confirm the prompt asking if you really want to reset the module with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

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 TIA Portal Module 001

® Once the CPU has been reset, click ® "Update accessible devices" again. The MAC address
of the connected SIMATIC S7-1500 can now be seen. Select ® "Assign IP address" under
® "Functions" in ® "Online & Diagnostics". Enter the following IP address here (example): IP
address: 192.168.0.1 Subnet mask 255.255.255.0. Click "Assign IP address" and this new
address will be assigned to your SIMATIC S7-1500.

® You will receive a message regarding successful transfer of parameters in the ® "Info" ®
"General" window.

Downloading a firmware update from the SIEMENS Support website

You can download current firmware updates free of charge from the Industry Online Support of
SIEMENS AG.

® Open your choice of Internet browser and enter the address ®

"support.automation.siemens.com".

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® Select your desired language ® "Language" ® "English".

In "Searching for product information", enter the CPU for which you need a firmware update. For
example:® "S7-1500 CPU1516F"

® Under "Filter criteria for entries" select the "Entry type" ® "Download" and click the entry with
firmware updates for your CPU and the associated display in the selection list.

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 TIA Portal Module 001

Various updates are offered in the next window. Select the update for your CPU that is recommended for
the upgrade.

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 TIA Portal Module 001

® If you have not already registered, do so in the next window. (® "Yes I would like to register
now"), or if already registered – log in with your "Login" and "Password". (® "Login")

Enter the requested data for the registration, select the option "Download of export restricted software"

and then save the registration. (® ® "Save")

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TIA Portal Module 001

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 TIA Portal Module 001

® Return to the login. After login you can save the firmware update on your computer.
(® "Save as")

® Enter the desired memory location on your computer and click ® "Save".

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® Back on the Industry Online Support website of SIEMENS AG, you can select the firmware
update for your display. Select the update recommended for the upgrade. You can then save
the firmware update on your computer. (® "Save as")

Enter the desired memory location on your computer and click ® "Save".

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 TIA Portal Module 001

® Click the downloaded compressed files for your CPU and the display in Windows Explorer
and select ® "Extract All" for each compressed file.

Firmware update of the CPU

The files with the firmware update can be imported into the SIMATIC S7-1500 CPU as follows.

® In the project tree under ® "Online access", select the network adapter that was set
previously. If you click ® "Update accessible devices", you will see the IP address of the
connected SIMATIC S7-1500. Select ® "Online & Diagnostics". Under the "General" menu
item, you can check the current firmware in your CPU in "Diagnostics".

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TIA Portal Module 001

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 TIA Portal Module 001

In the ® "Functions" menu, change to ® "Firmware update" ® "PLC". In the ® "Firmware loader"
sub-item, click ® "Browse".

® Select the previously downloaded and extracted firmware file ® "6ES7 ***-*****-****.upd" on
your computer and click ® "Open".

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 TIA Portal Module 001

® The following dialog indicates whether your firmware file is compatible with your CPU. Now
start the update. (® "Run update")

® The progress of the update and its successful completion are indicated with the following
dialogs. Click ® "OK" to confirm.

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4.3.5 Firmware update of the display

Once the firmware of the SIMATIC S7-1500 CPU has been updated, it is advisable to update the
firmware of the display.

® In the project tree under ® "Online access", select the network adapter that was set
previously. If you click ®"Update accessible devices", you will see the IP address of the
connected SIMATIC S7-1500. Select ® "Online & Diagnostics" here. In the ®"Functions"
menu, change to ® "Firmware update" ® "Display". In the ®"Firmware loader" sub-item,
click ®"Browse".

® Select the previously downloaded and extracted firmware file ® "6ES7 ***-*****-****.upd" on
your computer and click ® "Open".

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 TIA Portal Module 001

® The following dialog indicates whether your firmware file is compatible with your display. Now
start the update. (® "Run update")

® The progress of the update and its successful completion are indicated with the following
dialogs. Click ® "OK" to confirm.

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 31

Training Curriculum

TIA Portal Module 002

Unspecified Hardware Configuration
with SIMATIC S7-1500

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 TIA Portal Module 002

Table of contents
1 Goal .................................................................................................................................................... 34

2 Prerequisite......................................................................................................................................... 34

3 Required hardware and software ....................................................................................................... 35

4 Theory................................................................................................................................................. 36

4.1 SIMATIC S7-1500 automation system ................................................................................ 36

4.1.1 Range of modules ............................................................................................................... 37

4.1.2 Example configuration ......................................................................................................... 39

4.2 Operator control and display elements of the CPU 1516F-3 PN/DP .................................. 40

4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display .......................................... 40

4.2.2 Status and error displays..................................................................................................... 40

4.2.3 Operator control and connection elements behind the front flap ........................................ 41

4.2.4 SIMATIC memory card ........................................................................................................ 41

4.2.5 Mode switch......................................................................................................................... 42

4.2.6 Display of the CPU .............................................................................................................. 42

4.3 Memory areas of the CPU 1516F-3 PN/DP and the SIMATIC memory card ..................... 44

4.4 STEP 7 Professional V1X (TIA Portal V1X) programming software ................................... 46

4.4.1 Project.................................................................................................................................. 46

4.4.2 Hardware configuration ....................................................................................................... 46

4.4.3 Central and distributed automation structure ...................................................................... 47

4.4.4 Planning the hardware......................................................................................................... 48

4.4.5 TIA Portal – Project view and portal view............................................................................ 48

4.4.6 Basic settings for the TIA Portal .......................................................................................... 49

4.4.7 Setting the IP address on the programming device ............................................................ 50

4.4.8 Setting the IP address in the CPU....................................................................................... 53

4.4.9 Formatting the memory card in the CPU ............................................................................. 55

4.4.10 Resetting the CPU to factory settings ...................................................................................... 56

5 Task .................................................................................................................................................... 58

6 Planning .............................................................................................................................................. 59

7 Structured step-by-step instructions ................................................................................................... 59

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 TIA Portal Module 002

7.1 Create a new project ........................................................................................................... 59

7.2 Read the hardware of the SIMATIC S7-1500...................................................................... 60

7.3 Configure the Ethernet interface of the CPU 1516F-3 PN/DP ............................................ 66

7.4 Configure the access level for the CPU 1516F-3 PN/DP.................................................... 67

7.5 Insert power module PM 190W 120/230VAC...................................................................... 68

7.6 Configure the address areas of the digital input and output modules ................................. 69

7.7 Save and compile the hardware configuration .................................................................... 69

7.8 Download the hardware configuration to the device ........................................................... 70

7.9 Checklist .............................................................................................................................. 76

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 TIA Portal Module 002

UNSPECIFIED HARDWARE CONFIGURATION –

FOR A SIMATIC S7-1500

1 Goal
In this chapter, you will first learn how to create a project. Next you will be shown in one part of
the task how you can use the TIA Portal to detect hardware already installed and add it to a
project. This hardware will then be configured.

The SIMATIC S7 controllers listed in Chapter 3 can be used.

2 Prerequisite
You do not need any previous knowledge from other chapters to successfully complete this
chapter. You only need an S7-1500 controller.

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 TIA Portal Module 002

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
1 Engineering station Professional (TIA
Portal) as of V1X

4 Ethernet connection

3 SIMATIC S7-1500 controller

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 TIA Portal Module 002

4 Theory
4.1 SIMATIC S7-1500 automation system
The SIMATIC S7-1500 automation system is a modular controller system for the middle to upper
performance range. A comprehensive range of modules is available to optimally adapt the system
to the automation task.

SIMATIC S7-1500 is the next generation of the SIMATIC S7-300 and S7-400 automation systems
with the following new performance features.

– Increased system performance

– Integrated motion control functionality
– PROFINET IO IRT
– Integrated display for machine-level operation and diagnostics
– STEP 7 language innovations while maintaining proven functions
The S7-1500 controller consists of a power supply ①, a CPU with integrated display ② and input and
output modules for digital and analog signals ③. The modules are mounted on a mounting rail with
integrated DIN rail profile ④. If necessary, communication processors and function modules are also
used for special tasks such as stepper motor control.

④
②
②
③
①
①

The programmable logic controller (PLC) uses the S7 program to monitor and control a machine
or process. In doing so, the S7 program scans the IO modules via input addresses (%I) and
addresses their output addresses (%Q).
The system is programmed with the STEP 7 Professional V1X software.

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4.1.1 Range of modules

The SIMATIC S7-1500 is a modular automation system and offers the following range of
modules:
Central processing units (CPUs) with integrated display
The CPUs have different performance capability and execute the user program. In addition, the
other modules are supplied power via the backplane bus with the integrated system power
supply.
Additional properties and functions of the CPU:
• Communication via Ethernet
• Communication via PROFIBUS/PROFINET
• HMI communication for HMI devices
• Web server
• Integrated technology functions (e.g. PID controller, motion control, etc.)
• System diagnostics
• Integrated security (e.g. know-how, copy, access, integrity protection)

System power supply modules (PS) (rated input voltages 24 V DC to 230 V AC/DC)
with connection to the backplane bus supply the configured modules with the internal supply
voltage.

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 TIA Portal Module 002

Load current supply modules (PM) (rated input voltages 120/230 V AC)
do not have a connection to the backplane bus of the S7-1500 automation system. The load
current supply is used to supply 24 V DC to the system power supply of the CPU, the input and
output circuits of IO modules and the sensors and actuators.

IO modules
for digital input (DI) / digital output (DQ) / analog input (AI) / analog output (AQ)

Technology modules (TM)

as incremental encoders and pulse encoders with/without direction signal

Communication modules (CM)

for serial communication RS232 / RS422 / RS485, PROFIBUS and PROFINET

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 TIA Portal Module 002

SIMATIC memory card

up to a maximum of 2 GB for storing program data and for easy replacement of CPUs during
maintenance.

4.1.2 Example configuration

The following configuration of an S7-1500 automation system will be used for the program
example in this curriculum.

① ②

③ ④ ⑤ ⑥

① Load current supply module (PM) with 120/230 V AC, 50 Hz / 60 Hz, 190 W input and 24 V
DC / 8 A output

② Central processing unit CPU 1516F-3 PN/DP with integrated PROFIBUS and PROFINET
interfaces

③ IO module 32x digital input DI 32x24VDC HF

④ IO module 32x digital output DQ 32x24VDC/0.5A HF
⑤ IO module 8x analog input AI 8xU/I/RTD/TC ST

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⑥ IO module 4x analog output AQ 4xU/I ST

4.2 Operator control and display elements of the CPU 1516F-3

PN/DP
The figure below shows the operator control and display elements of a CPU 1516F-3 PN/DP
The arrangement and number of elements differ from this figure for other CPUs.

4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display

LED displays for the current operating mode and diagnostic status of the CPU
Display
Control keys

4.2.2 Status and error displays

The CPU comes with the following LED displays:

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4.2.3 Operator control and connection elements behind the front flap

LED displays for the current operating mode and diagnostic status of the CPU
Display connection
Slot for the SIMATIC memory card
Mode switch
LED displays for the 3 ports of the PROFINET interfaces X1 and X2
MAC addresses of the interfaces
PROFIBUS interface (X3)
PROFINET interface (X2) with 1 port
PROFINET interface (X1) with 2-port switch
Connection for supply voltage
Fastening screws

Note: The front flap with the display can be removed and inserted during operation.

4.2.4 SIMATIC memory card

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A SIMATIC Micro Memory Card is used as the memory module for the CPUs. This is a
preformatted memory card that is compatible with the Windows file system. It is available with
various storage capacities and can be used for the following purposes:

– Transportable data storage medium

– Program card
– Firmware update card

The MMC must be inserted to operate the CPU as the CPUs have no integrated load memory. A
commercially available SD card reader is needed to write/read the SIMATIC memory card with the
programming device or PG/PC. This allows files to be copied directly to the SIMATIC memory card
using Windows Explorer, for example.

Note: It is recommended that the SIMATIC memory card only be removed or inserted when the CPU is in
the POWER OFF state.

4.2.5 Mode switch

The mode switch allows you to set the operating mode of the CPU. The mode switch is designed
as a toggle switch with 3 switch positions.

Position Meaning Explanation

RUN RUN mode The CPU processes the user program.
STOP STOP mode The CPU is not executing the user program.
MRES Memory reset Position for CPU memory reset.

You can also use the button on the CPU operator panel of the STEP 7 Professional V1X software
in Online & Diagnostics to switch the operating mode (STOP or RUN).
The operator panel also contains an MRES button for performing a memory reset and displays
the status LEDs of the CPU.

4.2.6 Display of the CPU

The S7-1500 CPU has a front flap with a display and control keys. Control data and status data
can be displayed in various menus on the display and numerous settings can be configured. You
use the control keys to navigate through the menus.
The display of the CPU offers the following functions:
● 6 different display languages can be selected.
● Diagnostic messages are displayed in plain text.

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 TIA Portal Module 002

● The interface settings can be changed locally.

● Password assignment for display operation is possible through the TIA Portal.

View of the display of an S7-1500:

CPU status information

Submenu name
Information display field
Navigation aid, e.g. OK/ESC or the page number

Control keys of the display

● Four arrow keys: "up", "down", "left", "right"
● An ESC key
● An OK key

Functions of the "OK" and "ESC" keys

® For menu commands in which an input can be made:

– OK → valid access to the menu command, confirmation of input and exit from editing
mode
– ESC → restoration of original content (which means changes are not saved) and exit
from editing mode
® For menu commands in which no input can be made:

– OK → to next submenu command

– ESC → back to previous menu command

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Available submenus of the display:

Main menu Meaning Explanation

commands
Overview The "Overview" menu contains information about the
properties of the CPU.
Diagnostics The "Diagnostics" menu contains information about
diagnostic messages, the diagnostic description and the
indication of interrupts. There is also information about the
network properties of each interface of the CPU.
Settings In the "Settings" menu, the IP addresses of the CPU are
assigned, the date, time, time zones, operating modes
(RUN/STOP) and protection levels are set, the CPU
memory is reset and its factory settings are restored and the
status of firmware updates is displayed.
Modules The "Modules" menu contains information about the
modules that are used in your configuration. The modules
can be used as central or distributed modules.
Distributed modules are connected to the CPU via
PROFINET and/or PROFIBUS.
You have the option here to set the IP addresses for a CPU.
Display In the "Display" menu, settings are made for all aspects of
the display, such as the language setting, brightness setting
and Energy-saving mode. (Energy-saving darkens the
display. Standby mode switches off the display.)

4.3 Memory areas of the CPU 1516F-3 PN/DP and the SIMATIC
memory card
The following figure shows the memory areas of the CPU and the load memory on the SIMATIC
memory card.
In addition to the load memory, other data can be loaded onto the SIMATIC memory card using
Windows Explorer. This includes recipes, data logs, project backups and additional
documentation for the program.

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Code work memory

Code blocks (FC, FB, OB) Load memory
(on SIMATIC memory card)
Data work memory Ø Code blocks (FC, FB, OB)
Global data blocks Ø Data blocks (DB)
Instance data blocks Ø Hardware configuration
Technology objects Ø Technology objects

Retentive memory
Parts of:
Global data blocks
Instance data blocks
Technology objects
Bit memory, timers, counters

Additional memory areas

Bit memories, timers and counters
Temporary local data
Process images (I/O)

Load memory
Load memory is non-volatile memory for code blocks, data blocks, technology objects and the
hardware configuration. When these objects are downloaded to the CPU, they are first stored in
the load memory. This memory is located on the SIMATIC memory card.
Work memory
Work memory is volatile memory that contains the code and data blocks. The work memory is
integrated into the CPU and cannot be expanded. In S7-1500 CPUs, the work memory is divided
into two areas:

® Code work memory:

– The code work memory contains runtime-relevant parts of the program code.
® Data work memory:

– The data work memory contains the runtime-relevant parts of the data blocks and
technology objects.
At the operating mode transitions from POWER ON to startup and from STOP to startup, tags of
global data blocks, instance data blocks and technology objects are initialized with their start
values. Retentive tags retain their actual values that were saved in the retentive memory.
Retentive memory
Retentive memory is non-volatile memory for saving certain data in the event of power failure.
The tags and operand areas that have been defined as retentive are saved in the retentive
memory. This data is retained beyond power-off or power failure.
All other program tags are set to their start values at the operating mode transitions from POWER
ON to startup and from STOP to startup.
The content of retentive memory is deleted by the following actions:

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● Memory reset
● Reset to factory settings
Note: Certain tags of technology objects are also stored in the retentive memory. These
tags are not deleted by a memory reset.

4.4 STEP 7 Professional V1X (TIA Portal V1X) programming software

STEP 7 Professional V1X (TIA Portal V1X) software is the programming tool for the following
automation systems:

- SIMATIC S7-1500
- SIMATIC S7-1200
- SIMATIC S7-300
- SIMATIC S7-400
- SIMATIC WinAC

STEP 7 Professional V1X provides the following functions for plant automation:
- Configuration and parameter assignment of the hardware
- Specification of the communication
- Programming
- Testing, commissioning and servicing with operational/diagnostic functions
- Documentation
- Creation of visualizations for SIMATIC Basic Panels using the integrated WinCC Basic
software
- Visualization solutions for PCs and other panels can also be created with other WinCC
software packages
Support is provided for all functions through detailed online help.

4.4.1 Project
To implement a solution for an automation and visualization task, you create a project in the TIA
Portal. A project in the TIA Portal contains the configuration data for the configuration and
internetworking of devices as well as the programs and the configuration of the visualization.

4.4.2 Hardware configuration

The hardware configuration includes the configuration of the devices, consisting of the hardware of
the automation system, the intelligent field devices and the hardware for visualization. The
configuration of the networks specifies the communication between the various hardware
components. The individual hardware components are inserted in the hardware configuration from
catalogs.

The hardware of automation systems comprises controllers (CPUs), signal modules for input and
output signals (SMs) and communication processors, and interface modules (CP, IM). Power
supply and voltage supply modules (PS, PM) are also available to supply the modules.

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The signal modules and intelligent field devices connect the input and output data of the process to
be automated and visualized to the automation system.

Visualization
Visualisierung

Central structure
Zentrale Struktur

Dezentrale
Distributed Struktur
structure

Actuators/sensors
Aktoren/Sensoren

Figure 1: Example of hardware configuration with central and distributed structures

The hardware configuration enables the downloading of automation and visualization solutions to
the automation system and access to the connected signal modules by the controller.

4.4.3 Central and distributed automation structure

Figure 1 shows an automation structure that contains both central and distributed structures.

In central structures, the input and output signals of the process are transmitted by way of
conventional wiring to the signal modules, which are connected directly to the controller.
Conventional wiring refers to the connection of sensors and actuators using 2-wire or 4-wire
cables.

The distributed structure is the predominant structure used today. Here, the sensors and actuators
are wired conventionally only as far as the signal modules of the field devices. The signal
transmission from the field devices to the controller is implemented using an industrial
communication system.

Both classic fieldbuses such as PROFIBUS, Modbus and Foundation Fieldbus as well as Ethernet-
based communication systems such as PROFINET can be used as the industrial communication
system.

In addition, intelligent field devices in which stand-alone programs run can also be connected via
the communication system. These programs can also be created with the TIA Portal.

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4.4.4 Planning the hardware

Before you can configure the hardware, you must plan it (hardware planning). In general, you begin
by selecting which controllers are needed and how many. Next you select the communication
modules and signal modules. The selection of signal modules is based on the number and type of
inputs and outputs needed. As the final step, a power supply that ensures that the necessary
power is supplied must be selected for each controller or field device.

The functionality required and the ambient conditions are of vital importance for planning the
hardware configuration. For example, the temperature range in the application area sometimes
limits the devices available for selection. Fail-safe operation might be another requirement, for
example.

The TIA Selection Tool (Select automation technology ® TIA Selection Tool and follow the
instructions) provides you support. Note: TIA Selection Tool requires Java.

Note for online research: If more than one manual is available, you should look for the
description "Device Manual", "Product Manual" or simply "Manual" (as opposed to
"Function Manual", "List Manual", "System Manual", etc.) in order to find the device
specifications.

4.4.5 TIA Portal – Project view and portal view

The TIA Portal has two important views. When started, the TIA Portal displays the portal view by
default. This view makes getting started easier, especially for beginning users.

The portal view provides a task-oriented view of the tools for working on the project. Here, you can
quickly decide what you want to do and open the tool for the task at hand. If necessary, a change
to the project view takes place automatically for the selected task.

Figure 2 shows the portal view. At the bottom left, there is an option to switch between this view
and the project view.

Figure 2: Portal view

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The project view, as shown in Figure 3, is used for hardware configuration, programming, creation of the
visualization and many other tasks.

By default, the project view displays the menu bar with the toolbars at the top, the project tree with all
components of a project on the left and the so-called task cards with instructions and libraries, for
example, on the right.

If an element (for example, the device configuration) is selected in the project tree, it is displayed in the
center and can be worked on there.

Figure 3: Project view

4.4.6 Basic settings for the TIA Portal

® Users can specify their own default settings for certain settings in the TIA Portal. A few
important settings are shown here.

® In the project view, select the ®"Options" menu and then ® "Settings".

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One basic setting is the selection of the user interface language and the language for the program
display. In the curriculums to follow, "English" will be used for both settings.

® Under ® "General" in "Settings", select "User interface language ® English" and

"Mnemonic ® International".

Note: These settings can always be changed.

® When Safety CPUs are used (e.g. CPU 1516F-3 PN/DP) without the use of safety
engineering, it is recommended that automatic creation of the safety program be
deactivated before creating a project.

® In "Settings" under the ® "STEP 7 Safety" item, deactivate ® "Generate default fail-safe
program".

4.4.7 Setting the IP address on the programming device

To program SIMATIC S7-1500 from the PC, the programming device or a laptop, you need a
TCP/IP connection or an optional PROFIBUS connection.
For the PC and SIMATIC S7-1500 to communicate with each other via TCP/IP, it is important that
the IP addresses of both devices match.
First, we show you how to set the IP address of a computer with the Windows 7 operating
system.

® Locate the network icon in the taskbar at the bottom and click ® "Open Network
and Sharing Center".

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® In the open Network and Sharing Center window, click ® "Change adapter settings".

® Select the desired ® "Local Area Connection" that you want to use to connect to the
controller and click ® "Properties".

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® Next, select ® "Properties" for ® "Internet Protocol Version 4 (TCP/IP)".

® You can use the following IP address, for example ® IP address: 192.168.0.99 ® Subnet
mask 255.255.255.0 and accept the settings (® "OK")

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4.4.8 Setting the IP address in the CPU

The IP address of SIMATIC S7-1500 is set as follows.

® Select the Totally Integrated Automation Portal for this, which is opened here with a
double-click. (® TIA Portal V1X)

® Select ® "Online & Diagnostics" and open the ®"project view".

® In the project tree under ® "Online access", select the network adapter that was set previously. If you
click ® "Update accessible devices" here, you will see the IP address (if previously set) or the MAC
address (if IP address not yet assigned) of the connected SIMATIC S7-1500. Select ® "Online &
Diagnostics" here.

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® Under® "Functions", you now find the ® "Assign IP address" item. Enter the following IP
address here (example): ® IP address: 192.168.0.1 ® Subnet mask 255.255.255.0.
Next, click ® "Assign IP address" and this new address will be assigned to your
SIMATIC S7-1500.

Note: The IP address of the SIMATIC S7-1500 can also be set via the display on the
CPU, provided this is enabled in the hardware configuration.

® If the IP address was not successfully assigned, you will receive a message in the ®
"Info" window under ® "General".

4.4.9 Formatting the memory card in the CPU

® If the IP address could not be assigned, the program data on the CPU must be deleted.
This is accomplished in 2 steps: ® "Format memory card" and ®"Reset to factory
settings".

® First, select the ® "Format memory card" function and press the ® "Format" button.

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® Confirm the prompt asking if you really want to format the memory card with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

4.4.10 Resetting the CPU to factory settings

® Before you can reset the CPU, you must wait until the formatting in the CPU has finished.
Then you must select ® "Update accessible devices" and ® "Online & diagnostics" of
your CPU again. To reset the controller, select the ® "Reset to factory settings" function
and click ® "Reset".

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® Confirm the prompt asking if you really want to reset the module with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

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5 Task
Create a project and add the modules of the existing hardware (here: SIMATIC S7-1500F with
CPU 1516F-3 PN/DP) by using the automatic hardware detection of the TIA Portal. The following
modules must be detected:

– SIMATIC S7-1500F, CPU 1516F-3 PN/DP, WORK MEMORY 1.5 MB PROGRAM, 5

MB DATA, 1. INTERFACE, PROFINET IRT WITH 2 PORT SWITCH, 2. INTERFACE,
ETHERNET, 3. INTERFACE, PROFIBUS, 10 NS BITPERFORMANCE, SIMATIC
MEMORY CARD REQUIRED (order number: 6ES7 516-3FN01-0AB0)
– 1X SIMATIC S7-1500, DIGITAL INPUT MODULE DI 32 X DC24V, 32 CHANNELS IN
GROUPS OF 16 (order number: 6ES7521-1BL00-0AB0)
– 1X SIMATIC S7-1500, DIGITAL OUTPUT MODULE DQ 32 X DC24V / 0.5A; 32
CHANNELS (order number: 6ES7 522-1BL01-0AB0)
– 1X SIMATIC S7-1500, ANALOG INPUT MODULE AI 8 X U/I/RTD/TC, 16BIT
RESOLUTION 8 CHANNELS IN GROUPS OF 8 (6ES7 531-7KF00-0AB0)
– 1X SIMATIC S7-1500, ANALOG OUTPUT MODULE AQ 4 X U/I ST, 16BIT
RESOLUTION, 4 CHANNELS IN GROUPS OF 4 (order number: 6ES7 532-5HD00-
0AB0)
You must add the following module yourself:

– 1X SIMATIC PM 190W 120/230VAC STABILIZED POWER SUPPLY Input: 120/230

VAC output: 24 V DC / 8 A (order number: 6EP1333-4BA00)

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6 Planning
Because this is a new system, a new project must be created.

The hardware for this project is already specified by the existing hardware (here: SIMATIC
S7-1516F PN/DP). Therefore, a selection does not have to be made. Instead, the listed modules of
the Trainer Package are detected directly. The order numbers (see Task or Table 1) can be used
for checking purposes.

Module Order number Slot Address area

CPU 1516F-3 PN/DP 6ES7 516-3FN01-0AB0 1

DI 32x24VDC HF 6ES7 521-1BL00-0AB0 2 0…3
DQ 32 X DC24V / 0.5A HF 6ES7 522-1BL01-0AB0 3 0…3
AI 8 X U/I/RTD/TC, 16BIT 6ES7 531-7KF00-0AB0 4 64…79
AQ 4 X U/I ST, 16BIT 6ES7 532-5HD00-0AB0 5 64…71
Table 1: Overview of the planned configuration

The address areas must now be configured.

The power module is not automatically detected and must be manually added.

Module Order number Slot Address area

PM 190W 120/230VAC 6EP1333-4BA00 0

Table 2: Module to be manually added

As the final step, the hardware configuration must be compiled and downloaded. Any errors
present can be detected during compilation and incorrect modules can be detected when the
controller is started (only possible when hardware is present and structured identically).

The tested project must be saved and archived.

7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it is sufficient to focus on the numbered steps. Otherwise, simply
follow the steps of the instructions illustrated below.

7.1 Create a new project

® Select the Totally Integrated Automation Portal for this, which is opened here with a
double-click. (® TIA Portal V1X)

® In the portal view under the "Start" menu, select the command ® "Create new project".

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® Modify Project name, Path, Author and Comment as appropriate and click ® "Create".

® The project will be created and opened and the menu "Start", "First steps" will open
automatically.

7.2 Read the hardware of the SIMATIC S7-1500

® In the ® "Start" portal, select ® "First steps" ® "Devices & Networks" ® "Configure a
device".

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® The "Show all devices" menu opens in the "Devices & Networks" portal.

® Switch to the "Add new device" menu.

® Create a new CPU. Use an unspecified model of the S7-1500 CPU with order number
6ES7 5XX-XXXXX-XXXX for this.

(Controllers ® SIMATIC S7-1500 ® CPU ® Unspecified CPU 1500 ® 6ES75XX-

XXXXX-XXXX ® V1.8)

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® Assign a device name (Device name ® "CPU_1500").

® Select "Open device view".

® Click "Add".

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® The TIA Portal now switches automatically to the project view and displays a notice there
that this device is not specified. In order to have the hardware configuration automatically
detected, start detection by clicking "detect" in the yellow information box (® detect).

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® Select the type of your PG/PC interface. (® Type of the PG/PC interface: PN/IE).

® You can now select the network adapter you want to use to establish an Ethernet
connection to the PLC. (® PG/PC interface: Intel(R) Ethernet Connection I217-LM)

® The search for devices in the network must be started by clicking the ®
button.

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® All accessible nodes are found and listed. If you have selected the correct CPU, the
corresponding CPU and all the connected modules will be detected when you click
"Detect".

Note: If the list does not contain your CPU, ensure that you have selected the correct network adapter
and established a connection between the laptop and CPU.

® The TIA Portal shows the complete device configuration of the selected CPU. Only the
power module is lacking. This can be placed on slot 0 of the mounting rail later.

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Note: You can now configure the CPU there according to your specifications. Possible
settings include the PROFINET and PROFIBUS DP interfaces, startup characteristics,
cycle, password protection, communication load and many others.

7.3 Configure the Ethernet interface of the CPU 1516F-3 PN/DP

® Select the CPU with a double-click

® Under ® "Properties", open the ® "PROFINET-interface [X1]" menu and select the ®
"Ethernet addresses" entry there.

® Under "Interface connected with", only the "Not connected" entry is available.

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® Add an Ethernet subnet with the ® "Add new subnet" button.

® Keep the pre-assigned "IP address" and "Subnet mask".

7.4 Configure the access level for the CPU 1516F-3 PN/DP
® Switch to the ® "Protection" menu and select access level ® "Full access incl. fail-safe
(no protection)".

Note: The setting "Full access incl. fail-safe (no protection)" is recommended because a
safety program is not created here and thus we also do not have to assign a password.

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7.5 Insert power module PM 190W 120/230VAC

® Find the correct module in the hardware catalog and insert the power module into slot 0.
(® Hardware Catalog ® PM ® PM 190W 120/230VAC (order number 6EP1333-4BA00)
® Slot 0)

Note: If a module as well as the power module is planned for one slot, it is not possible to
place it at another position even in the device configuration.

® Compare your device configuration with the following figure.

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7.6 Configure the address areas of the digital input and output
modules
® The next step is to check the address areas of the inputs and output cards and adapt
them if necessary. DI/DO should have an address area of 0…3 and AI/AO should have
an address area of 64…79 and 64…71, respectively. (® Device overview ® DI
32x24VDC HF_1 ® I address: 0..3 ® DQ 32x24VDC/0.5A HF_1 ® Q address: 0...3 ®
AI 8xU/I/RTD/TC ST_1 ® I address: 64…79 ® AQ 4xU/I ST_1 ® Q address: 64…71)

Note: To show and hide the Device overview, you must click the small arrow next to
"Device data" on the right side of the hardware configuration.

7.7 Save and compile the hardware configuration

® Before you compile the configuration, you should save your project by clicking the ®

button. To compile your CPU with the device configuration, first select the

® "CPU_1500 [CPU1516F-3 PN/DP]" folder and click the ® "Compile" icon.

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Note: "Save project" should be used repeatedly when working on a project since this does not happen
automatically. A prompt to save the project only occurs when the TIA Portal is closed.

® If the project was compiled without errors, you see the following screen.

7.8 Download the hardware configuration to the device

® To download your entire CPU, select the ® "CPU_1500 [CPU1516F-3 PN/DP]" folder

and click the ® "Download to device" icon.

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® The manager for configuring the connection properties (extended download) opens.

® First, the interface must be correctly selected. This happens in three steps.

® Type of the PG/PC interface ® PN/IE

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® PG/PC interface ® here: Intel(R) Ethernet Connection I217-LM

® Connection to interface/subnet ® "PN/IE_1"

® The ® "Show all compatible devices" check box must be selected. The search for

devices in the network is started by clicking the ® button.

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® If your CPU is shown in the "Compatible devices in target subnet" list, it must be selected.
The download can then be started. (® CPU 1516F-3 PN/DP ® "Load")

® You first obtain a preview. Confirm the prompt ® "Overwrite all" and continue with ®
"Load".

Note: The symbol should be visible in every line of the "Load preview". You can find
additional information in the "Message" column.

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® The ® "Start all" option will be selected next before the download operation can be
completed with ® "Finish".

® After a successful download, the project view will open again automatically. A loading
report appears in the information field under "General". This can be helpful when
troubleshooting an unsuccessful download.

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7.9 Checklist

No. Description Completed

1 Project was created
2 Slot 0: Power module with correct order number
3 Slot 1: CPU with correct order number

4 Slot 1: CPU with correct firmware version

5 Slot 2: Digital input module with correct order number
6 Slot 2: Digital input module with correct firmware version
7 Address area of the digital input module is correct
8 Slot 3: Digital output module with correct order number
9 Slot 3: Digital output module with correct firmware version
10 Slot 3: Address area of the digital output module is correct

11 Slot 4: Analog input module with correct order number

12 Slot 4: Analog input module with correct firmware version

13 Slot 4: Address area of the analog input module is correct

14 Slot 5: Analog output module with correct order number
15 Slot 5: Analog output module with correct firmware version
16 Slot 5: Address area of the analog output module is correct
17 Hardware configuration was compiled without error message
18 Hardware configuration was downloaded without error message
19 Project was successfully archived

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SCE Training Curriculum

TIA Portal Module 003

Decentral Hardware configuration
with SIMATIC S7-1500 and
ET 200SP via PROFINET

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Table of contents
1 Goal .................................................................................................................................................... 80

2 Prerequisite......................................................................................................................................... 80

3 Required hardware and software ....................................................................................................... 80

4 Theory................................................................................................................................................. 82

4.1 SIMATIC S7-1500 automation system ....................................................................................... 82

4.1.1 Range of modules............................................................................................................... 83

4.1.2 Example configuration ........................................................................................................ 85

4.2 Operator control and display elements of the CPU 1516F-3 PN/DP.......................................... 85

4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display ......................................... 86

4.2.2 Status and error displays .................................................................................................... 86

4.2.3 Operator control and connection behind the front flap ....................................................... 87

4.2.4 SIMATIC Memory Card ...................................................................................................... 87

4.2.5 Mode switch ........................................................................................................................ 88

4.2.6 Display der CPU ................................................................................................................. 88

4.3 Memory areas of the CPU 1516F-3 PN/DP and the SIMATIC memory card............................. 90

4.4 Configuration and operation of the SIMATIC ET 200SP ............................................................ 92

4.4.1 SIMATIC ET 200SP Distributed IOIO ................................................................................. 92

4.4.2 Range of modules............................................................................................................... 93

4.4.3 Example configuration ........................................................................................................ 95

4.5 STEP 7 Professional V1X (TIA Portal V1X) programming software .......................................... 96

4.5.1 Project................................................................................................................................. 96

4.5.2 Hardware configuration....................................................................................................... 96

4.5.3 Central and distributed automation structure...................................................................... 97

4.5.4 Planning the hardware ........................................................................................................ 97

4.5.5 TIA Portal – Project view and portal view ........................................................................... 98

4.5.6 Basic settings for the TIA Portal ......................................................................................... 99

4.5.7 Setting the IP address on the programming device.......................................................... 100

4.5.8 Setting the IP address in the CPU .................................................................................... 102

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4.5.9 Formatting the memory card in the CPU .......................................................................... 104

4.5.10 Resetting the CPU to factory settings............................................................................... 105

4.5.11 Setting the IP address in the ET 200SP ........................................................................... 106

4.5.12 Reading the firmware version of the ET 200SP ............................................................... 108

5 Task .................................................................................................................................................. 109

6 Planning ............................................................................................................................................ 110

7 Structured step-by-step instructions ................................................................................................. 111

7.1 Create a new project................................................................................................................. 111

7.2 Insert the CPU 1516F-3 PN/DP................................................................................................ 112

7.3 Configure the Ethernet interface of the CPU 1516F-3 PN/DP ................................................. 115

7.4 Configure the fail-safe operation of the CPU 1516F-3 PN/DP ................................................. 116

7.5 Configure the access level for the CPU 1516F-3 PN/DP ......................................................... 117

7.6 Insert power module PM 190W 120/230VAC........................................................................... 117

7.7 Insert the ET 200SP interface module IM155-6PN HF ............................................................ 119

7.8 Configure the ET 200SP / IM 155-6PN HF............................................................................... 120

7.9 Insert the 2 digital input modules DI 8x24VDC HF ................................................................... 122

7.10 Insert the 2 digital output modules DQ 8x24VDC/0.5A HF ...................................................... 124

7.11 Replace components in the hardware configuration ................................................................ 124

7.12 Insert the server module ........................................................................................................... 125

7.13 Configure the address areas DI/DQ: 0…1................................................................................ 126

7.14 Configuration of the potential groups of the Base Units ........................................................... 126

7.15 Save and compile the hardware configuration ......................................................................... 129

7.16 Assign device name to interface module IM 155-6PN HF........................................................ 130

7.17 Download the hardware configuration to the device ................................................................ 133

7.18 Checklist ................................................................................................................................... 138

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DECENTRAL HARDWARE CONFIGURATION –

SIMATIC S7-1516F PN/DP WITH ET 200SP
VIA PROFINET

1 Goal
In this chapter, you will first learn how to create a project. You are then shown how the
hardware is configured.

The SIMATIC S7 controllers listed in Chapter 3 can be used.

2 Prerequisite
You do not need any previous knowledge from other chapters to successfully complete this
chapter.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card

4 ET 200SP distributed IO for PROFINET with 16DI/16DO and 2AI/1AO

Configuration example
Interface module IM155-6PN HF with Bus Adapter BA 2xRJ45
2x IO module 8x digital input DI 8x24VDC HF
2x IO module 8x digital output DQ 8x24VDC/0.5A HF
2x IO module 2x analog input AI 2xU/I 2, 4-wire HS
IO module 2x analog output AQ 2xU/I HS
Server module

5 Ethernet connection between engineering station and controller and

between controller and ET 200SP distributed IO

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2 SIMATIC STEP 7
1 Engineering station Professional (TIA
Portal) as of V13
5 Ethernet connection

3 SIMATIC S7-1500 controller

5 Ethernet connection

4 ET 200SP distributed IO

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4 Theory
4.1 SIMATIC S7-1500 automation system
The SIMATIC S7-1500 automation system is a modular controller system for the middle to upper
performance range. A comprehensive range of modules is available to optimally adapt the system
to the automation task.

SIMATIC S7-1500 is the next generation of the SIMATIC S7-300 and S7-400 automation systems
with the following new performance features.

– Increased system performance

– Integrated motion control functionality
– PROFINET IO IRT
– Integrated display for machine-level operation and diagnostics
– STEP 7 language innovations while maintaining proven functions
The S7-1500 controller consists of a power supply ①, a CPU with integrated display ② and input
and output modules for digital and analog signals ③. The modules are mounted on a mounting
rail with integrated DIN rail profile ④. If necessary, communication processors and function
modules are also used for special tasks such as stepper motor control.

④
②
②
③
①
①

The programmable logic controller (PLC) uses the S7 program to monitor and control a machine
or process. In doing so, the S7 program scans the IO modules via input addresses (%I) and
addresses their output addresses (%Q).
The system is programmed with the STEP 7 Professional V1X software.

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4.1.1 Range of modules

The SIMATIC S7-1500 is a modular automation system and offers the following range of
modules:
Central processing units (CPUs) with integrated display
The CPUs have different performance capability and execute the user program. In addition, the
other modules are supplied power via the backplane bus with the integrated system power
supply.
Additional properties and functions of the CPU:
• Communication via Ethernet
• Communication via PROFIBUS/PROFINET
• HMI communication for HMI devices
• Web server
• Integrated technology functions (e.g. PID controller, motion control, etc.)
• System diagnostics
• Integrated security (e.g. know-how, copy, access, integrity protection)
• Integrated digital and analog inputs and outputs (Compact CPUs)

System power supply modules (PS) (rated input voltages 24 V DC to 230 V AC/DC)
with connection to the backplane bus supply the configured modules with the internal supply
voltage.

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Load current supply modules (PM) (rated input voltages 120/230 V AC)
do not have a connection to the backplane bus of the S7-1500 automation system. The load
current supply is used to supply 24 V DC to the system power supply of the CPU, the input and
output circuits of IO modules and the sensors and actuators.

IO modules
for digital input (DI) / digital output (DQ) / analog input (AI) / analog output (AQ)

Technology modules (TM)

as incremental encoders and pulse encoders with/without direction signal.

Communication modules (CM)

for serial communication RS232 / RS422 / RS485, PROFIBUS and PROFINET.

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SIMATIC memory card

up to a maximum of 32 GB for storing program data and for easy replacement of CPUs during
maintenance.

4.1.2 Example configuration

The following configuration of an S7-1500 automation system will be used for the program
example in this curriculum.

① ②

① Load current supply module (PM) with 120/230 V AC, 50 Hz / 60 Hz, 190 W input and
24 V DC / 8 A output
② Central processing unit CPU 1516F-3 PN/DP with integrated PROFIBUS and PROFINET
interfaces

4.2 Operator control and display elements of the CPU 1516F-3 PN/DP
The figure below shows the operator control and display elements of a CPU 1516F-3 PN/DP.
The arrangement and number of elements differ from this figure for other CPUs.

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4.2.1 Front view of the CPU 1516F-3 PN/DP with integrated display

4.2.2 Status and error displays

The CPU comes with the following LED displays:

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4.2.3 Operator control and connection behind the front flap

Note: The front flap with the display can be removed and inserted during operation.

Note: The PROFINET field devices (ET 200SP in this case) should be connected to the
PROFINET interface(X1) with the 2 ports.

4.2.4 SIMATIC Memory Card

A SIMATIC Micro Memory Card is used as the memory module for the CPUs. This is a
preformatted memory card that is compatible with the Windows file system. It is available with
various storage capacities and can be used for the following purposes:

– Transportable data storage medium

– Program card
– Firmware update card
The MMC must be inserted to operate the CPU as the CPUs have no integrated load memory. A
commercially available SD card reader is needed to write/read the SIMATIC memory card with the

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programming device or PC. This allows files to be copied directly to the SIMATIC memory card
using Windows Explorer, for example.

Note: It is recommended that the SIMATIC memory card only be removed or inserted
when the CPU is in the POWER OFF state.

4.2.5 Mode switch

The mode switch allows you to set the operating mode of the CPU. The mode switch is designed
as a toggle switch with 3 switch positions.

Position Meaning Explanation

RUN RUN mode The CPU processes the user program.
STOP STOP mode The CPU is not executing the user program.
MRES Memory reset Position for CPU memory reset.

You can also use the button on the CPU operator panel of the STEP 7 Professional V1X software
in Online & Diagnostics to switch the operating mode (STOP or RUN).
The operator panel also contains an MRES button for performing a memory reset and displays
the status LEDs of the CPU.

4.2.6 Display der CPU

The S7-1500 CPU has a front flap with a display and control keys. Control data and status data
can be displayed in various menus on the display and numerous settings can be configured. You
use the control keys to navigate through the menus.
The display of the CPU offers the following functions:
● 6 different display languages can be selected.
● Diagnostic messages are displayed in plain text.
● The interface settings can be changed locally.
● Password assignment for display operation is possible through the TIA Portal.

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View of the display of an S7-1500:

Control keys of the display

● Four arrow keys: "up", "down", "left", "right"

● An ESC key
● An OK key

Functions of the "OK" and "ESC" keys

® For menu commands in which an input can be made:

– OK → valid access to the menu command, confirmation of input and exit from editing
mode
– ESC → restoration of original content (which means changes are not saved) and exit
from editing mode
® For menu commands in which no input can be made:

– OK → to next submenu command

– ESC → back to previous menu command

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Available submenus of the display:

Main menu Meaning Explanation

commands
Overview The "Overview" menu contains information about the
properties of the CPU.
Diagnostics The "Diagnostics" menu contains information about
diagnostic messages, the diagnostic description and the
indication of interrupts. There is also information about the
network properties of each interface of the CPU.
Settings In the "Settings" menu, the IP addresses of the CPU are
assigned, the date, time, time zones, operating modes
(RUN/STOP) and protection levels are set, the CPU
memory is reset and its factory settings are restored and the
status of firmware updates is displayed.
Modules The "Modules" menu contains information about the
modules that are used in your configuration. The modules
can be used as central or distributed modules.
Distributed modules are connected to the CPU via
PROFINET and/or PROFIBUS.
You have the option here to set the IP addresses for a CPU.
Display In the "Display" menu, settings are made for all aspects of
the display, such as the language setting, brightness setting
and Energy-saving mode. (Energy-saving darkens the
display. Standby mode switches off the display.)

4.3 Memory areas of the CPU 1516F-3 PN/DP and the SIMATIC
memory card
The following figure shows the memory areas of the CPU and the load memory on the SIMATIC
memory card.
In addition to the load memory, other data can be loaded onto the SIMATIC memory card using
Windows Explorer. This includes recipes, data logs, project backups and additional
documentation for the program.

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Load memory
Load memory is non-volatile memory for code blocks, data blocks, technology objects and the
hardware configuration. When these objects are downloaded to the CPU, they are first stored in
the load memory. This memory is located on the SIMATIC memory card.
Work memory
Work memory is volatile memory that contains the code and data blocks. The work memory is
integrated into the CPU and cannot be expanded. In S7-1500 CPUs, the work memory is divided
into two areas:

® Code work memory:

– The code work memory contains runtime-relevant parts of the program code.
® Data work memory:

– The data work memory contains the runtime-relevant parts of the data blocks and
technology objects.
At the operating mode transitions from POWER ON to startup and from STOP to startup, tags of
global data blocks, instance data blocks and technology objects are initialized with their start
values. Retentive tags retain their actual values that were saved in the retentive memory.
Retentive memory
Retentive memory is non-volatile memory for saving certain data in the event of power failure.
The tags and operand areas that have been defined as retentive are saved in the retentive
memory. This data is retained beyond power-off or power failure.
All other program tags are set to their start values at the operating mode transitions from POWER
ON to startup and from STOP to startup.
The content of retentive memory is deleted by the following actions:
● Memory reset

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● Reset to factory settings

Note: Certain tags of technology objects are also stored in the retentive memory. These
tags are not deleted by a memory reset.

4.4 Configuration and operation of the SIMATIC ET 200SP

4.4.1 SIMATIC ET 200SP Distributed IOIO

SIMATIC ET 200SP Distributed IO is a modular distributed IO system for connecting process
signals to a central automation system such as SIMATIC S7-1500. A comprehensive range of
modules is available to optimally adapt the system to the automation task.
Distributed IO are often used when signals must be transmitted over a larger distance and the
associated wiring overhead is too high. The signals can be collected locally at the remote location
and connected to the central controller via a bus system. In the case of the ET 200SP system,
devices can be connected via PROFINET or PROFIBUS.
The ET 200SP distributed IO is mounted on a standard mounting rail ⑦ and is composed of an
interface module ① with bus adapter ⑥, up to 32/64 IO modules ④ inserted on BaseUnits ②,
③ and a terminating server module ⑤.

②
④
①

The distributed IO provide inputs and outputs locally for the process connection, which can be
read and written by the central processing unit via a bus protocol. In doing so, the IO modules are
scanned in the S7 program using input addresses (%I) and addressed using output addresses
(%Q) in the usual way.
Because the distributed IO are an extension of the central controller, the system is also
configured with the STEP 7 Professional V1X software.

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4.4.2 Range of modules

The SIMATIC ET 200SP is a modular distributed IO system and offers the following range of
modules:
Interface modules with pluggable bus adapter
for connection of distributed IO to a central processing unit.
The bus adapter enables selection of any type of connection system. Interface modules have
their own power supply, which is not connected via the backplane bus.

BaseUnits
as universal basic modules for electrical and mechanical connection of the IO modules.
They are available in a light version BU..D that opens a new potential group for the voltage supply
over the backplane bus and in a dark version BU..B that continues the potential group. At least
one light BaseUnit BU..D must always be used in order to supply at least one potential group with
voltage. The IO modules are inserted on the BaseUnits.

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IO modules
for digital input (DI) / digital output (DQ) / analog input (AI) / analog output (AQ).
They are available in versions for 24 V DC ① and 400 V AC ②

① ②

Communication modules (CM)

for a point-to-point (PtP) connection ① or connection to the IO-Link ② and AS-i ③
communication systems.

① ③
②

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Server module
as a termination for the configuration of the ET 200SP system.
It can be used as a holder for 3 spare fuses. It serves as a terminating resistor for the backplane
bus and is thus a mandatory component.

4.4.3 Example configuration

The following configuration of an ET 200SP distributed IO system will be used for the program
example in this curriculum.

④ ⑤ ⑥

① ② ③ ④ ⑤ ⑥

① Interface module IM155-6PN HF with Bus Adapter BA 2xRJ45

② IO module 8x digital input DI 8x24VDC HF (2x)

③ IO module 8x digital output DQ 8x24VDC/0.5A HF (2x)

④ IO module 2x analog input AI 2xU/I 2, 4-wire HS (2x)

⑤ IO module 2x analog output AQ 2xU/I HS (1x)

⑥ Server module

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4.5 STEP 7 Professional V1X (TIA Portal V1X) programming software

STEP 7 Professional V1X (TIA Portal V1X) software is the programming tool for the following
automation systems:

- SIMATIC S7-1500
- SIMATIC S7-1200
- SIMATIC S7-300
- SIMATIC S7-400
- SIMATIC WinAC

STEP 7 Professional V1X provides the following functions for plant automation:
- Configuration and parameter assignment of the hardware
- Specification of the communication
- Programming
- Testing, commissioning and servicing with operational/diagnostic functions
- Documentation
- Creation of visualizations for SIMATIC Basic Panels using the integrated WinCC Basic
software
- Visualization solutions for PCs and other panels can also be created with other WinCC
software packages

Support is provided for all functions through detailed online help.

4.5.1 Project
To implement a solution for an automation and visualization task, you create a project in the TIA
Portal. A project in the TIA Portal contains the configuration data for the configuration and
internetworking of devices as well as the programs and the configuration of the visualization.

4.5.2 Hardware configuration

The hardware configuration includes the configuration of the devices, consisting of the hardware of
the automation system, the intelligent field devices and the hardware for visualization. The
configuration of the networks specifies the communication between the various hardware
components. The individual hardware components are inserted in the hardware configuration from
catalogs.

The hardware of automation systems comprises controllers (CPUs), signal modules for input and
output signals (SMs) and communication processors, and interface modules (CP, IM). Power
supply and voltage supply modules (PS, PM) are also available to supply the modules.

The signal modules and intelligent field devices connect the input and output data of the process to
be automated and visualized to the automation system.

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Visualization

Central structure

Distributed structure

Actuators/sensors

Figure 1: Example of hardware configuration with central and distributed structures

The hardware configuration enables the downloading of automation and visualization solutions to
the automation system and access to the connected signal modules by the controller.

4.5.3 Central and distributed automation structure

Figure 1 shows an automation structure that contains both central and distributed structures.

In central structures, the input and output signals of the process are transmitted by way of
conventional wiring to the signal modules, which are connected directly to the controller.
Conventional wiring refers to the connection of sensors and actuators using 2-wire or 4-wire
cables.

The distributed structure is the predominant structure used today. Here, the sensors and actuators
are wired conventionally only as far as the signal modules of the field devices. The signal
transmission from the field devices to the controller is implemented using an industrial
communication system.

Both classic fieldbuses such as PROFIBUS, Modbus and Foundation Fieldbus as well as Ethernet-
based communication systems such as PROFINET can be used as the industrial communication
system.

In addition, intelligent field devices in which stand-alone programs run can also be connected via
the communication system. These programs can also be created with the TIA Portal.

4.5.4 Planning the hardware

Before you can configure the hardware, you must plan it (hardware planning). In general, you begin
by selecting which controllers are needed and how many. Next you select the communication
modules and signal modules. The selection of signal modules is based on the number and type of

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inputs and outputs needed. As the final step, a power supply that ensures that the necessary
power is supplied must be selected for each controller or field device.

The functionality required and the ambient conditions are of vital importance for planning the
hardware configuration. For example, the temperature range in the application area sometimes
limits the devices available for selection. Fail-safe operation might be another requirement, for
example.

The TIA Selection Tool (Select automation technology ® TIA Selection Tool and follow the
instructions) provides you support. Note: TIA Selection Tool requires Java.

Note for online research: If more than one manual is available, you should look for the
description "Device Manual", "Product Manual" or simply "Manual" (as opposed to
"Function Manual", "List Manual", "System Manual", etc.) in order to find the device
specifications.

4.5.5 TIA Portal – Project view and portal view

The TIA Portal has two important views. When started, the portal view appears by default. This
view makes getting started easier, especially for beginning users.

The portal view provides a task-oriented view of the tools for working on the project. Here, you can
quickly decide what you want to do and open the tool for the task at hand. If necessary, a change
to the project view takes place automatically for the selected task.

Figure 2 shows the portal view. At the bottom left, there is an option to switch between this view
and the project view.

Figure 2: Portal view

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The project view, as shown in Figure 3 is used for hardware configuration, programming, creation
of the visualization and many other tasks.

By default, the project view displays the menu bar with the toolbars at the top, the project tree with
all components of a project on the left and the so-called task cards with instructions and libraries,
for example, on the right.

If an element (for example, the device configuration) is selected in the project tree, it is displayed in
the center and can be worked on there.

Figure 3: Project view

4.5.6 Basic settings for the TIA Portal

® Users can specify their own default settings for certain settings in the TIA Portal. A few
important settings are shown here.

® In the project view, select the ®"Options" menu and then ® "Settings".

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® One basic setting is the selection of the user interface language and the language for the
program display. In the curriculums to follow, "English" will be used for both settings.

® Under ® "General" in "Settings", select "User interface language ® English" and

"Mnemonic ® International".

Note: These settings can always be changed.

® When Safety CPUs are used (e.g. CPU 1516F-3 PN/DP) without the use of safety
engineering, it is recommended that automatic creation of the safety program be
deactivated before creating a project.

® In "Settings" under the ® "STEP 7 Safety" item, deactivate ® "Generate default fail-
safe program".

4.5.7 Setting the IP address on the programming device

To program SIMATIC S7-1500 from the PC, the programming device or a laptop, you need a
TCP/IP connection or an optional PROFIBUS connection.
For the PC and SIMATIC S7-1500 to communicate with each other via TCP/IP, it is important that
the IP addresses of both devices match.
First, we show you how to set the IP address of a computer with the Windows 7 operating
system.

® Locate the network icon in the taskbar at the bottom and click ® "Open Network
and Sharing Center".

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® In the open Network and Sharing Center window, click ® "Change adapter settings".

® Select the desired ® "Local Area Connection" that you want to use to connect to the
controller and click ® "Properties".

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® Next, select ® "Properties" for ® "Internet Protocol Version 4 (TCP/IP)".

® You can use the following IP address, for example ® IP address: 192.168.0.99 ® Subnet
mask 255.255.255.0 and accept the settings (® "OK")

4.5.8 Setting the IP address in the CPU

The IP address of SIMATIC S7-1500 is set as follows.

® Select the Totally Integrated Automation Portal for this, which is opened here with a
double-click. (® TIA Portal V1X)

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® Select ® "Online & Diagnostics" and open the ®"project view".

® In the project tree under ® "Online access", select the network adapter that was set
previously. If you click ® "Update accessible devices" here, you will see the IP address (if
previously set) or the MAC address (if IP address not yet assigned) of the connected
SIMATIC S7-1500. Select ® "Online & Diagnostics" here.

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® Under® "Functions", you now find the ® "Assign IP address" item. Enter the following
IP address here (example): ® IP address: 192.168.0.1 ® Subnet mask 255.255.255.0.
Next, click ® "Assign IP address" and this new address will be assigned to your
SIMATIC S7-1500.

Note: The IP address of the SIMATIC S7-1500 can also be set via the display on the
CPU, provided this is enabled in the hardware configuration.

® If the IP address was not successfully assigned, you will receive a message in the ®
"Info" window under ® "General".

4.5.9 Formatting the memory card in the CPU

® If the IP address could not be assigned, the program data on the CPU must be deleted.
This is accomplished in 2 steps: ® "Format memory card" and ®"Reset to factory
settings".

® First, select the ® "Format memory card" function and press the ® "Format" button.

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® Confirm the prompt asking if you really want to format the memory card with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

4.5.10 Resetting the CPU to factory settings

® Before you can reset the CPU, you must wait until the formatting in the CPU has finished.
Then you must select ® "Update accessible devices" and ® "Online & diagnostics" of
your CPU again. To reset the controller, select the ® "Reset to factory settings" function
and click ® "Reset".

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® Confirm the prompt asking if you really want to reset the module with ® "Yes".

® If necessary, stop the CPU. (® "Yes")

4.5.11 Setting the IP address in the ET 200SP

The IP address of the ET 200SP is set as follows.

® Select the Totally Integrated Automation Portal for this, which is opened here with a
double-click. (® TIA Portal V1X)

® Select ® "Online & Diagnostics" and open the ®"Project view".

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® In the project tree under ® "Online access", select the network adapter that was set
previously. If you click ® "Update accessible devices" here, you will see the IP address (if
previously set) or the MAC address (if the IP address is not yet assigned) of the
connected ET 200SP. Select ® "Online & Diagnostics" here.

® Under® "Functions", you now find the ® "Assign IP address" item. Enter the following
IP address here (example): ® IP address: 192.168.0.2 ® Subnet mask 255.255.255.0.
Next, click ® "Assign IP address" and this new address will be assigned to your
ET 200SP.

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® A feedback message for the assignment of the IP address is provided in the ® "Info"
window under ® "General".

Note: If a communication connection already exists between the ET 200SP (as device)
and a higher-level controller (as controller), the IP address cannot be changed.

4.5.12 Reading the firmware version of the ET 200SP

® Before you can read the firmware version of the ET 200SP, you must select ® "Update
accessible devices" and ® "Online & diagnostics" of your ET 200SP again. You can read
the Short description, Article number, Hardware version and Firmware version in menu
item ® "Diagnostics" ® "General".

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5 Task
Create a project and configure the following modules of your hardware, which correspond to one
part of SIMATIC CPU 1516F PN/DP Safety and SIMATIC ET 200SP Digital.

- SIMATIC S7-1500F, CPU 1516F-3 PN/DP, WORK MEMORY 1.5 MB PROGRAM,

5 MB DATA,1. INTERFACE, PROFINET IRT WITH 2 PORT SWITCH, 2. INTERFACE,
ETHERNET, 3. INTERFACE, PROFIBUS, 10 NS BITPERFORMANCE, SIMATIC
MEMORY CARD REQUIRED (order number: 6ES7 516-3FN01-0AB0)
- 1X SIMATIC PM 1507 24 V/8 A STABILIZED POWER SUPPLY INPUT: 120/230 V AC
OUTPUT: 24 V DC / 8 A (order number: 6EP1333-4BA00)
- 1X INTERFACE MODULE IM155-6PN HF (order number: 6ES7 155-6AU00-0CN0)
- 1X BUS ADAPTER BA 2XRJ45 (order number: 6ES7 193-6AR00-0AA0)
- 2X DI 8X24VDC/0.5A HF (order number: 6ES7 131-6BF00-0CA0
- 2X DQ 8X24VDC/0.5A HF (order number: 6ES7 132-6BF00-0CA0)
- Server module (order number: 6ES7 193-6PA00-0AA0)

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6 Planning
Because this is a new system, a new project must be created.

The hardware for this project is already specified by the existing hardware. Therefore, a selection
does not have to be made. Instead, the listed modules of the trainer packages only have to be
inserted in the project and connected. The order numbers (see Table 1 and Table 2) can be used
to check that the correct modules are inserted.

Module Order number Slot Address area

PM 190W 120/230VAC 6EP1333-4BA00 0

CPU 1516F-3 PN/DP 6ES7516-3FN01-0AB0 1
Table 1: Modules of the S7-1500

Module Order number Slot Address area

IM155-6PN HF 6ES7155-6AU00-0CN0 0
DI 8x24VDC HF 6ES7131-6BF00-0CA0 1 0
DI 8x24VDC HF 6ES7131-6BF00-0CA0 2 1
DQ 8x24VDC/0.5A HF 6ES7132-6BF00-0CA0 3 0
DQ 8x24VDC/0.5A HF 6ES7132-6BF00-0CA0 4 1
Server module 6ES7193-6PA00-0AA0 5
Table 2: Modules of the ET 200SP

The Base Units are relevant for additional handling of the ET 200SP modules. These determine
whether the potential is taken from the left terminal (dark Base Unit) or whether a new voltage
supply must be connected and thus a new potential group is created (light Base Unit). The
applicable rule here is that a new potential must always be provided on slot 1.

All Base Units included in the trainer packages are type BU15-P16+A0+2D (6ES7193-6BP00-
0DA0). As a result, the light Base Unit version is set by default.

As the final step, the hardware configuration is saved, compiled, downloaded and started.

Any errors present can be detected during compilation and incorrect modules can be detected
when the controller is started (only possible when hardware is present and structured identically).

The result is archived to back up the working version.

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it is sufficient to focus on the numbered steps. Otherwise, simply
follow the steps of the instructions illustrated below.

7.1 Create a new project

® Select the Totally Integrated Automation Portal for this, which is opened here with a
double-click. (® TIA Portal V1X)

® In the portal view under the "Start" menu, select ® "Create new project".

® Modify Project name, Path, Author and Comment as appropriate and click ® "Create".

® The project is created and opened and the menu "Start", "First steps" opens
automatically.

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7.2 Insert the CPU 1516F-3 PN/DP

® In the ® "Start" ® portal, select "First steps" ® "Devices & Networks" ® "Configure a
device".

® In the "Devices & Networks" portal, the "Show all devices" menu opens

® Switch to the "Add new device" menu.

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® The specified model of the CPU will now be added as a new device.

(Controllers ® SIMATIC S7-1500 ® CPU ® CPU 1516F-3 PN/DP ® 6ES7516-3FN01-

0AB0 ® V1.8)

® Assign a device name (Device name ® "CPU_1516F").

® Select "Open device view".

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® Click "Add".

Note: The desired CPU may have multiple versions that differ in functionality (work
memory, integrated memory, technology functions, etc.). In this case, you should ensure
that the selected CPU corresponds to the existing hardware.

Note: Different firmware versions are often offered for the hardware. In this case, it is
recommended that the latest firmware (selected by default) be used and that the CPU be
upgraded, if necessary.

® The TIA Portal now changes automatically to the project view and displays the selected
CPU in the device configuration in slot 1 of a rail.

® Select the CPU with a double-click

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Note: You can now configure the CPU there according to your specifications. Possible
settings include the PROFINET and PROFIBUS DP interfaces, startup characteristics,
cycle, communication load and many others.

7.3 Configure the Ethernet interface of the CPU 1516F-3 PN/DP

® Double-click the CPU to select it. Then open the ® "PROFINET interface [X1]" menu in
® "Properties" and select the ® "Ethernet addresses" entry there.

® Under "Interface networked with", only the "Not networked" entry is available.

® Add an Ethernet subnet with the ® "Add new subnet" button.

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® Keep the preassigned "IP address" and "Subnet mask".

7.4 Configure the fail-safe operation of the CPU 1516F-3 PN/DP

® In the ® "Fail-safe" menu, select ® "F-activation" and select ® "Disable F-activation"
there.

® Confirm the prompt asking if you want to continue with ® "Yes".

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7.5 Configure the access level for the CPU 1516F-3 PN/DP
® Switch to the ® "Protection" menu and select access level ® "Full access incl. fail-safe
(no protection)".

Note: The "Full access incl. fail-safe (no protection)" setting is recommended because we
do not have to assign a password.

7.6 Insert power module PM 190W 120/230VAC

® Find the correct module in the hardware catalog and insert the power module in slot 0.
(® Hardware Catalog ® PM ® PM 190W 120/230VAC (order number 6EP1333-4BA00)
® Slot 0)

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Note: To select a component in the hardware catalog, you can simply enter the order
number in the Search field and then click the "Search down" icon . The hardware
catalog will open at the correct position.

Note: When you double-click a module in the hardware catalog, you insert it at the next
available compatible slot.

Note: If a module such as the power module is planned only for one slot, it is also not
possible to place it at another position in the device configuration.

® Compare your device configuration with the following figure.

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7.7 Insert the ET 200SP interface module IM155-6PN HF

® Open the network view (® Network view)

® Find the correct IM155-6PN HF interface module in the hardware catalog and insert it by
moving it to the network view using drag-and-drop. (® Hardware Catalog ®
Distributed IO → ET 200SP → Interface modules → PROFINET → IM 155-6 PN HF →
6ES7 155-6AU00-0CN0 → Version: V3.1)

® Assign the field device of the CPU 1516F by first clicking on the interface of the
IM155-6PN HF in the network view and then connecting it to the PROFINET interface
(X1) of the CPU 1516F.

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7.8 Configure the ET 200SP / IM 155-6PN HF

® To configure the IM155-6PN HF, first select the IO device. (® IO device 1 )

® In ® "Properties", open the ® "General" menu and enter the "Name" →

"SortingStation01".

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Note: This name is then applied as the device name for PROFINET communication.

® Under "PROFINET device name interface[X1]", the IP address can then be set or the
IO device and the "PROFINET device name" can be checked.
(® PROFINET interface[X1] ® Ethernet addresses ® IP protocol → IP address:
192.168.0.2 → PROFINET → PROFINET device name → SortingStation01)

® The settings for the 'IO cycle' such as 'Update time' and 'Watchdog time' can also be set
here for the device.
(® PROFINET interface[X1] ® Advanced options ® Real time settings → IO cycle →
Update time → 1,000 ms → Watchdog time → 3,000 ms)

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7.9 Insert the 2 digital input modules DI 8x24VDC HF

® Double-click the PROFINET device to change to the device view of the ET 200SP.

® Note: You can also open the device view of the different devices in the drop-down menu
at the top left of the device view.

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® Find the correct digital input module with the matching order number and version in
the hardware catalog. Insert the digital input module into slot 1. (®Hardware Catalog
® DI ® DI 8x24VDC HF → 6ES7 131-6BF00-0CA0 → Version: V1.2)

Notes:
When you double-click a module in the hardware catalog, you insert it automatically at
the next available compatible slot .Insert a digital input module of the same type into
slot 2

If you do not use a slot, you must close the gap before you compile. Otherwise, an error
message occurs.

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7.10 Insert the 2 digital output modules DQ 8x24VDC/0.5A HF

® Find the correct digital output module with the matching order number and version in the
hardware catalog. Insert two digital output modules into slots 3 and 4. (® Hardware
catalog ® DQ ® DQ 8x24VDC/0.5A HF → (6ES7 132-6BF00-0CA0) ® Version: V1.2)

7.11 Replace components in the hardware configuration

® If it becomes necessary to replace a component in the hardware configuration with a
newer version or a different type, this can be done by right-clicking the component and
selecting "Change device". The new replacement component can be selected in the
displayed dialog and the selection can be applied with "OK". (® Change device ® OK)

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Note: If the new component is not displayed for selection, it is not compatible with the
previous component. In this case, the old component must be deleted and the new
component must then be inserted from the hardware catalog.

7.12 Insert the server module

® Find the correct server module with matching order number and version in the hardware
catalog. Insert the server module into slot 5.
(® Hardware Catalog ® Server module ® 6ES7 193-6PA00-0AA0 ® Version: V1.0)

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Note: If you forget the server module, it is automatically created when the device
configuration is compiled.

7.13 Configure the address areas DI/DQ: 0…1

® The next step is to check the address areas of the inputs and output cards and adapt
them if necessary. Inputs and outputs (DI/DQ) should have an address area of 0…1.

(® Device overview ® DI ® I addresses: 0/1 ® DQ ® O addresses: 0/1)

Note: To show and hide the Device overview, you must click the small arrow next to
"Device data" on the right side of the hardware configuration.

7.14 Configuration of the potential groups of the Base Units

® To change the potential group of a Base Unit, select the associated module and open the
Potential group section in the general properties.
(Slot 2 → Properties → General → Potential group)

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® Select the "Enable new potential group (light BaseUnit)" option.

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® The Base Unit now becomes light in the configuration.

® Repeat these steps for slots 3 to 4 and compare the device configuration with the
following figure.

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7.15 Save and compile the hardware configuration

® Before you compile the configuration, you should save your project by clicking the

® button. To compile your CPU with the device configuration, first select

the ® "CPU_1516F [CPU1516F-3 PN/DP]" folder and click the "Compile" icon ® .

Note: "Save project" should be used repeatedly when working on a project since this
does not happen automatically. A prompt to save the project only occurs when the
TIA Portal is closed.

® If the project was compiled without errors, you see the following screen.

Note: A warning appears here because no protection level has been configured. This
warning can be ignored.

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7.16 Assign device name to interface module IM 155-6PN HF

® To obtain an overview of the assigned addresses within a project, you can click

the " " icon in the "Network view".

( ® Network view ® Show addresses)

® In order for the controller, CPU1516F-3 PN/DP in this case, to find the assigned
PROFINET devices in the network, the device name must be assigned to them. This is
done by selecting the network connecting the devices in the "Network view" and clicking

the " " icon.

(® Assign device name )

Note: The IP addresses set in the project are assigned by the controller to the devices
later when the communication connection is established.

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® Online access must be correctly set in the dialog for assignment of the PROFINET device
names. Any device can then be selected individually and filtered by devices of the same
type. If a new device is being connected for the first time, the list has to be updated again.
( ® PROFINET device name: sortingstation01 ® Type of PG/PC interface: PN/IE ®
PG/PC interface: here: Intel(R) Ethernet Connection I217-LM ® Only show devices of

the same type ® )

® The correct device must be always be clearly determined by the MAC address printed on
the device before the name is assigned. To check this, you can also have the LEDs on
the device flash.
(® ®

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® Successful assignment of the PROFINET device name should be checked before closing
the dialog. (® )

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7.17 Download the hardware configuration to the device

® To download your entire CPU, select the ® "CPU_1516F [CPU1516F-3 PN/DP]" folder

and click the ® "Download to device" icon.

® The manager for configuring the connection properties (extended download) opens.

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® First, the interface must be correctly selected. This happens in three steps.

® Type of the PG/PC interface ® PN/IE

®PG/PC interface ® here: Intel(R) Ethernet Connection I217-LM

® Connection to interface/subnet ® "PN/IE_1"

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® The ® "Show all compatible devices" check box must then be selected. The search for
devices in the network is started by clicking the ® button.

® If your CPU is shown in the "Compatible devices in target subnet" list, it must be selected
and the download started.
(® CPU 1516F-3 PN/DP ® )

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® You first obtain a preview. Confirm the prompt ® "Overwrite all" and continue
with ® .

Note: The symbol should be visible in every line of the "Load preview". You can find
additional information in the "Message" column.

® The ® "Start all" option will be selected next before the download operation can be
completed with ® .

® After a successful download, the project view will open again automatically. A download
report appears in the information field under "General". This can be helpful when
troubleshooting an unsuccessful download.

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7.18 Checklist

No. Description Completed

1 Project was created
2 Slot 0: Power module with correct order number
3 Slot 1: CPU with correct order number

4 Slot 1: CPU with correct firmware version

5 IM of the ET 200SP created as distributed IO
6 CPU and IM connected to the same subnet
7 IM is assigned to the CPU

8 ET 200SP slot 1…2: Digital input module with correct order number

9 ET 200SP slot 1…2: Digital input module with correct firmware version

10 ET 200SP slot 1…2: Address area of the digital input module is correct
11 ET 200SP slot 3…4: Digital output module with correct order number

12 ET 200SP slot 3…4: Digital output module with correct firmware version

13 ET 200SP slot 3…4: Address area of the digital output module is correct
14 ET 200SP slot 5: Server module with correct order number

15 ET 200SP slot 5: Server module with correct firmware version

16 ET 200SP modules have all the correct potential groups set for the
Base Units

17 Hardware configuration was compiled without error message

18 Hardware configuration was downloaded without error message
19 Project was successfully archived

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Training Curriculum

TIA Portal Module 004

Basics of FC Programming
with SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 141
2 Prerequisite....................................................................................................................................... 141
3 Required hardware and software ..................................................................................................... 141
4 Theory............................................................................................................................................... 142
4.1 Operating system and application program .............................................................................. 142
4.2 Organization blocks................................................................................................................... 142
4.3 Process image and cyclic program processing......................................................................... 144
4.4 Functions ................................................................................................................................... 145
4.5 Function blocks and instance data blocks................................................................................. 145
4.6 Global data blocks..................................................................................................................... 146
4.7 Library-compatible code blocks................................................................................................. 147
4.8 Programming languages ........................................................................................................... 148
5 Task .................................................................................................................................................. 149
6 Planning ............................................................................................................................................ 149
6.1 EMERGENCY STOP ................................................................................................................ 149
6.2 Manual mode – Conveyor motor in manual mode .................................................................... 149
7 Structured step-by-step instructions ................................................................................................. 150
7.1 Retrieve an existing project ....................................................................................................... 150
7.2 Create a new tag table .............................................................................................................. 151
7.3 Create new tags within a tag table ............................................................................................ 153
7.4 Import "Tag_table_sorting_station" ........................................................................................... 154
7.5 Create function FC1 "MOTOR_MANUAL" for the conveyor motor in manual mode ................ 156
7.6 Define the interface of function FC1 "MOTOR_MANUAL"........................................................ 157
7.7 Program FC1: MOTOR_MANUAL ............................................................................................ 159
7.8 Program organization block OB1 – Control of the forward belt tracking in manual mode ........ 165
7.9 Program organization block OB1 – Control of the backward belt tracking in manual mode..... 170
7.10 Save and compile the program ................................................................................................. 171
7.11 Download the program .............................................................................................................. 172
7.12 Monitor program blocks............................................................................................................. 173
8 Checklist ........................................................................................................................................... 176

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BASICS OF FC PROGRAMMING
1 Goal
In this chapter, you will get to know the basic elements of a control program – the
organization blocks (OBs), functions (FCs), function blocks (FBs) and data blocks
(DBs). In addition, you will be introduced to library-compatible function und function block
programming. You will get to know the Function Block Diagram (FBD) programming
language and use it to program a function (FC1) and an organization block (OB1).

2 Prerequisite
This chapter builds on the hardware configuration of SIMATIC S7 CPU1516F-3 PN/DP.
However, other hardware configurations that have digital input and output cards can be used.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V13

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Operating system and application program
Every controller (CPU) contains an operating system, which organizes all functions and
processes of the CPU that are not associated with a specific control task. The tasks of the
operating system include the following:
- Performing a warm restart
- Updating the process image of the inputs and outputs
- Cyclically calling the user program
- Detecting interrupts and calling interrupt OBs
- Detecting and handling errors
- Managing memory areas
The operating system is an integral component of the CPU and comes pre-installed.
The user program contains all functions that are necessary for executing your specific
automation task. The tasks of the user program include the following:
- Checking the basic requirements for a warm restart using startup OBs
- Processing of process data, i.e. activation of output signals as a function of the input
signal states
- Reaction to interrupts and interrupt inputs
- Error handling during normal program execution

4.2 Organization blocks

Organization blocks (OBs) form the interface between the operating system of the controller
(CPU) and the application program. They are called from the operating system and control the
following operations:
- Cyclic program processing (e.g. OB1)
- Startup characteristics of the controller
- Interrupt-driven program processing
- Error handling
A project must have an organization block for cyclic program processing at a minimum.
An OB is called by a start event as shown in Figure 1. In addition, the individual OBs have
defined priorities so that, for example, an OB82 for error handling can interrupt the cyclic OB1.

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Startup routine
ON (Run)
OB 100 Warm
restart ...

Cyclic program
processing Interrupt-driven
Cycle program processing
OB 1
OB 10 ... 17
OB 56
Interruption
Interrupt ...

Interruption Error handling

Error
OB 80
OB 82
OB 121
OB 122
...
Operating system
Figure
1: Start events in the operating system and OB call
When a start event occurs, the following reactions are possible:
- If an OB has been assigned to the event, this event triggers the execution of the assigned
OB. If the priority of the assigned OB is greater than the priority of the OB that is currently
being executed, it is executed immediately (interrupt). If not, the assigned OB waits until
the higher-priority OB has been completely executed.
- If an OB is not assigned to the event, the default system reaction is performed.
Table 1 gives a couple of examples of start events for a SIMATIC S7-1500, their possible OB
number(s) and the default system reaction in the event the organization block is not present in
the controller.

Start event Possible OB Default system

numbers reaction

Startup 100, ³ 123 Ignore

Cyclic program 1, ³ 123 Ignore
Time-of-day interrupt 10 to 17, ³ 123 -
Update interrupt 56 Ignore
Scan cycle monitoring time 80 STOP
exceeded once

Diagnostic interrupt 82 Ignore

Programming error 121 STOP

IO access error 122 Ignore

Table 1: OB numbers for various start events

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4.3 Process image and cyclic program processing

When the cyclic user program addresses the inputs (I) and outputs (O), it does not query the
signal states directly from the input/output modules. Instead, it accesses a memory area of the
CPU. This memory area contains an image of the signal states and is called the process
image.
The cyclic program processing sequence is as follows:
1. At the start of the cyclic program, a query is sent to determine whether or not the
individual inputs are energized. This status of the inputs is stored in the process image of the
inputs (PII). In doing so, the information 1 or "High" is stored for energized inputs and the
information 0 or "Low" for de-energized inputs.
2. The CPU now executes the program stored in the cyclic organization block. For the
required input information, the CPU accesses the previously read process image of the
inputs (PII) and the results of logic operation (RLOs) are written to a so-called process
image of the outputs (PIQ).
3. At the end of the cycle, the process image of the outputs (PIQ) is transferred as the
signal state to the output modules and these are energized or de-energized. The sequence
then continues again with Item 1.

1. Save status of inputs in PII.

PLC program in the PII

program memory
2. Processing the Local data
1st instruction
program instruction-by-
2nd instruction
instruction with access Bit memory
3rd instruction
to PII and PIQ
4th instruction
... Data blocks

PIQ
Last instruction

3. Transfer status from the PIQ to the outputs.

Figure 2: Cyclic program processing

Note: The time the CPU needs for this sequence is called cycle time. This depends, in turn,
on the number and type of instructions and the processor performance of the controller.

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4.4 Functions
Functions (FCs) are logic blocks without memory. They have no data memory in which
values of block parameters can be stored. Therefore, all interface parameters must be
connected when a function is called. To store data permanently, global data blocks must be
created beforehand.
A function contains a program that is executed whenever the function is called from another
code block.
Functions can be used, for example, for the following purposes:
- Math functions – that return a result dependent on input values.
- Technological functions – such as individual controls with binary logic operations.
A function can also be called several times at different points within a program.

Organization block
Main [OB1]

Calls the MOTOR_MANUAL

MOTOR_MANUAL [FC1]
[FC1] function
Contains a program for
controlling a conveyor
in manual mode, for
example.

The function has no

memory.

Figure 3: Function with call from organization block Main [OB1]

4.5 Function blocks and instance data blocks

Function blocks are code blocks that store their input, output and in-out tags as well as static
tags permanently in instance data blocks, so that they are available after the block has been
executed. For this reason, they are also referred to as blocks with "memory".
Function blocks can also operate with temporary tags. Temporary tags are not stored in the
instance DB, however. Instead, they are only available for one cycle.
Function blocks are used for tasks that cannot be implemented with functions:
- Whenever timers and counters are required in the blocks.
- Whenever information must be saved in the program, such as pre-selection of the
operating mode with a button.

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Function blocks are always executed when called from another code block. A function block
can also be called several times at different points within a program. This facilitates the
programming of frequently recurring complex functions.
A call of a function block is referred to as an instance. Each instance of a function block is
assigned a memory area that contains the data that the function block uses. This memory is
made available by data blocks created automatically by the software.
It is also possible to provide memory for multiple instances in one data block in the form of a
multi-instance. The maximum size of instance data blocks varies depending on the CPU. The
tags declared in the function block determine the structure of the instance data block.

Instance data block

MOTOR_AUTO_DB1
Organization block [DB1] as memory
Main [OB1] for the call of
Function block
function block
Calls function block MOTOR_AUTO [FB1]
MOTOR_AUTO
MOTOR_AUTO [FB1] [FB1]
together with its Contains a program for
instance data block controlling a conveyor
MOTOR_AUTO_DB1 in automatic mode, for
[DB1] example
The function block
uses instance data
block
MOTOR_AUTO_DB1
[DB1] as memory in
this call.

Figure 4: Function block and instance with call from organization block Main [OB1]

4.6 Global data blocks

In contrast to logic blocks, data blocks contain no instructions. Rather, they serve as memory
for user data.
Data blocks thus contain variable data that is used by the user program. You can define the
structure of global data blocks as required.
Global data blocks store data that can be used by all other blocks (see Figure 5). Only the
associated function block should access instance data blocks. The maximum size of data
blocks varies depending on the CPU.

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Function_10
Global DB
Access for all blocks
(DB_Global)

Function_11

Function_ Instance DB Access only for function data block_12

block_12 (DB_Instance)

Figure 5: Difference between global DB and instance DB.

Application examples for global data blocks are:

- Saving of information about a storage system. "Which product is located where?"
- Saving of recipes for particular products.

4.7 Library-compatible code blocks

A user program can be created with linear or structured programming. Linear programming
writes the entire user program in the cycle OB, but is only suitable for very simple programs for
which other less expensive control systems, such as LOGO!, can now be used.
Structured programming is always recommended for more complex programs. Here, the
overall automation task can be broken down into small sub-tasks in order to implement a
solution for them in functions and function blocks.
In this case, library-compatible logic blocks should be created preferentially. This means that
the input and output parameters of a function or function block are defined generally and only
supplied with the current global tags (inputs/outputs) when the block is used.

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Figure 6: Library-compatible function with call in OB1

4.8 Programming languages

The available programming languages for programming functions are Function Block Diagram
(FBD), Ladder Logic (LAD), Statement List (STL) and Structured Control Language (SCL). For
function blocks, the GRAPH programming language is additionally available for programming
graphical step sequences.
The Function Block Diagram (FBD) programming language will be presented in the
following.
FBD is a graphical programming language. The representation is based on electronic
switching systems. The program is mapped in networks. A network contains one or more logic
operation paths. Binary and analog signals are linked by boxes. The graphical logic symbols
known from Boolean algebra are used to represent the binary logic.
You can use binary functions to query binary operands and to logically combine their signal
states. The following instructions are examples of binary functions: "AND operation", "OR
operation" and "EXCLUSIVE OR operation". These are shown in Figure 7.

Figure 7: Binary functions in FBD and associated logic table

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You can thus use simple instructions, for example, to control binary outputs, evaluate edges
and execute jump functions in the program.
Program elements such as IEC timers and IEC counters provide complex instructions.
The empty box serves as a placeholder in which you can select the required instruction.
Enable input EN (enable)/ Enable output ENO (enable output) mechanism:
- An instruction without EN/ENO mechanism is executed independent of the signal state at
the box inputs.

- Instructions with EN/ENO mechanism are only executed if enable input "EN input has
signal state "1". When the box is processed correctly, enable output "ENO" has signal
state "1". As soon as an error occurs during the processing, the "ENO" enable output is
reset. If enable input EN is not connected, the box is always executed.

5 Task
The following functions of the sorting station process description will be planned, programmed
and tested in this chapter:
- Manual mode – Conveyor motor in manual mode

6 Planning
The programming of all functions in OB1 is not recommended for reasons of clarity and
reusability. The majority of the program code will therefore be moved into functions (FCs) and
function blocks (FBs). The decision on which functions are be moved to FCs and which is to
run in OB 1 is planned below.

6.1 EMERGENCY STOP

The EMERGENCY STOP does not require a separate function. Just like the operating mode,
the current state of the EMERGENCY STOP relay can be used directly at the blocks.

6.2 Manual mode – Conveyor motor in manual mode

Manual mode of the conveyor motor is to be encapsulated in a function (FC)
"MOTOR_MANUAL". On the one hand, this preserves the clarity of OB1. On the other hand, it
enables reuse if another conveyor belt is added to the station. Table 2 lists the planned
parameters.

Input Data Comment

type
Manual_mode_active BOOL Manual mode activated
Pushbutton_manual_mode BOOL Pushbutton manual mode conveyor on
Enable_OK BOOL All enable conditions OK

Safety_shutoff_active BOOL Safety shutoff active, e.g. emergency stop

pressed

Output

Conveyor_motor_manual_mode BOOL Control of the conveyor motor in manual

mode
Table 2: Parameters for FC "MOTOR_MANUAL"

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Output Conveyor_motor_manual_mode is ON as long as Pushbutton_manual_mode is

pressed, manual mode is activated, the enable conditions are OK and the safety shutoff is not
active.

7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can start programming the function (FC) "MOTOR_MANUAL", we need a
project with a hardware configuration (e.g.
SCE_EN_012_101_Hardware_Configuration_S7-1516F_R1502.zap). To retrieve an
existing project that has been archived, you must select the relevant archive with ®
Project ® Retrieve in the project view Confirm your selection with Open. (® Project ®
Retrieve ® Select a .zap archive ® Open)

® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK". (® Target directory ® OK)

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7.2 Create a new tag table

® In the project view, navigate to the ® PLC tags of your controller and create a new tag
table by double-clicking ® Add new tag table.

® Rename the tag table you just created as "Tag_table_sorting_station" (® right-click

"Tag_table_1" ® "Rename" ® Tag_table_sorting_station).

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® Open this tag table with a double-click. (® Tag_table_sorting_station)

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7.3 Create new tags within a tag table

® Add the name Q1 and confirm the entry with the Enter key. If you have not yet created
additional tags, TIA Portal now automatically assigns data type "Bool" and address %I0.0
(I 0.0) (® <Add> ® Q1 ® Enter).

® Change the address to %Q0.0 (Q 0.0) by entering this directly or by clicking the drop-
down arrow to open the Addressing menu, changing the operand identifier to Q and
confirming with Enter or by clicking the check mark. (® %I0.0 ® Operand identifier ® Q
® )

® Enter the "Conveyor motor M1 forwards fixed speed" comment for the tag.

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® Add a new Q2 tag in line 2. TIA Portal has automatically assigned the same data type as
in line 1 and has incremented the address by 1 to %Q0.1 (Q0.1). Enter the comment
"Conveyor motor M1 backwards fixed speed".

(® <Add> ® Q2 ® Enter ® Comment ® Conveyor motor M1 backwards fixed speed)

7.4 Import "Tag_table_sorting_station"

® To insert an existing symbol table, right-click on an empty field of the created
"Tag_table_sorting_station". Select "Import file" in the shortcut menu.

(® Right-click in an empty field of the tag table ® Import file)

® Select the desired symbol table (e.g. in .xlsx format) and confirm the selection with
"Open".

(® SCE_EN_020-100_Tag_table_sorting_station… ® Open)

® When the import is finished, you will see a confirmation window and have an opportunity
to view the log file for the import. Click ® OK.

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® You can see that some addresses have been highlighted in orange. These are duplicate
addresses and the names of the associated tags have been numbered automatically to
avoid confusion.

® Delete the duplicate tags by selecting the lines and pressing the Del key on your
keyboard or by selecting "Delete" in the shortcut menu.

(® Right-click on selected tags ® Delete)

® You now have a complete symbol table of the digital inputs and outputs in front of you.
Save your project under the name 032-100_FCProgramming.

(® Project ® Save as ...®032-100_FCProgramming ® Save)

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7.5 Create function FC1 "MOTOR_MANUAL" for the conveyor

motor in manual mode
® In the PLC programming section of the portal view, click "Add new block" to create a new
function.

(® PLC programming ® Add new block ® )

® Rename your new block to: "MOTOR_MANUAL", set the language to FBD and keep
automatic assignment of the number. Select the "Add new and open" check box. You are
then taken automatically to your created function block in the project view.Click "Add".

(® Name: MOTOR_MANUAL® Language: FBD ® Number: Automatic ® Add new

and open ® Add)

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7.6 Define the interface of function FC1 "MOTOR_MANUAL"

® If you selected "Add new and open", the project view opens with a window for creating
the block you just added.

® You can find the interface description of your function in the upper section of your
programming view.

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® A binary output signal is needed for controlling the conveyor motor. For this reason, we
first create local output tag #Conveyor_motor_manual_mode of the "Bool" type. Enter
comment "Control of the conveyor motor in manual mode" for the parameter.

(® Output: Conveyor_motor_manual_mode ® Bool ® Control of the conveyor motor in

manual mode)

® Add parameter #Manual_mode_active as the input interface under Input and confirm the
entry with the Enter key or by exiting the entry field. Data type "Bool" is assigned
automatically. This will be retained. Next, enter the associated comment "Manual mode
activated".

(® Manual_mode_active ® Enter ® Bool ® Manual mode activated)

® Add parameters #Pushbutton_manual_mode, #Enable_OK and #Safety_shutoff_active

as additional binary input parameters under Input and check their data types. Add
descriptive comments.

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® For purposes of program documentation, assign the block title, a block comment and a
helpful network title for Network 1.

(® Block title: Motor control in manual mode ® Network 1: Control of the conveyor motor
in manual mode)

7.7 Program FC1: MOTOR_MANUAL

® Below the interface description, you see a toolbar in the programming window with
various logic functions and below that an area with networks. We have already specified
the block title and the title for the first network there. Programming is performed within the
networks using individual logic blocks. Distribution among multiple networks helps to
preserve the clarity of the program. In the following, you will get to know the various ways
you can insert logic blocks.

® You can see a list of instructions you can use in the program on the right side of your
programming window. Under ® Basic instructions ® Bit logic operations, find function –
[=] (Assignment) and use a drag-and-drop operation to move it to Network 1 (green line
appears, mouse pointer with + symbol).

(® Instructions ® Basic instructions ® Bit logic operations ® –[=])

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® Now use drag-and-drop to move your output parameter #Conveyor_motor_manual_mode

onto <??.?> above the block you just inserted. The best way to select a parameter in the

interface description is by "grabbing" it at the blue symbol .

(® Conveyor_motor_manual_mode)

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® This determines that the #Conveyor_motor_manual_mode parameter is written by this

block. Still missing, however, are the input conditions so that this actually happens. For
this, use drag-and-drop to move input parameter #Manual_mode_active to the left side of
the assignment block.

(® Manual_mode_active)

® The input of the assignment block will also be logically combined with other parameters
by an AND logic operation. To do this, first click the input of the block to which
#Manual_mode_active is already connected, so that the input line has a blue background.

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® Click the icon in your logic toolbar to insert an AND logic operation between the
#Manual_mode_active tag and your assignment block.

® Double-click the second input of the & logic operation <??.?> and enter the letter "P" in
the field that appears in order to see a list of available tags starting with "P".Click the
#Pushbutton_manual_mode tag and apply with ® Enter.

(® &- block ® <??.?> ® P ® #Pushbutton_manual_mode ® Enter)

Note: When assigning tags in this way, there is a risk of a mix-up with the global tags from the
tag table. The previously presented procedure using drag and drop from the interface
description should therefore be used preferentially.

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® To ensure that the output can only be controlled when the enable conditions are met and
the safety shutoff is not active, the #Enable_OK and #Safety_shutoff_active input tags
are logically combined with the AND logic operation. To do this, click twice on the yellow

star of your AND block to add two additional inputs.

® Add input tags #Enable_OK and #Safety_shutoff_active to your newly created inputs of
the AND block.

® Negate the input connected to parameter #Safety_shutoff_active by selecting it and

clicking .

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® Do not forget to click . The finished function "MOTOR_MANUAL" [FC1] in

FBD is shown below.

® Under "General" in the properties of the block, you can change the "Language" to LAD
(Ladder Logic) (®Properties ® General ® Language: LAD)

® The program has the following appearance in LAD.

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7.8 Program organization block OB1 – Control of the forward belt

tracking in manual mode
® Before programming organization block "Main [OB1]", we switch the programming
language to FBD (Function Block Diagram). To do so, first click on "Main [OB1]" in the
"Program blocks" folder.

(® CPU_1516F[CPU 1516F-3 PN/DP ® Program blocks ® Main [OB1] ® Switch

programming language ® FBD)

® Open the "Main [OB1]" organization block with a double-click.

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® Assign Network 1 the name "Control conveyor tracking forward in manual/jog mode"

(® Network 1:... ®Control conveyor motor forwards in manual mode)

® Use drag-and-drop to move your "MOTOR_MANUAL [FC1]" function onto the green line
in Network 1.

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® A block with the interface you defined and connections EN and ENO are inserted in
Network 1.

® To insert an AND before input parameter "Enable_OK", select this input and insert the

AND by clicking the icon in your logic toolbar (® ).

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® Click the yellow star of the AND block to add another input (® ).

® To connect the block to the global tags from "Tag_table_sorting_station", we have two
options:

® Either select the "Tag_table_sorting_station" in the project tree and use drag-and-drop to
move the desired global tag from the Details view to the interface of FC1
(® Tag_table_sorting_station ® Details view. ® -SO2 ® Manual_mode_active)

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® Or, enter the starting letters (e.g. "-S") of the desired global tag for <??.?> and select the
global input tag "-S0" (%I0.2) from the displayed list (® Manual_mode_active ® -S ®
-S0).

® Insert the other input tags "-S3", "-K0", "-B1", "-S4" and "-A1" and insert output tag "-Q1"
(%Q0.0) at output "Conveyor_motor_manual_mode".

® Negate the querying of input tags "-S0", "-S4" and "-A1" by selecting them and clicking

(® -S0 ® ® -S4 ® ® -A1 ® ).

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7.9 Program organization block OB1 – Control of the backward

belt tracking in manual mode
® Assign Network 2 the name "Control conveyor motor backwards in manual mode" and
insert your "MOTOR_MANUAL [FC1]" function using drag-and-drop, as you did
previously in Network 1.

® Connect your function as shown here. You obtain the following result in the FBD
(Function Block Diagram) programming language.

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® The result in the LAD (Ladder Logic) programming language has the following
appearance.

7.10 Save and compile the program

® To save your project, select the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu

(® ® Program blocks ® ).

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® The "Info", "Compile" area shows which blocks were successfully compiled.

7.11 Download the program

® After successful compilation, the complete controller with the created program, as
previously described in the modules for hardware configuration, can be downloaded

(® ).

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7.12 Monitor program blocks

® The desired block must be open for monitoring the downloaded program. The monitoring

can be activated/deactivated by clicking the icon. (® Main [OB1] ® )

Note: The monitoring here is signal-related and controller-dependent. The signal states at the
terminals are indicated with TRUE or FALSE.

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® The "MOTOR_MANUAL" [FC1] function called in the "Main [OB1]" organization block can
be selected directly for "Open and monitor" after right-clicking (® "MOTOR_MANUAL"
[FC1] ® Open and monitor).

Note: The monitoring here is function-related and controller-independent. The actuation of

sensors and the station status are shown here with TRUE or FALSE.

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® If a particular point of use of the "MOTOR_MANUAL" [FC1] function is to be monitored,

the call environment can be selected using the icon (® ® Call environment ®
OK)

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8 Checklist
No. Description Completed

1 Compiling successful and without error message

2 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
3
MANUAL mode (-S0 = 0)
Activate conveyor manual mode conveyor forward (-S3 = 1)
then conveyor motor forwards fixed speed (-Q1 = 1)

4 Same as 3 but activate EMERGENCY OFF (-A1 = 0) ® -Q1 = 0

5 Same as 3 but AUTO mode (-S0 = 1) ® -Q1 = 0

6 Same as 3 but switch off station (-K0 = 0) ® -Q1 = 0

7 Same as 3 but cylinder not retracted (-B1 = 0) ® -Q1 = 0

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
8
MANUAL mode (-S0 = 0)
Activate conveyor manual mode reverse (-S4 = 1)
then conveyor motor backwards fixed speed (-Q2 = 1)

9 Same as 8 but activate EMERGENCY OFF (-A1 = 0) ® -Q2 = 0

10 Same as 8 but AUTO mode (-S0 = 1) ® -Q2 = 0

11 Same as 8 but switch off station (-K0 = 0) ® -Q2 = 0

12 Same as 8 but cylinder not retracted (-B1 = 0) ® -Q2 = 0

Same as 8 but also activate manual mode conveyor forwards

13
(-S3 = 1) ® -Q1 = 0 and -Q2 = 0

14 Project successfully archived

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Training Curriculum

TIA Portal Module 005

Basics of FB Programming
with SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 179
2 Prerequisite....................................................................................................................................... 179
3 Required hardware and software ..................................................................................................... 179
4 Theory............................................................................................................................................... 180
4.1 Operating system and application program .............................................................................. 180
4.2 Organization blocks................................................................................................................... 180
4.3 Process image and cyclic program processing......................................................................... 182
4.4 Functions ................................................................................................................................... 183
4.5 Function blocks and instance data blocks................................................................................. 183
4.6 Global data blocks..................................................................................................................... 184
4.7 Library-compatible code blocks................................................................................................. 185
4.8 Programming languages ........................................................................................................... 186
5 Task .................................................................................................................................................. 187
6 Planning ............................................................................................................................................ 187
6.1 EMERGENCY STOP ................................................................................................................ 187
6.2 Automatic mode - Conveyor motor............................................................................................ 188
7 Structured step-by-step instructions ................................................................................................. 188
7.1 Retrieve an existing project ....................................................................................................... 188
7.2 Create a new tag table .............................................................................................................. 189
7.3 Create new tags within a tag table ............................................................................................ 191
7.4 Import "Tag_table_sorting_station" ........................................................................................... 192
7.5 Create function block FB1 "MOTOR_AUTO" for the conveyor motor in automatic mode ........ 194
7.6 Define the interface of FB1 "MOTOR_AUTO" .......................................................................... 195
7.7 Program FB1: MOTOR_AUTO.................................................................................................. 197
7.8 Program organization block OB1 – Control of the forward belt tracking in automatic mode .... 204
7.9 The result in the LAD (Ladder Logic) programming language has the following appearance. . 208
7.10 Save and compile the program ................................................................................................. 209
7.11 Download the program .............................................................................................................. 209
7.12 Monitor program blocks............................................................................................................. 210
8 Checklist ........................................................................................................................................... 213

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BASICS OF FB PROGRAMMING
1 Goal
In this chapter, you will get to know the basic elements of a control program – the
organization blocks (OBs), functions (FCs), function blocks (FBs) and data blocks
(DBs). In addition, you will be introduced to library-compatible function und function block
programming. You will get to know the Function Block Diagram (FBD) programming
language and use it to program a function block (FB1) and an organization block (OB1).

2 Prerequisite
This chapter builds on the hardware configuration of SIMATIC S7 CPU1516F-3 PN/DP.
However, other hardware configurations that have digital input and output cards can be used.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V1X

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Operating system and application program
Every controller (CPU) contains an operating system, which organizes all functions and
processes of the CPU that are not associated with a specific control task. The tasks of the
operating system include the following:
- Performing a warm restart
- Updating the process image of the inputs and outputs
- Cyclically calling the user program
- Detecting interrupts and calling interrupt OBs
- Detecting and handling errors
- Managing memory areas
The operating system is an integral component of the CPU and comes pre-installed.
The user program contains all functions that are necessary for executing your specific
automation task. The tasks of the user program include the following:
- Checking the basic requirements for a warm restart using startup OBs
- Processing of process data, i.e. activation of output signals as a function of the input
signal states
- Reaction to interrupts and interrupt inputs
- Error handling during normal program execution

4.2 Organization blocks

Organization blocks (OBs) form the interface between the operating system of the controller
(CPU) and the application program. They are called from the operating system and control the
following operations:
- Cyclic program processing (e.g. OB1)
- Startup characteristics of the controller
- Interrupt-driven program processing
- Error handling
A project must have an organization block for cyclic program processing at a minimum.
An OB is called by a start event as shown in Figure 1. In addition, the individual OBs have
defined priorities so that, for example, an OB82 for error handling can interrupt the cyclic OB1.

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Startup routine
ON (Run)
OB 100 Warm
restart ...

Cyclic program
processing Interrupt-driven
Cycle program processing
OB 1
OB 10 ... 17
OB 56
Interruption
Interrupt ...

Interruption Error handling

Error
OB 80
OB 82
OB 121
OB 122
...
Operating system
Figure 1:
Start events in the operating system and OB calls
When a start event occurs, the following reactions are possible:
- If an OB has been assigned to the event, this event triggers the execution of the assigned
OB. If the priority of the assigned OB is greater than the priority of the OB that is currently
being executed, it is executed immediately (interrupt). If not, the assigned OB waits until
the higher-priority OB has been completely executed.
- If an OB is not assigned to the event, the default system reaction is performed.

Table 1 gives a couple of examples of start events for a SIMATIC S7-1500, their possible OB
number(s) and the default system reaction in the event the organization block is not present in
the controller.

Start event Possible OB Default system

numbers reaction

Startup 100, ³ 123 Ignore

Cyclic program 1, ³ 123 Ignore
Time-of-day interrupt 10 to 17, ³ 123 -
Update interrupt 56 Ignore
Scan cycle monitoring time 80 STOP
exceeded once

Diagnostic interrupt 82 Ignore

Programming error 121 STOP

IO access error 122 Ignore

Table 1: OB numbers for various start events

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4.3 Process image and cyclic program processing

When the cyclic user program addresses the inputs (I) and outputs (O), it does not query the
signal states directly from the input/output modules. Instead, it accesses a memory area of the
CPU. This memory area contains an image of the signal states and is called the process
image.
The cyclic program processing sequence is as follows:
1. At the start of the cyclic program, a query is sent to determine whether or not the
individual inputs are energized. This status of the inputs is stored in the process image of the
inputs (PII). In doing so, the information 1 or "High" is stored for energized inputs and the
information 0 or "Low" for de-energized inputs.
2. The CPU now executes the program stored in the cyclic organization block. For the
required input information, the CPU accesses the previously read process image of the
inputs (PII) and the results of logic operation (RLOs) are written to a so-called process
image of the outputs (PIQ).
3. At the end of the cycle, the process image of the outputs (PIQ) is transferred as the
signal state to the output modules and these are energized or de-energized. The sequence
then continues again with Item 1.

1. Save status of inputs in PII.

PLC program in the PII

program memory
2. Processing the Local data
1st instruction
program instruction-by-
2nd instruction
instruction with access Bit memory
3rd instruction
to PII and PIQ
4th instruction
... Data blocks

PIQ
Last instruction

3. Transfer status from the PIQ to the outputs.

Figure 2: Cyclic program processing

Note: The time the CPU needs for this sequence is called cycle time. This depends, in turn,
on the number and type of instructions and the processor performance of the controller.

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4.4 Functions
Functions (FCs) are logic blocks without memory. They have no data memory in which
values of block parameters can be stored. Therefore, all interface parameters must be
connected when a function is called. To store data permanently, global data blocks must be
created beforehand.
A function contains a program that is executed whenever the function is called from another
code block.
Functions can be used, for example, for the following purposes:
- Math functions – that return a result dependent on input values.
- Technological functions – such as individual controls with binary logic operations.
A function can also be called several times at different points within a program.

Organization block
Main [OB1]

Calls the MOTOR_MANUAL

MOTOR_MANUAL [FC1]
[FC1] function
Contains a program for
controlling a conveyor
in manual mode, for
example.

The function has no

memory.

Figure 3: Function with call from organization block Main [OB1]

4.5 Function blocks and instance data blocks

Function blocks are code blocks that store their input, output and in-out tags as well as static
tags permanently in instance data blocks, so that they are available after the block has been
executed. For this reason, they are also referred to as blocks with "memory".
Function blocks can also operate with temporary tags. Temporary tags are not stored in the
instance DB, however. Instead, they are only available for one cycle.
Function blocks are used for tasks that cannot be implemented with functions:
- Whenever timers and counters are required in the blocks.
- Whenever information must be saved in the program, such as pre-selection of the
operating mode with a button.

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Function blocks are always executed when called from another code block. A function block
can also be called several times at different points within a program. This facilitates the
programming of frequently recurring complex functions.
A call of a function block is referred to as an instance. Each instance of a function block is
assigned a memory area that contains the data that the function block uses. This memory is
made available by data blocks created automatically by the software.
It is also possible to provide memory for multiple instances in one data block in the form of a
multi-instance. The maximum size of instance data blocks varies depending on the CPU. The
tags declared in the function block determine the structure of the instance data block.

Instance data block

MOTOR_AUTO_DB1
Organization block [DB1] as memory
Main [OB1] for the call of
Function block function block
Calls function block MOTOR_AUTO [FB1] MOTOR_AUTO
MOTOR_AUTO [FB1] [FB1]
together with its Contains a program for
instance data block controlling a conveyor
MOTOR_AUTO_DB1 in automatic mode, for
[DB1] example
The function block
uses instance data
block
MOTOR_AUTO_DB1
[DB1] as memory in
this call.

Figure 4: Function block and instance with call from organization block Main [OB1]

4.6 Global data blocks

In contrast to logic blocks, data blocks contain no instructions. Rather, they serve as memory
for user data.
Data blocks thus contain variable data that is used by the user program. You can define the
structure of global data blocks as required.
Global data blocks store data that can be used by all other blocks (see Figure 5). Only the
associated function block should access instance data blocks. The maximum size of data
blocks varies depending on the CPU.

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Function_10
Global DB
Access for all blocks
(DB_Global)

Function_11

Function_ Instance DB Access only for function data

block_12 (DB_Instance) block_12

Figure 5: Difference between global DB and instance DB.

Application examples for global data blocks are:

- Saving of information about a storage system. "Which product is located where?"
- Saving of recipes for particular products.

4.7 Library-compatible code blocks

A user program can be created with linear or structured programming. Linear programming
writes the entire user program in the cycle OB, but is only suitable for very simple programs for
which other less expensive control systems, such as LOGO!, can now be used.
Structured programming is always recommended for more complex programs. Here, the
overall automation task can be broken down into small sub-tasks in order to implement a
solution for them in functions and function blocks.
In this case, library-compatible logic blocks should be created preferentially. This means that
the input and output parameters of a function or function block are defined generally and only
supplied with the current global tags (inputs/outputs) when the block is used.

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Figure 6: Library-compatible function with call in OB1

4.8 Programming languages

The available programming languages for programming functions are Function Block Diagram
(FBD), Ladder Logic (LAD), Statement List (STL) and Structured Control Language (SCL). For
function blocks, the GRAPH programming language is additionally available for programming
graphical step sequences.
The Function Block Diagram (FBD) programming language will be presented in the
following.
FBD is a graphical programming language. The representation is based on electronic
switching systems. The program is mapped in networks. A network contains one or more logic
operation paths. Binary and analog signals are linked by boxes. The graphical logic symbols
known from Boolean algebra are used to represent the binary logic.
You can use binary functions to query binary operands and to logically combine their signal
states. The following instructions are examples of binary functions: "AND operation", "OR
operation" and "EXCLUSIVE OR operation". These are shown in Figure 7.

Figure 7: Binary functions in FBD and associated logic table

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You can thus use simple instructions, for example, to control binary outputs, evaluate edges
and execute jump functions in the program.
Program elements such as IEC timers and IEC counters provide complex instructions.
The empty box serves as a placeholder in which you can select the required instruction.
Enable input EN (enable)/ Enable output ENO (enable output) mechanism:
- An instruction without EN/ENO mechanism is executed independent of the signal state at
the box inputs.

- Instructions with EN/ENO mechanism are only executed if enable input "EN input has
signal state "1". When the box is processed correctly, enable output "ENO" has signal
state "1". As soon as an error occurs during the processing, the "ENO" enable output is
reset. If enable input EN is not connected, the box is always executed.

5 Task
The following functions of the sorting station process description will be planned, programmed
and tested in this chapter:
- Automatic mode - Conveyor motor

6 Planning
The programming of all functions in OB1 is not recommended for reasons of clarity and
reusability. The majority of the program code will therefore be moved into functions (FCs) and
function blocks (FBs). The decision on which functions is to be moved to the FB and which is
to run in OB 1 is planned below.

6.1 EMERGENCY STOP

The EMERGENCY STOP does not require a separate function. Just like the operating mode,
the current state of the EMERGENCY STOP relay can be used directly at the blocks.

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6.2 Automatic mode - Conveyor motor

Automatic mode of the conveyor motor is to be encapsulated in a function block (FB)
"MOTOR_AUTO". On the one hand, this preserves the clarity of OB1. On the other hand, it
enables reuse if another conveyor belt is added to the station. Table 2 lists the planned
parameters.

Input Data Comment

type
Automatic_mode_active BOOL Automatic mode activated
Start BOOL Pushbutton automatic start
Stop BOOL Pushbutton automatic stop
Enable_OK BOOL All enable conditions OK
BOOL Safety shutoff active, e.g. emergency stop
Safety_shutoff_active
pressed

Output
BOOL Control of the conveyor motor in automatic
Conveyor_motor_automatic_mode
mode

Static
BOOL Memory used for start/stop automatic mode
Memory_automatic_start_stop

Table 2: Parameters for FB "MOTOR_AUTO"

The Memory_automatic_start_stop is latched with Start but only if the reset conditions are not
present.
The Memory_automatic_start_stop is reset if Stop is present or safety shutoff is active or
automatic mode is not activated (manual mode).
The Conveyor_motor_automatic_mode output is controlled when
Memory_automatic_start_stop is set and the enable conditions are met.

7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can start programming the function block (FB) "MOTOR_AUTO", we need a
project with a hardware configuration (e.g.
SCE_EN_012_101_Hardware_Configuration_S7-1516F_R1502.zap). To retrieve an
existing project that has been archived, you must select the relevant archive with ®
Project ® Retrieve in the project view. Confirm your selection with Open. (® Project ®
Retrieve ® Select a .zap archive ® Open)

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® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK". (® Target directory ® OK)

7.2 Create a new tag table

® In the project view, navigate to the ® PLC tags of your controller and create a new tag
table by double-clicking ® Add new tag table.

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® Rename the tag table you just created as "Tag_table_sorting_station" (® right-click

"Tag_table_1" ® "Rename" ® Tag_table_sorting_station).

® Open this tag table with a double-click. (® Tag_table_sorting_station)

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7.3 Create new tags within a tag table

® Add the name Q1 and confirm the entry with the Enter key. If you have not yet created
additional tags, TIA Portal now automatically assigns data type "Bool" and address %I0.0
(I 0.0) (® <Add> ® Q1 ® Enter).

® Change the address to %Q0.0 (Q 0.0) by entering this directly or by clicking the drop-
down arrow to open the Addressing menu, changing the operand identifier to Q and
confirming with Enter or by clicking the check mark. (® %I0.0 ® Operand identifier ® Q
® )

® Enter the "Conveyor motor M1 forwards fixed speed" comment for the tag.

® Add a new Q2 tag in line 2. TIA Portal has automatically assigned the same data type as
in line 1 and has incremented the address by 1 to %Q0.1 (Q0.1). Enter the comment
"Conveyor motor M1 backwards fixed speed".

(® <Add> ® Q2 ® Enter ® Comment ® Conveyor motor M1 backwards fixed speed)

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7.4 Import "Tag_table_sorting_station"

® To insert an existing symbol table, right-click on an empty field of the created
"Tag_table_sorting_station". Select "Import file" in the shortcut menu.

(® Right-click in an empty field of the tag table ® Import file)

® Select the desired symbol table (e.g. in .xlsx format) and confirm the selection with
"Open".

(® SCE_EN_020-100_Tag_table_sorting_station… ® Open)

® When the import is finished, you will see a confirmation window and have an opportunity
to view the log file for the import. Click ® OK.

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® You can see that some addresses have been highlighted in orange. These are duplicate
addresses and the names of the associated tags have been numbered automatically to
avoid confusion.

® Delete the duplicate tags by selecting the lines and pressing the Del key on your
keyboard or by selecting "Delete" in the shortcut menu.

(® Right-click on selected tags ® Delete)

® You now have a complete symbol table of the digital inputs and outputs in front of you.
Save your project under the name 032-100_FCProgramming.

(® Project ® Save as ... ®032-200_FBProgramming ® Save)

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7.5 Create function block FB1 "MOTOR_AUTO" for the conveyor

motor in automatic mode
® In the PLC programming section of the portal view, click "Add new block" to create a new
function block.

(® PLC programming ® Add new block ® )

® Rename your new block to: "MOTOR_AUTO", set the language to FBD and keep
automatic assignment of the number. Select the "Add new and open" check box. You are
then taken automatically to your created function block in the project view.Click "Add".

(® Name: MOTOR_AUTO®Language: FBD ® Number: Automatic ® Add new and

open ® Add)

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7.6 Define the interface of FB1 "MOTOR_AUTO"

® If you selected "Add new and open", the project view opens with a window for creating
the block you just added.

® You can find the interface description of your function block in the upper section of your
programming view.

® A binary output signal is needed for controlling the conveyor motor. For this reason, we
first create local output tag #Conveyor_motor_automatic_mode of the "Bool" type. Enter
the comment "Control of the conveyor motor in automatic mode" for the parameter.

(® Output: Conveyor_motor_automatic_mode ® Bool ® Control of the conveyor motor

in automatic mode)

® Add parameter #Automatic_mode_active as the input interface under Input and confirm
the entry with the Enter key or by exiting the entry field. Data type "Bool" is assigned

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automatically. This will be retained. Next, enter the associated comment "Automatic mode
activated".

(® Automatic_mode_active ® Bool ® Automatic mode activated)

® Add parameters #Start, #Stop, #Enable_OK and #Safety_shutoff_active as additional

binary input parameters under Input and check their data types. Add descriptive
comments.

The conveyor is started and stopped with pushbuttons. We therefore need a "Static" tag
as a memory. Under Static, add tag #Memory_automatic_start_stop and confirm the entry
with the Enter key or by exiting the entry field. Data type "Bool" is assigned automatically.
This will be retained. Enter the associated comment "Memory used for start/stop
automatic mode". (® Memory_automatic_start_stop ® Bool ® Memory used for
start/stop automatic mode)

® For purposes of program documentation, assign the block title, a block comment and a
helpful network title for Network 1.

(® Block title: Motor control in automatic mode ® Network 1:

Memory_automatic_start_stop and control of the conveyor motor in automatic mode)

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7.7 Program FB1: MOTOR_AUTO

® Below the interface description, you see a toolbar in the programming window with
various logic functions and below that an area with networks. We have already specified
the block title and the title for the first network there. Programming is performed within the
networks using individual logic blocks. Distribution among multiple networks helps to
preserve the clarity of the program. In the following, you will get to know the various ways
you can insert logic blocks.

® You can see a list of instructions you can use in the program on the right side of your
programming window. Under ® Basic instructions ® Bit logic operations, find function

(Assignment) and use a drag-and-drop operation to move it to Network 1

(green line appears, mouse pointer with + symbol).

(® Instructions ® Basic instructions ® Bit logic operations ® )

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® Now use drag-and-drop to move your output parameter

#Conveyor_motor_automatic_mode onto <??.?> above the block you just inserted. The
best way to select a parameter in the interface description is by "grabbing" it at the blue

symbol .

(® Conveyor_motor_automatic_mode)

® This determines that the #Conveyor_motor_automatic_mode parameter is written by this

block. Still missing, however, are the input conditions so that this actually happens. An
SR flip-flop and #Enable_OK parameter are logically combined with an AND logic
operation at the input of the assignment block. To do this, first click the input of the block
so that the input line has a blue background.

® Click the icon in your logic toolbar to insert an AND logic operation before your
assignment block.

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® Use drag-and-drop to move input parameter #Enable_OK onto the second input of the &

logic operation <??.?>. (® Enable_OK)

® Use drag-and-drop to move the Set/reset flip-flop function from the list of
instructions under ® Basic instructions ® Bit logic operations onto the first input of the &
operation .

(® Instructions ® Basic instructions ® Bit logic operations ® ® )

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® The SR flip-flop requires a memory tag. For this, use drag-and-drop to move static

parameter #Memory_automatic_start_stop onto the <??.?> above the SR flip-flop. (®

Memory_automatic_start_stop)

® The #Memory_automatic_start_stop will be set with input tag #Start. Click twice on the
S input of the SR flip-flop <??.?> and enter "Start" in the field that appears in order to see
a list of available tags starting with "Start".Click the #Start tag and apply with ® Enter.

(® SR flip-flop ® <??.?> ® Start ® #Start ® Enter)

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Note: When assigning tags in this way, there is a risk of a mix-up with the global tags from the
tag table. The previously presented procedure using drag and drop from the interface
description should therefore be used preferentially.

® Multiple conditions are to be able to stop the conveyor. An OR block is therefore needed
at the R1 input of the SR flip-flop. First, click the R1 input of the SR flip-flop so that the
input line has a blue background.

® Click the icon in your logic toolbar to insert an OR logic operation.

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® The OR block has 2 inputs initially. In order to logically combine an additional input tag,
click the yellow star of the OR block.

® Add input tags #Stop, #Safety_shutoff_active and #Automatic_mode_active to the 3

inputs of the OR block.

® Negate the input connected to parameter #Automatic_mode_active by selecting it and

clicking .

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® Do not forget to click . The finished function block "MOTOR_AUTO" [FB1]

in FBD is shown below.

® Under "General" in the properties of the block, you can change the "Language" to LAD
(Ladder Logic) (®Properties ® General ® Language: LAD)

® The program has the following appearance in LAD.

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7.8 Program organization block OB1 – Control of the forward belt

tracking in automatic mode
® Before programming organization block "Main [OB1]", we switch the programming
language to FBD (Function Block Diagram). To do so, first click on "Main [OB1]" in the
"Program blocks" folder.

(® CPU_1516F[CPU 1516F-3 PN/DP ® Program blocks ® Main [OB1] ® Switch

programming language ® FBD)

® Open the "Main [OB1]" organization block with a double-click.

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® Assign Network 1 the name "Control conveyor tracking forward in automatic mode"

(® Network 1:... ®Control conveyor motor forwards in automatic mode)

® Use drag-and-drop to move your "MOTOR_AUTO [FB1]" function block onto the green
line in Network 1.

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® The instance data block for this call of FB1 is created automatically. Assign a name and
apply it with OK. (® MOTOR_AUTO_DB1 ® OK)

® A block with the interface you defined, the instance data block and connections EN and
ENO are inserted in Network 1.

® To insert an AND before input parameter "Enable_OK", select this input and insert the

AND by clicking the icon in your logic toolbar (® ).

® To connect the block to the global tags from "Tag_table_sorting_station", we have two
options:

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® Either select the "Tag_table_sorting_station" in the project tree and use drag-and-drop to
move the desired global tag from the Details view to the interface of FC1 ( ®
Tag_table_sorting_station ® Details view. ® S0 ® Automatic_mode_active)

® Or, enter the starting letters (e.g. "S") “-S”of the desired global tag for <??.?> and select
the global input tag "-S0" (%I0.2) from the displayed list. (® Automatic_mode_active ® S
® -S0)

® Insert the other input tags "-S1", "-S2", "-K0", "-B1" and "-A1" and insert output tag "-Q1"
(%Q0.0) at output "Conveyor_motor_automatic_mode".

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® Negate the querying of input tags "-S2" and "-A1" by selecting them and clicking .

(® -S2 ® ® -A1 ® )

7.9 The result in the LAD (Ladder Logic) programming language has
the following appearance.

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7.10 Save and compile the program

® To save your project, select the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu

(® ® Program blocks ® ).

® The "Info", "Compile" area shows which blocks were successfully compiled.

7.11 Download the program

® After successful compilation, the complete controller with the created program, as
previously described in the modules for hardware configuration, can be downloaded

(® ).

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7.12 Monitor program blocks

® The desired block must be open for monitoring the downloaded program. The monitoring

can be activated/deactivated by clicking the icon. (® Main [OB1] ® )

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Note: The monitoring here is signal-related and controller-dependent. The signal states at the
terminals are indicated with TRUE or FALSE.

® The "MOTOR_AUTO" [FB1] function block called in the "Main [OB1]" organization block
can be selected directly for "Open and monitor" after right-clicking (® "MOTOR_AUTO"
[FB1] ® Open and monitor).

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Note: The monitoring here is function-related and controller-independent. The actuation of

sensors and the station status are shown here with TRUE or FALSE.

® If a particular point of use of a "MOTOR_AUTO" [FB1] function block that is called

multiple times is to be monitored, this can be performed using the icon. There are two
alternatives available for specifying the call environment: using the call environment or

the instance data block. (® ® Instance data block ® MOTOR_AUTO_DB1 [DB1] ®

Call environment ® Address: OB1 ® Details: Main NW1 ® OK).

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8 Checklist
No. Description Completed

1 Compiling successful and without error message

2 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
3
Pushbutton automatic stop not actuated (-S2 = 1)
Briefly press the automatic start pushbutton (-S1 = 1)
then conveyor motor forwards fixed speed (-Q1 = 1)
switches on and stays on.

4 Briefly press the automatic stop pushbutton (-S2 = 0) ® Q1 = 0

5 Activate EMERGENCY OFF (-A1 = 0) ® Q1 = 0

6 Manual mode (-S0 = 0) ® Q1 = 0

7 Switch off station (-K0 = 0) ® Q1 = 0

8 Cylinder not retracted (-B1 = 0) ® Q1 = 0

9 Project successfully archived

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TIA Portal Module 006

IEC Timers and IEC Counters
Multi-instances for SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 216
2 Prerequisite....................................................................................................................................... 216
3 Required hardware and software ..................................................................................................... 216
4 Theory............................................................................................................................................... 217
4.1 Instances and multi-instances in SIMATIC S7-1500 ................................................................ 217
4.1.1 Instance data blocks/single instances .............................................................................. 217
4.1.2 Multi-instances .................................................................................................................. 218
5 Planning ............................................................................................................................................ 219
5.1 Automatic mode - Conveyor motor with time function .............................................................. 219
6 Structured step-by-step instructions ................................................................................................. 219
6.1 Retrieve an existing project ...................................................................................................... 219
6.2 Addition of an IEC timer TP to FB1 "MOTOR_AUTO" ............................................................. 221
6.3 Update the block call in the organization block ........................................................................ 226
6.4 Save and compile the program................................................................................................. 227
6.5 Download the program ............................................................................................................. 228
6.6 Monitor program blocks ............................................................................................................ 229
7 Checklist ........................................................................................................................................... 231

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IEC TIMERS AND IEC COUNTERS MULTI-

INSTANCES FOR SIMATIC S7-1500
1 Goal
In this chapter, you will become acquainted with the use of single instances and multi-
instances for programming of the SIMATIC S7-1500 with the TIA Portal programming tool.
The module explains the various types of instance data blocks and shows step-by-step how to
add IEC timers and IEC counters to a program block.

2 Prerequisite
This chapter builds on the FB programming with the SIMATIC S7 CPU1516F-3 PN/DP. You
can use the following project for this chapter.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V13

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller
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4 Theory
4.1 Instances and multi-instances in SIMATIC S7-1500
The call of a function block is referred to as an instance. An instance is assigned to every call
of a function block and serves as a data memory. It stores the actual parameters and the static
data of the function block.
The tags declared in the function block determine the structure of the instance data block.
Use of single instances and multi-instances
You can assign instances as follows:
Call as a single instance:
- A separate instance data block for each instance of a function block
Call as a multi-instance:
- One instance data block for several instances of one or more function blocks

4.1.1 Instance data blocks/single instances

The call of a function block that is assigned its own instance data block is called a single
instance.
If the function block was created according to the rules for library-compatible standard blocks,
it can also be called multiple times.
However, you must assign another instance data block for each call as a single instance.

Example of single instances:

The following figure shows the control of two motors using one function block FB10 and two
different data blocks:
The different data for the individual motors, such as speed, acceleration time and total
operating time, are saved in the instance data blocks DB10 and DB11.

OB1

Call of FC1 FC1

DB10
Call of FB10 with FB10
instance DB10 Instance DB for
for control of Standard block second call with
Motor 1 with motor data for Motor 1
program

DB11
Call of FB10 with FB10
instance DB11 Instance DB for
for control of Standard block second call with
Motor 2 with motor data for Motor 2
program

Note: Some commands, such as timers and counters, react like function blocks. When these
are called, they also require an assigned memory area, e.g. in the form of an instance data
block.

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4.1.2 Multi-instances
You may want to limit the number of data blocks used for instances or this may be necessary
due to lack of memory in the utilized CPU.
If other function blocks, timers, counters, etc. that already exist will be called in a function
block in your user program, you can call these other function blocks without separate (i.e.,
additional) instance DBs.
Simply select ‘Multi-instance’ for the call options:

Notes: Multi-instances enable a called function block to store its data in the instance data
block of the calling function block.

In this case, the calling block must always be a function block.

This allows you to concentrate the instance data in one instance data block and thus make
better use of the number of DBs available.

Incidentally, this is always required when the calling block is to remain available for reuse as a
standard block.

Example of multi-instances:
The following figure shows two calls of an IEC_Timer of type TP (pulse) within a function
block.
The different data for the two counters is stored as different multi-instances in the instance
data block DB1 of the calling function block FB1.

OB1
DB1
Call FB1 with FB1 (Instance DB for
instance DB1 FB1)
Call IEC_Timer #Timer1
as multi-instance of type IEC_Timer
#Timer1
Static tag

#Timer1
Call IEC_Timer IEC_Timer
as multi-instance #Timer2 #Timer2
#Timer2 IEC_Timer as of type IEC_Timer
multi-instance

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5 Planning
The IEC timer is programmed as an addition to the MOTOR_AUTO [FB1] function block from
the "032-200_FBProgramming.zap13" project. This project must be retrieved in order to add
the IEC timer TP (latching pulse). A multi-instance will be created as a memory for the timer.

5.1 Automatic mode - Conveyor motor with time function

The Memory_automatic_start_stop is latched with Start but only if the reset conditions are not
present.
The Memory_automatic_start_stop is reset if Stop is present or safety shutoff is active or
automatic mode is not activated (manual mode).
The Conveyor_motor_automatic_mode output is activated when
Memory_automatic_start_stop is set, the enable conditions are met and
Memory_conveyor_start_stop is set.
To save energy, the conveyor should only run when a part is present.
For this reason, the Memory_conveyor_start_stop is set when Sensor_chute_occupied signals
a part and reset when Sensor_end_of_conveyor produces a negative edge or safety shutoff is
active or automatic mode is not activated (manual mode).
Addition of time function:
Because the Sensor_end_of_conveyor is not able to be mounted directly at the end of the
conveyor, the Sensor_end_of_conveyor signal must be stretched.
To achieve this, a latching pulse will be inserted between Sensor_end_of_conveyor and the
negative edge detection.

6 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

6.1 Retrieve an existing project

® Before we can expand the "MOTOR_AUTO [FB1]" function block, we must retrieve the
"032-200_FBProgramming.zap13" project from chapter "SCE_EN_032-200
FBProgramming". To retrieve an existing project that has been archived, you must select
the relevant archive with ® Project ® Retrieve in the project view. Confirm your selection
with Open. (® Project ® Retrieve ® Select a .zap archive ® Open)

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® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK". (® Target directory ® OK)

Save the opened project under the name 032-300_IEC_Timers_Counters.

® Project ® Save as ... ® 032-300-IEC_Timers_Counters ® Save)

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6.2 Addition of an IEC timer TP to FB1 "MOTOR_AUTO"

® First, open the "MOTOR_AUTO [FB1]" function block with a double-click.

® Insert another network at the beginning of the "MOTOR_AUTO [FB1]" function block by

selecting the ® "block title" and then clicking the ® icon for "Insert network".

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® Add helpful information to the block comment and the network title of "Network 1:".

® On the right side of your programming window, you will see the timer functions in the list
of instructions. Under ® Basic instructions ® Timer operations, find function
(Generate pulse) and use a drag-and-drop operation to move it to Network 1 (green line
appears, mouse pointer with + symbol).

(® Instructions ® Basic instructions ® Timer operations ® )

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® The timer function requires a memory. Here, this memory is made available within the
instance data block by the function block without the creation of a new instance data
block. Select the ®"Multi-instance" option for this. Enter a name for the multi-instance
and confirm with ® "OK". (® Multi-instance ® IEC_Timer_overrun ® OK)

® As a result, a tag structure of "Static" type suitable for TP Timer will be created in the
interface description.

Note: A multi-instance can only be used for programming within a function block because
static tags are only available there.

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® Use drag-and-drop to move input parameter #Sensor_end_of_conveyor to <??.?> in front

of parameter "IN" of TP Timer so that this will be started at a positive edge at input
#Sensor_end_of_conveyor. The best way to select a parameter in the interface
description is by "grabbing" it at the blue symbol. (® Sensor_end_of_conveyor)

® Enter the required pulse duration of 2 seconds in front of parameter "PT" (® 2s )

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® The entry of 2s is converted automatically to the IEC-Time format suitable for the IEC
timer and is shown as constant "T#2s".

® Now move output "Q" from tag structure "IEC_Timer_overrun" onto input "CLK" of
negative edge "N_TRIG" in Network 2. This will replace the #Sensor_end_of_conveyor
input tag previously entered there and the conveyor will be stopped by a negative edge of
the IEC_Timer_overrun pulse.

(® Network 2 ® IEC_Timer_overrun® Q ® #Sensor_end_of_conveyor)

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® Do not forget to click . The finished function block "MOTOR_AUTO" [FB1]

with the timer is shown in FBD below.

6.3 Update the block call in the organization block

® Open the "Main [OB1]" organization block with a double-click.

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® In Network 1 of the "Main [OB1" organization block, instance data block

"MOTOR_AUTO_DB1" for the "MOTOR_AUTO [FB1]" function block appears incorrect,
because the additional memory for the TP Timer has not yet been added there. Click the

®" " icon for "Update inconsistent block calls". This will add the

"MOTOR_AUTO_DB1" instance data block correctly again. (® )

6.4 Save and compile the program

® To save your project, select the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu

(® ® Program blocks ® ).

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® The "Info", "Compile" area shows which blocks were successfully compiled.

6.5 Download the program

® After successful compilation, the complete controller with the created program including
the hardware configuration, as previously described in the modules, can be downloaded.

(® )

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6.6 Monitor program blocks

® The desired block must be open for monitoring the downloaded program. The monitoring

can now be activated/deactivated by clicking the icon. (® Main [OB1] ® )

Note: The monitoring here is signal-related and controller-dependent. The signal states at the
terminals are indicated with TRUE or FALSE.

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® The "MOTOR_AUTO" [FB1] function block called in the "Main [OB1]" organization block
can be selected directly for "Open and monitor" after right-clicking, thereby allowing the
program code in the function block with the TP Timer to be monitored.
(® "MOTOR_AUTO" [FB1] ® Open and monitor)

Note: The monitoring here is function-related and controller-independent. The actuation of

sensors and the station status are shown here with TRUE or FALSE.

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7 Checklist
No. Description Completed

1 Compiling successful and without error message

2 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
3 Pushbutton automatic stop not actuated (-S2 = 1)
Briefly press the automatic start pushbutton (-S1 = 1)
Sensor at chute activated (-B4 = 1)
then conveyor motor forwards fixed speed (-Q1 = 1) switches
on and stays on.
Sensor at end of conveyor activated (-B7 = 1) ® -Q1 = 0
4
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0) ® -Q1 =
5
0

6 Activate EMERGENCY OFF (-A1 = 0) ® -Q1 = 0

7 Manual mode (-S0 = 0) ® -Q1 = 0

8 Switch off station (-K0 = 0) ® -Q1 = 0

9 Cylinder not retracted (-B1 = 0) ® -Q1 = 0

10 Project successfully archived

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Training Curriculum

TIA Portal Module 007

Basics of Diagnostics
with SIMATIC S7-1500

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Table of contents

1 Goal.......................................................................................................................234
2 Prerequisite ...........................................................................................................234
3 Required hardware and software ..........................................................................234
4 Theory ...................................................................................................................235
4.1 Fault diagnostics and hardware faults ...................................................................................... 235
4.2 Hardware diagnostics ............................................................................................................... 235
4.3 Diagnostics for program blocks ................................................................................................ 236
5 Task ......................................................................................................................237
6 Planning ................................................................................................................237
6.1 Online interface......................................................................................................................... 237
7 Structured step-by-step instructions ......................................................................238
7.1 Retrieve an existing project ...................................................................................................... 238
7.2 Download the program ............................................................................................................. 238
7.3 Go online................................................................................................................................... 240
7.4 Online & diagnostics of the SIMATIC S7 controller .................................................................. 243
7.5 Online/offline comparison ......................................................................................................... 250
7.6 Monitor and modify tags ........................................................................................................... 253
7.7 Force tags ................................................................................................................................. 256
7.8 Checklist ................................................................................................................................... 259

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BASICS OF DIAGNOSTIC FUNCTIONS

1 Goal
In this module, the reader will become acquainted with the tools that support troubleshooting.
This module will present diagnostic functions that, for example, you can test with the TIA
project.

2 Prerequisite
This chapter builds on the hardware configuration of SIMATIC S7 CPU1516F-3 PN/DP.
However, other hardware configurations that have digital input and output cards can be used.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station Portal) as of V1X

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory

4.1 Fault diagnostics and hardware faults

Faults can be caused by a variety of things.
Two error patterns can be distinguished for faults that occur after a transition to RUN.
1. The CPU goes to or stays in STOP mode. The yellow STOP LED lights up, and other
indicator LEDs light up on the CPU, power supply unit, IO modules or bus modules.
A CPU fault has occurred in this case. For example, a module in the AS might be defective or
have an incorrect parameter assignment, or a bus system fault might be present.
An interruption analysis will be performed in this instance by evaluating the hardware
diagnostics and by reading the module status in the diagnostic buffer of the CPU.

2. The CPU is in faulty RUN mode. The green RUN LED lights up and other indicator LEDs
light up or flash on the CPU, power supply unit, IO modules or bus modules.

In this case, a fault may have occurred in the IO devices or power supply.
A visual check is performed initially to narrow down the fault area. The indicator LEDs on the
CPU and IO devices are evaluated. The diagnostic data of the faulty IO and bus modules are
read from the hardware diagnostics. In addition, a fault analysis can be performed using a
watch table on the programming device.

4.2 Hardware diagnostics

The device view in online mode of the TIA Portal provides you a quick overview of the
configuration and system status of the automation system.

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Figure 1: Online view of device configuration

4.3 Diagnostics for program blocks

The project tree window of the TIA Portal in online mode provides you an overview of the
programmed blocks of the user program. With the help diagnostic symbols, a comparison of
the program blocks used offline and online is displayed.

Figure 2: Online view of the Main [OB1] block

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5 Task
The following diagnostic functions will be shown and tested in this chapter:
- Diagnostic symbols in the online view of the TIA Portal
- Device diagnostics with module status
- Offline/online comparison
- Monitoring and modifying tags
- Forcing tags

6 Planning
The diagnostic functions will be performed using a finished project as an example.
A project in the TIA Portal that was previously downloaded to the controller should be open for
this.
In our case, after starting the TIA Portal, a previously created project will be retrieved from the
archive and downloaded to the associated controller.
Afterwards, you can start implementing the diagnostic functions in the TIA Portal.

6.1 Online interface

Online diagnostics are only possible when the correct communication connection to the CPU
has been set up beforehand. Here, we are connected via Ethernet/PROFINET.
When connecting online, you must therefore set the appropriate interfaces for your automation
system.

Figure 3: Go online

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can start the diagnostic functions, we need a project with programming and a
hardware configuration.
(e.g., SCE_EN_032-100_FC-Programming….zap).
To retrieve an existing project that has been archived, you must select the relevant
archive with ® Project ® Retrieve in the project view.
Confirm your selection with "Open".
(® Project ® Retrieve ® Select a .zap archive ® Open)

® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK". (® Target directory ® OK)

7.2 Download the program

® After the project has been successfully retrieved, the controller can be selected and

downloaded together with the created program. (® )

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® Select the correct interfaces and click "Start search". (® "PN/IE" ® Selection of the
network adapter of the PG/PC ® Direct at slot ‘1 X1‘® "Start search")

Once "Scan and information retrieval completed" appears, click "Load". (® "Load")

® Before downloading can be started, other actions may have to be set (highlighted in pink).
Click "Load" again. (® "Load“).

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® After loading, first select the "Start all" check box under Action.

Click "Finish". (® select check box ® "Finish")

7.3 Go online
® To get started with the diagnostic functions, we will select our controller ("PLC_1") and
click "Go online". (® PLC_1 ® Go online)

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® Once the online connection to the "PLC_1" controller is established, the CPU can be

started or stopped with the following buttons . Diagnostic information in the form
of symbols will already be available in the project tree and in the diagnostics window.

Symbols for the comparison status in the project tree

® The diagnostic symbols in the project tree show a comparison status representing the
online/offline comparison of the project structure.

Symbol Meaning
Folder contains objects whose online and offline versions are different (only in the
project tree)
Online and offline versions of the object are different
Object only exists online
Object only exists offline
Online and offline versions of the object are the same

® Double-click "Device configuration".

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Operating state symbols for CPUs and CPs

® The graphical representation and device information window show the various operating
states of the CPU or communication processors (CPs).

Symbol Operating state

RUN
STOP

STARTUP
HOLD
DEFECT

Unknown operating state

The configured module does not support display of the operating
state.

Diagnostic symbols for modules and devices in the device overview

® The graphical representation and Device overview window display the operating states of
the various modules, CPU, or CP using the following symbols.

Symbol Meaning
The connection to a CPU is currently being established.
The CPU is not accessible at the set address.

The type of CPU configured and type of CPU actually present are
incompatible.
During the establishment of the online connection to a protected CPU, the
password dialog was terminated without input of the correct password.
No fault

Maintenance required
Maintenance demanded
Fault

The module or device is deactivated.

The module or device cannot be accessed from the CPU (valid for modules
and devices below a CPU).
Diagnostic data is not available because the current online configuration
data differs from the offline configuration data.
The configured module or device and the module or device actually present
are incompatible (valid for modules or devices below a CPU).
The configured module does not support display of the diagnostic status
(valid for modules below a CPU).
The connection has been established, but the state of the module is
currently still being determined.
The configured module does not support display of the diagnostic status.
Error in lower-level component: A error is present in at least one lower-level
hardware component.

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Color coding of ports and Ethernet cables

® The status of ports and Ethernet cables can be diagnosed in the Network view and
Topology view.

® The following table shows the possible colors and their respective meaning.

Color Meaning
No fault or maintenance required
Maintenance demanded
Communication error

7.4 Online & diagnostics of the SIMATIC S7 controller

® Double-click "Online & diagnostics" in the project tree.

(® Online & diagnostics)

® A CPU operator panel, the cycle time and the memory utilization are displayed in the
Online tools on the right side. Switch the CPU to RUN here. (® RUN)

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® The working area window contains general information about the CPU. (® General)

® If diagnostic information is available, it is displayed in Diagnostic status.

(® Diagnostic status)

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® Detailed Information on the individual events is displayed in Diagnostics buffer.

(® Diagnostics buffer)

® Next you receive information about the cycle time of the executed program.
(® Cycle time)

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® The memory utilization can be seen here in detail. (® Memory)

® Information about the display is also available for the CPU 1516F. (® Display)

® The network settings and the status of the PROFINET interfaces [X1] and [X2] can also
be displayed.

(® PROFINET interface [X1] or ® PROFINET interface [X2])

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® In "Assign IP address" under Functions, you can assign the IP address to a controller.
However, this is only possible when no hardware has been downloaded to the CPU.

(® Functions ® Assign IP address)

® Under "Set time", you can set the time of the CPU.

(® Functions ® Set time)

® Under "Firmware update", you can update the firmware of the PLC or the display.

(® Functions ® Firmware update)

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® Under "Assign name", you can assign a PROFINET device name to the configured field
devices on PROFINET. The device name of the CPU cannot be changed here. It can only
be changed by downloading a modified hardware configuration.

(® Functions ® Assign name)

® Under "Reset to factory settings", you can restore the factory settings for the CPU. After
restoring the factory settings, the CPU configuration and the program must be imported
again from the inserted memory card. Therefore, the memory card must be formatted
before the restoring the factory settings.

(® Format memory card ® Format ® Reset to factory settings ® Retain or delete IP

address ® Reset)

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® Finally, the service data can be saved under Functions.

(® Functions ® Save service data)

® The online connection should be disconnected again before the next chapter.

(® Online access ® Disconnect online connection)

® The TIA Portal is now back in offline mode. The orange-colored bars and the diagnostic
symbols are no longer displayed.

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7.5 Online/offline comparison

® It is often important to know whether the saved data matches the data loaded in the
controller. First, remove the negation from the "Safety_shutoff_active" tag at the AND
function in the "MOTOR_MANUAL [FC1]" block.

Save the "MOTOR_MANUAL [FC1]" block, but do NOT download it to the controller.

Close the "MOTOR_MANUAL [FC1]" block again.

® To compare, right-click the "PLC_1" controller and select "Compare", "Offline/online".

(® Select controller ® Compare ® Offline/online)

® The Compare editor online opens.

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® If, for example, block differences are indicated , first select the block involved. You can

then click the button to "Start detailed comparison".

(® MOTOR_MANUAL ® Start detailed comparison).

® The selected offline/online block will be compared in the code block comparison. A
detailed description of the difference is shown in the comparison result.

® Close the window of the code block comparison.

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® An action can be selected for the block involved in the Compare editor.

Either the "MOTOR_MANUAL" block will be downloaded from the programming device to
the controller and overwritten there or the "MOTOR_MANUAL" block will be imported
from the controller and overwritten in the TIA Portal.

Select the "Upload from device" action. (← Upload from device)

® Click the "Execute actions" button . (® Execute actions)

® Confirm "Upload from device". (® Upload from device)

® After the upload, there are no more differences. You should now save your project again
and close the online connection.

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7.6 Monitor and modify tags

® To monitor and modify tags, you need a watch table.

Double-click "Add new watch table" in the project tree.

(® Add new watch table)

® Open the newly created "Watch_table_1" by double-clicking it. (® "Watch_table_1")

® You can enter individual tags in the table or you can select the
"Tag_table_sorting_station" and the tags to be monitored, and drag them from the Details
view to the watch table.

(® Default tag table)

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® To have all monitoring and modifying functions available for selection, the following
columns can be displayed:

‘All modify columns’ and ‘All expanded mode columns’ .

Continue by selecting the trigger timing for the monitoring.

(® Permanent)

The following monitoring and modifying modes are available:

· Permanent (in this mode, the inputs are monitored/modified at the start of the
cycle and the outputs at the end.)
· Once only, at start of scan cycle
· Once only, at end of scan cycle
· Permanently, at start of scan cycle
· Permanently, at end of scan cycle
· Once only, at transition to STOP
· Permanently, at transition to STOP

Process image of the inputs

"At start of scan cycle" trigger point

OB 1
At transition to STOP trigger point

"At end of cycle" trigger point

Process image of the outputs

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® Next, click "Monitor all values once and now" or "Monitor all values according to

trigger settings" . (® Monitor all)

® To modify tags, enter the desired "Modify values". Next, click to "Modify all activated

values once and now" or to "Modify all activated values by Modify with trigger
condition".

(® TRUE ® modifies all activated values by "Modify with trigger condition")

® Confirm the warning with 'Yes'. (® Yes)

® The output becomes active even though the programmed conditions are not met.

Note: If the watch table is closed or the connection to the PLC is lost, all modify commands
become ineffective.

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7.7 Force tags

® The “Force” function can be used to assign a fixed value to tags. Force values are
specified in a similar way as for the "Modify tags" function but, in contrast, are retained
after the CPU is stopped. The main differences between "Modify tags" and the "Force"
function are as follows: In contrast with "Modify tags", the "Force" function does not allow
you to assign values to data blocks, timers, counters and bit memory.

IO device inputs (e.g., IWxx:P) cannot be modified, although they can be pre-assigned by
the "Force" function.

Unlike with the "Modify" function, values permanently assigned by the "Force" function
cannot be overwritten by the user program.

If you close the force table, the force values are retained. This is not the case with the
"Modify" function.

If the online connection to the CPU is interrupted, the tags assigned with the "Force"
function retain their value.

® To force tags, you must first double-click the force table to open it.

(® Force table)

® Select the “Q1” operand with address %Q0.0 from the list. (® Q1)

® With forcing, the operands are entered with direct IO access (%Q0.0:P).

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® Enter the desired force value and activate it .

Click "Start or replace forcing" . The new force request is transferred to the CPU.

(® %Q0.0:P ® TRUE ® ® Start or replace forcing)

® Confirm the warning with 'Yes'. (® Yes)

® Forcing is activated and the yellow MAINT LED on the CPU lights up. In addition, an F on
a red background is shown at the top right of the display of the S7-1500.

Note: If the watch table is closed or the connection to the PLC is lost, forcing remains active,
and the yellow FRCE LED on the CPU continues to be lit.

® If you want to ‘Stop forcing’, simply click "Stop forcing" , and confirm the next dialog
with "Yes".

(® Stop forcing) 'Yes' (® Yes)

Forcing is stopped and the yellow MAINT LED on the CPU goes out.

® If there is already a force request in the controller, this is indicated by the symbol in
the watch table.

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® If you now click , additional information is displayed. (® )

® If there is already a force request in the controller, it can also be displayed and stopped
via the online device view. For this, you need to right-click the CPU in online mode of the
device view and select "Update and display forced operands".

(® right-click the CPU ® Update and display forced operands")

® The force table with the current force requests will now be displayed and you can stop

these. (® Stop forcing)

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7.8 Checklist
No. Description Completed

1 Project 032-100_FB-programming… successfully retrieved.

CPU 1516F from project 032-100_FB-Programming…

2
successfully downloaded.

3 CPU 1516F connected online.

4 Status of the CPU 1516F checked with Online & diagnostics.

Offline/online comparison of blocks in the CPU 1516F

5
performed.

6 Watch_table_1 created.

Tags (-S0 / -S3 / -K0 / -B1 / -S4 / -A1 / -Q1) entered in watch
7
table.
Switch on conveyor motor forwards by modifying the output
8
(-Q1 = 1) in watch table.
Switch off conveyor motor forwards by modifying the output
9
(-Q1 = 0) in watch table.

10 Open force table

11 Tag ( -Q1:P) entered in force table.

Switch on conveyor motor forwards by forcing the output

12
(-Q1 = 1) in force table.

13 Force output -Q1 to switch off again.

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Siemens Automation Cooperates with Education | 05/2017

TIA Portal Module 008

Diagnostics via the Web
with SIMATIC S7-1500

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Table of contents

1 Goal .................................................................................................................................................. 262

2 Prerequisite....................................................................................................................................... 262
3 Required hardware and software ..................................................................................................... 262
4 Theory............................................................................................................................................... 263
4.1 System diagnostics: Automated creation of error messages ................................................... 263
4.2 Diagnostics via web server ....................................................................................................... 263
4.3 Diagnostics with the integrated display .................................................................................... 264
5 Task .................................................................................................................................................. 265
6 Planning ............................................................................................................................................ 265
7 Structured step-by-step instructions ................................................................................................. 265
7.1 Retrieve an existing project ...................................................................................................... 265
7.2 Configure the web server.......................................................................................................... 266
7.3 Configure the display ................................................................................................................ 269
7.4 Configure system diagnostics................................................................................................... 270
7.5 Activate the diagnostics of the power supply for the AQ module and download the PLC ....... 271
7.6 Trigger error message .............................................................................................................. 273
7.7 Display alarms in Online & diagnostics .................................................................................... 274
7.8 Diagnostics for the S7-1500 via the web .................................................................................. 275
7.9 Diagnostics for the S7-1500 via the integrated display ............................................................ 283
7.10 Checklist ................................................................................................................................... 284

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WEB SERVER AND ADVANCED DIAGNOSTICS

1 Goal
In this module, the reader will become acquainted with additional tools that are helpful for
troubleshooting.
In particular, we will show you how automated alarm texts can be generated in the TIA Portal
for hardware faults and system errors. These can then be displayed not only in the TIA Portal
but also on the display of the CPU as well as via the web server of the CPU 1516F-3 PN/DP. It
is also possible to bring these into the message windows of HMI systems for viewing.

2 Prerequisite
This chapter builds on the hardware configuration of the SIMATIC S7 CPU1516F-3 PN/DP.
However, other hardware configurations can be used.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V13

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 System diagnostics: Automated creation of error messages
In the TIA Portal, the diagnostics of devices and modules is collectively referred to as system
diagnostics. The monitoring functions are automatically derived from the hardware
configuration.
All SIMATIC products have integrated diagnostic functions which you can use to detect and
remedy faults. The components automatically signal a possible disruption of operation and
provide additional detailed information. Undesired downtimes can be minimized with plant-
wide diagnostics.
The following states are monitored by the system in the running plant:
- Device failure
- Pull/plug error
- Module fault
- IO access error
- Channel fault
- Parameter assignment error
- Failure of the external auxiliary voltage

4.2 Diagnostics via web server

The web server enables monitoring and administering of the CPU by authorized users over a
network.
This permits evaluation and diagnostics over long distances. Monitoring and evaluation is
possible without the TIA Portal; all you need is a web browser.
The web server is deactivated in the delivery state of the CPU. This means that you must load
a project in which the web server is activated to enable access using the web browser.
The web server offers the following security functions:
- Access via secure "https" transmission protocol
- User authorization by means of a user list
- Restriction of access from certain interfaces
You need a web browser to access the HTML pages of the CPU.
The following web browsers have been tested for communication with the CPU:
- Internet Explorer (Version 8)
- Mozilla Firefox (Version 21)
- Mobile Safari (iOS5)

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Figure 1: Web server of the CPU 1516F-3 PN/DP with alarm text from the system diagnostics

Note: Make sure that you protect the CPU from manipulation and unauthorized access
through the use of different methods (e.g., limiting network access, using firewalls).

4.3 Diagnostics with the integrated display

The S7-1500 CPU has a front flap with a display and control keys. Control data and status
data can be displayed in various menus on the display and numerous settings can be made.
You use the control keys to navigate through the menus.
The display of the CPU offers the following functions:
- 6 different display languages can be selected.
- Diagnostic messages are displayed in plain text.
- The interface settings can be changed locally.
- Password assignment for display operation is possible through the TIA Portal.

Figure 2: Display of the CPU 1516F-3 PN/DP with alarm text from the system diagnostics

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5 Task
The following advanced diagnostic functions will be shown and tested in this chapter:
- Configuration of web server of the CPU 1516F-3 PN/DP
- Configuration of display of the CPU 1516F-3 PN/DP
- Create hardware fault and system error alarms with the system diagnostics
- Display alarms via the web server of the CPU 1516F-3 PN/DP
- Display alarms via the integrated display of the CPU 1516F-3 PN/DP

6 Planning
The diagnostic functions will be performed using a finished project as an example. A project in
the TIA Portal that was previously downloaded to the controller should be open for this. In our
case, once you have started the TIA Portal, you will retrieve a previously created project that
was archived and download it to the associated controller.
You can then configure the web server, the display and the system diagnostics in the TIA
Portal. To test the system diagnostics, we will disconnect the monitored analog output module
from its supply voltage.

7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we begin with diagnostics via the web server, we need a project from the
SCE_EN_032-410 Basics_Diagnostics module.
(e.g., SCE_EN_032-410_Basics_Diagnostics_2_R1503.zap13)
To retrieve an existing project that has been archived, you must select the relevant
archive with ®Project ®Retrieve in the project view.
Confirm your selection with "Open".
(® Project ® Retrieve ® Select a .zap archive ® Open)

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® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
(® Target directory ® OK)

7.2 Configure the web server

® To configure the web server, open the device configuration of the CPU 1516F-3 PN/DP.
(® CPU_1516F [CPU 1516F-3 PNDP] ® Device configuration)

® Select the CPU and choose the 'Web server' menu item in the properties.
(® CPU_1516F ® Properties ® Web server)

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® Activate the web server on this module and confirm the security note.
(® Activate web server on this module ® OK)

® Leave the check mark for 'Enable automatic update', and select the security settings
of the 'Everybody' user. Enable this user to carry out all possible actions and accept your
settings.
(® ® )

Notes: You can also create multiple users here with different authorizations. These users then
require a password.

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® As a result of these authorizations, the 'Everybody' user is now automatically assigned

the access level 'Administrative'.

® In the 'Watch tables' menu item, the 'Watch table_Cylinder' can now be entered in the
web server.
(®Watch table_Cylinder ® )

® Accessing is read-only. (® Read)

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® User-defined web pages will not be created here. For reasons of plant safety / security,
we will enable only PROFINET interface_1 for access to the web server.
(® Enabled web server access ® PROFINET interface_1)

7.3 Configure the display

® The settings for the display of diagnostics data can also be changed on the integrated
display of the CPU 1516F-3 PN/DP. First, the general settings are selected as shown
here.
(® Display ® General)

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® In the 'Watch tables' menu item, the 'Watch table_Cylinder' can now be entered in the
display.
(®Watch table_Cylinder ® )

® If desired, a user-defined logo can also be shown on the display

(® User-defined logo page)

7.4 Configure system diagnostics

® An important function for effective troubleshooting is the integrated system diagnostics.
This is always activated for the SIMATIC S7-1500. The alarm categories can be selected
in the alarm settings and, if desired, an 'Acknowledgment' can be specified.

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Notes: The indicated alarm class is important so that it can be selected in the alarm windows
of the operator panel (e.g., TP1500, TP700, etc.).

7.5 Activate the diagnostics of the power supply for the analog
output module and download the PLC

® Once the web server, display and system diagnostics have been configured in the
controller, we also activate the diagnostics for the supply voltage for the analog output
module. The controller can then be selected and downloaded together with the created
program.
(® Device configuration ® AQ 4xU/I ST_1 ® Output 0 – 3 ® Outputs ® Channel 0 ®

Diagnostics ® No supply voltage L+® CPU_1516F [CPU 1516F-3 PN/DP]® )

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® Select the correct interface and click 'Start search'.

(® PN/IE ® Selection of the network adapter of the PG/PC ® Direct at slot ‘1 X1‘® Start
search)

Once "Scan and information retrieval completed" appears, click 'Load'.

(® Load)

® Before downloading can be started, other actions may have to be selected. Click 'Load'
again.
(® override all ®Load)

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® After loading, first select the "Start all" check box and click 'Finish'.
(® Start all ® Finish)

7.6 Trigger error message

® The power supply of the analog output module is via terminals 41-44 of the supply
element. Remove this supply element, as shown here, from the front connector to trigger
an error message. Result: the red ERROR LED on the CPU is lit and an error message is
triggered. The following pages describe where and how you can view this error message.

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7.7 Display alarms in Online & diagnostics

® To get started with the diagnostic functions, we will select our controller 'CPU_1516F' and
click 'Online & diagnostics'. Under 'Online access' select 'Receive alarms' for the
'Alarms' item. (® CPU_1516F ® Online & diagnostics ® Online access ® Alarms ®
Receive alarms)

® Select the correct interface and click 'Go online'.

(® Go online)

® The error message can now be checked in the 'Alarm display' under 'Diagnostics'.
(® Diagnostics ® Alarm display)

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7.8 Diagnostics for the S7-1500 via the web

® To be able to access the Web server of the CPU 315F-2 PN/DP we open any Web
browser on a PC that is connected to the CPU via TCP/IP.

® There we enter the IP address of the CPU 1516F-3 PN/DP. (® 192.168.0.1)

® On the displayed web page, we first select the language and then click 'ENTER'.
(® English ® ENTER)

® On the 'Home Page' we see general information about the PLC and its status.
(® Home Page)

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® Hardware, Firmware Version and Serial number are displayed besides other information
under 'Diagnostics'.
(® Diagnostics)

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® Under 'Diagnostics Buffer' we see descriptive information for all events in the CPU. Event
information is recorded in a circular buffer. The most recent alarm is displayed in the top
line.
(® Diagnostics Buffer)

® The status of the individual modules of our SIMATIC S7-1500 is displayed with additional
details in the 'Module Information' view.
(® Module Information)

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® The alarm texts generated in the CPU 1516F-3 PN/DP are available in 'Alarms'.
(® Alarms)

Note: Here we see the failure of the supply voltage for the digital input module with activated
diagnostic error interrupt.

® Details about communication settings and communication errors are displayed under
'Communication'.

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® Devices that are connected to the individual ports of the CPU 1516F-3 PN/DP and the
addresses of these devices can be displayed under 'Topology'. There are various views
for this. In the case of larger network structures, the entire network structure of a plant
can be displayed and faulty connections shown in the status, provided this function is
supported by the individual components.
(® Topology)

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® Values of the individual tags can be displayed under 'Tag status'.

(® Tag status)

® 'Tag tables' that are linked with the web server, such as the 'Watch table_Cylinder', can
also be displayed.
(® Tag tables ® Watch table_Cylinder)

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® Individually created pages for the visualization and also for operator control of processes
would be seen under 'Customer pages'. (® Customer pages)

® Data can be stored directly on the memory card in the CPU or loaded from there using
the 'Filebrowser'. (® Filebrowser)

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® This means, for example, that you can read and edit the log files written by the CPU
without having to use the TIA Portal. (® DataLogs)

7.9 Diagnostics for the S7-1500 via the integrated display

® The user also has the ability to call up a variety of diagnostic information via the display.
For example, the alarm texts generated by the system diagnostics can be displayed in the
'Diagnostics' menu under 'Alarms'.
(® Diagnostics ® Alarms)

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7.10 Checklist

No. Description Completed

Project 032-410_Basics_Diagnostics_2… successfully
1
retrieved.
Web server for the CPU 1516F from project 032-410_Basics
2
Diagnostics_2… successfully configured.
Display for the CPU 1516F from project 032-410_Basics
3
Diagnostics_2… successfully configured.
System diagnostics for the CPU 1516F from project 032-
4
410_Basics Diagnostics_2… successfully configured.
Diagnostics of the supply voltage for the analog output
5
module activated.
CPU 1516F from project 032-410_Basics Diagnostics_2…
6
successfully downloaded.

7 Power supply disconnected from analog output module.

Display of alarm text from the system diagnostics in the alarm

8
display of the TIA Portal.
Display of the alarm text from the system diagnostics via the
9
web server of the CPU 1516F.
Display of the alarm text from the system diagnostics on the
10
display of the CPU 1516F.

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Training Curriculum

TIA Portal Module 009

Analog Values
for SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 287
2 Prerequisite....................................................................................................................................... 287
3 Required hardware and software ..................................................................................................... 288
4 Theory............................................................................................................................................... 289
4.1 Analog signals .......................................................................................................................... 289
4.2 Measuring transducers ............................................................................................................. 289
4.3 Analog modules – A/D converter .............................................................................................. 289
4.4 Data types of the SIMATIC S7-1500 ........................................................................................ 290
4.5 Reading/outputting analog values ............................................................................................ 291
4.6 Normalizing analog values........................................................................................................ 292
5 Task .................................................................................................................................................. 292
6 Planning ............................................................................................................................................ 292
6.1 Analog control of the conveyor speed ...................................................................................... 292
6.2 Technology diagram ................................................................................................................. 293
6.3 Reference list ............................................................................................................................ 293
7 Structured step-by-step instructions ................................................................................................. 295
7.1 Retrieve an existing project ...................................................................................................... 295
7.2 Create the "MOTOR_SPEEDCONTROL" function .................................................................. 296
7.3 Configuration of the analog output channel.............................................................................. 303
7.4 Expand the tag table to include analog signals ........................................................................ 304
7.5 Call the block in the organization block .................................................................................... 305
7.6 Save and compile the program................................................................................................. 307
7.7 Download the program ............................................................................................................. 308
7.8 Monitor program blocks ............................................................................................................ 308
8 Checklist ........................................................................................................................................... 310

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ANALOG VALUES FOR SIMATIC S7-1500

1 Goal
In this chapter, you will become acquainted with the analog value processing of the SIMATIC
S7-1500 with the TIA Portal programming tool.
The module explains the acquisition and processing of analog signals and gives a step-by-
step description of read and write access to analog values in the SIMATIC S7-1500.
The SIMATIC S7 controllers listed in Chapter 3 can be used.

2 Prerequisite
This chapter builds on the chapter IEC Timers and Counters with the SIMATIC S7 CPU1516F-
3 PN/DP. You can use the following project for this chapter, for example: 032-300 IEC Timers
and Counters.zap13

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3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs and analog inputs and outputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V13

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Analog signals
In contrast to a binary signal, which can assume only two signal states (“Voltage present +24
V” and “Voltage not present 0 V”), analog signals can assume any value within a defined
range. A typical example of an analog sensor is a potentiometer. Depending on the position of
the knob, any resistance can be set, up to the maximum value.

Examples of analog quantities in control engineering:

- Temperature -50 to +150 °C
- Flow rate 0 to 200 l/min
- Speed -500 to +50 rpm
- etc.

4.2 Measuring transducers

These quantities are converted to electrical voltages, currents or resistances with the help of a
measuring transducer. If, for example, a speed is to be measured, the speed range of 500 to
1500 rpm can be converted to a voltage range of 0 to +10 V using a measuring transducer. At
a measured speed of 865 rpm, the measuring transducer would output a voltage value of
+3.65 V.

500 865 1500 U/min

365 1500 rpm

10 V:1000
10V: 1000U/min
rpm ==0.01
0,01V/rpm
V/U/min
1000rpm
1000 U/min 365 rpm x 0.01 V/rpm = 3.65 V
365 U/min x 0,01 V/U/min = 3,65
10V

0V +10V
+10 V

4.3 Analog modules – A/D converter

These electrical voltages, currents or resistances are then connected to an analog module that
digitizes this signal for further processing in the PLC.
If analog quantities will be processed with a PLC, the read-in voltage, current or resistance
value must be converted to digital information. The analog value is converted to a bit pattern.
This conversion is referred to as analog-to-digital conversion (A/D conversion). This means,
for example, that the voltage value of 3.65 V is stored as information in a series of binary
digits.
The result of this conversion is always a 16-bit word for SIMATIC products. The integrated
ADC (analog-to-digital converter) of the analog input module digitizes the analog signal being
acquired and approximates its value in the form of a stepped curve. The most important
parameters of an ADC are its resolution and conversion rate.
The more binary digits the digital representation uses, the finer the resolution is. For example,
if only 1 bit was available for the voltage range of 0 to +10 V, you would only know whether the
measured voltage is between 0 and +5 V or between +5 V and +10 V. With 2 bits, the range
can be divided into 4 individual ranges, i.e., 0 to 2.5 / 2.5 to 5 / 5 to 7.5 / 7.5 to 10 V.
Conventional A/D converters in control engineering use 8 or 11 bits for converting.

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1: Analog value
2. Digital value
With 8 bits you have 256 individual ranges, while 11 bits provide a resolution of 2048
individual ranges.

0A/0V 20mA/10V
10 V: 2048 = 0.0048828
à Voltage differences of <5 mV can be
11-bit detected

2048

4.4 Data types of the SIMATIC S7-1500

The SIMATIC S7-1500 has many different data types for representing different numerical
formats. A list of some of the elementary data types is given below.

Data type Size (bits) Range Example of constant entry

Bool 1 0 to 1 TRUE, FALSE, O, 1
Byte 8 16#00 to 16#FF 16#12, 16#AB
Word 16 16#0000 to 16#FFFF 16#ABCD, 16#0001
DWord 32 16#00000000 to 16#FFFFFFFF 16#02468ACE
Char 8 16#00 to 16#FF 'A', ‘r’, ‘@’
Sint 8 -128 to 127 123,-123
Int 16 -32,768 to 32,767 123, -123
Dint 32 -2,147,483,648 to 2,147,483,647 123, -123
USInt 8 0 to 255 123
Ulnt 16 0 to 65,535 123
UDInt 32 0 to 4,294,967,295 123
Real 32 +/-1.18 x 10 -38 to +/-3.40 x 10 38 123.456, -3.4, -1.2E+12, 3.4E-
3
LReal 64 +/-2.23 x 10 -308 to +/-1.79 x 10 308 12345.123456789
-1.2E+40
Time 32 T#-24d_20h_31 m_23s_648ms to T#5m_30s
T#24d_20h_31 m_23s_647ms 5#-2d
Saved as: -2,147,483,648 ms to T#1d_2h_15m_30x_45ms
+2,147,483,647 ms
String Variable 0 to 254 characters in byte size 'ABC'

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Note: The 'INT' and 'REAL' data types play a large role in analog value processing. This is
because read-in analog values exist as 16-bit integers in the 'INT' format, and in order to
ensure exact further processing only 'REAL' floating-point numbers should be used due to
rounding errors in the case of 'INT'.

4.5 Reading/outputting analog values

Analog values are read into the PLC or output from the PLC as word information. These words
are accessed, for example, with the following operands:

%IW 64 Analog input word 64

%QW 64 Analog output word 64

Each analog value (“channel”) occupies one input or output word. The format is ‘Int’, an
integer.

The addressing of input and output words conforms to the addressing in the device overview.
For example:

Here, the address of the first analog input would be %IW 64, that of the second analog input
%IW 66, that of the third analog input %IW68, that of the fourth analog input %IW70, that of
the fifth analog input %IW72, that of the sixth analog input %IW74, that of the seventh analog
input %IW 76 and that of the eighth analog input %IW78.

The address of the first analog output would be %QW64, that of the second analog output
%QW66, that of the third analog output %QW 68 and that of the fourth analog output %QW70.

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The analog value transformation for further processing in the PLC is the same for analog
inputs and analog outputs.
The digitized value ranges are as follows:

Nominal range of the analog

0A/0V 10 mA/5 V 20mA/10V value

Digitalized value for further

13824 27648 processing in the PLC

Often, these digitized values still have to be normalized by further processing them in the PLC
in an appropriate manner.

4.6 Normalizing analog values

If an analog input value exists as a digitized value in the range +/- 27648, it must usually still
be normalized so that the numerical values correspond to the physical quantities in the
process.
Likewise, the analog output usually results from setting of a normalized value that then still has
to be scaled to the output value +/- 27648.
In the TIA Portal, ready-made blocks or arithmetic operations are used for normalizing and
scaling.
For this to be carried out as exactly as possible, the values for the normalizing must be
converted to the REAL data type to minimize rounding errors.

5 Task
In this chapter, a function for analog control of the conveyor speed will be added to the
program from chapter "SCE_EN_032-300 IEC Timers and Counters".

6 Planning
The analog control of the conveyor speed will be programmed in the
"MOTOR_SPEEDCONTROL" [FC10] function as an expansion of the "SCE_EN_032-300 IEC
Timers and Counters" project. This project must be retrieved from the archive in order to add
this function. The "MOTOR_ SPEEDCONTROL" [FC10] function will be called in the "Main“
[OB1]" organization block and wired. The control of the conveyor motor must be changed
to - Q3 (conveyor motor -M1 variable speed).

6.1 Analog control of the conveyor speed

The speed will be set at an input of the "MOTOR_SPEEDCONTROL" [FC10] function in
revolutions per minute (range: +/- 50 rpm). The data type is 32-bit floating-point number
(Real).
First, the function will be checked for correct entry of the speed setpoint in the range +/- 50
rpm.

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If the speed setpoint is outside the range +/- 50 rpm, the value 0 with data type 16-bit integer
(Int) will be output at the output. The return value of the function (Ret_Val) will then be
assigned the value TRUE (1).

If the speed setting is within the range +/- 50 rpm, this value will first be normalized to the
range 0…1 and then scaled to +/- 27648 with data type 16-bit integer (Int) for output as the
speed manipulated value at the analog output.
The output will then be connected with signal U1 (manipulated value speed of the motor in 2
directions +/- 10V corresponds to +/- 50 rpm).

6.2 Technology diagram

Here you see the technology diagram for the task.

Figure 1: Technology diagram

Figure 2: Control panel

6.3 Reference list

The following signals are required as global operands for this task.

DI Type Identifier Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop OK NC
I 0.1 BOOL -K0 Main switch "ON" NO
Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/ automatic (1)
Auto = 1

I 0.3 BOOL -S1 Pushbutton automatic start NO

I 0.4 BOOL -S2 Pushbutton automatic stop NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO

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I 1.3 BOOL -B7 Sensor part at end of conveyor NO

DO Type Identifier Function

Q 0.2 BOOL -Q3 Conveyor motor -M1 variable speed

Manipulated value speed of the motor in 2

QW 64 BOOL -U1
directions +/- 10V corresponds to +/- 50 rpm

Legend for reference list

DI Digital Input DO Digital Output

AI Analog Input AO Analog Output

I Input Q Output

NC Normally Closed

NO Normally Open

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can expand the "SCE_EN_032-300_IEC_Timers_Counters.zap13 project from
chapter "SCE_EN_032-300_IEC_Timers_Counters", we must retrieve this project from
the archive. To retrieve an existing project that has been archived, you must select the
relevant archive with ® Project ® Retrieve in the project view. Confirm your selection
with Open.
(® Project ® Retrieve ® Select a .zap archive ® Open)

® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
(® Target directory ® OK)

® Save the opened project under the name 032-500_Analog_Values.

(® Project ® Save as … ® 032-500_Analog_Values ® Save)

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7.2 Create the "MOTOR_SPEEDCONTROL" function

® Select the 'Program blocks' folder of your CPU 1516F-3 PN/DP and then click "Add new
block" to create a new function there.

(® CPU_1516F [CPU 1516F-3 PN/DP] ® Add new block)

® Select in the next dialog and rename your new block to:
"MOTOR_SPEEDCONTROL". Set the language to FBD and manually assign the number
"10". Select the "Add new and open" check box. Click "OK".

(® ® Name: MOTOR_SPEEDCONTROL ® Language: FBD ® Number: 10 Manual

® Add new and open ® OK)

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® Create the local tags with their comments as shown here and change the data type of the
'Return' tag from 'Void' to 'Bool'.
(® Bool)

Note: Be sure to use the correct data types.

® Insert an Assignment ' ' in the first network and an 'And' ' in front of it. Then use
drag-and-drop to move the 'Comparator operation' 'Less or equal' from the 'Basic

instructions' onto the first input of the AND logic operation.

(® ® ® Basic instructions ® Comparator operations® CMP<=)

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® Next use drag-and-drop to move the 'Comparator operation' 'Greater or equal' onto the

second input of the AND logic operation.

(® Basic instructions ® Comparator operations® CMP>=)

® Connect the contacts in Network 1 with the constants and local tags as shown here. The
data types in the comparator operations are automatically adapted to 'Real'.

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® Use drag-and-drop to move the 'Conversion operation' 'NORM_X' into Network 2 in order
to normalize the speed setpoint of +/- 50 rpm to +/- 1.
(® Basic instructions ® Conversion operations ® NORM_X)

® Connect the contacts in Network 2 with the constants and local tags as shown here. The
data types in 'NORM_X' are automatically adapted to 'Real'.

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® Use drag-and-drop to move the 'Conversion operation' 'SCALE_X' into Network 3 in order
to scale the speed setpoint from the normalized +/- 1 onto the range for the analog output
+/- 27468.
(® Basic instructions ® Conversion operations ® SCALE_X)

® Connect the contacts with the constants and local tags in Network 3 as well, as shown
here. The data types in 'SCALE_X' are automatically changed to 'Real' or 'Int'.

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® Insert an Assignment ' ' in the fourth network. Use drag-and-drop to move the 'Move'
command from the 'Move operations' folder under 'Basic instructions' in front of the
Assignment.

(® ® Basic instructions ® Move operations ® MOVE)

® The contacts in Network 4 will now be connected with constants and local tags as shown
here. If the speed setpoint is not within the range +/- 50 rpm, the value '0' is output at the
analog output and the value TRUE is assigned to the return value (Return) of the
"MOTOR_SPEEDCONTROL“ function.

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® Do not forget to click . The finished function "MOTOR_SPEEDCONTROL"

[FC10] in FBD is shown below.

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7.3 Configuration of the analog output channel

® Double-click the 'Device configuration' to open it.

® Check the address setting and the configuration of the analog output channel 0.
(® Q address: 64…71 ® Properties ® General ® Output 0 - 3 ® Outputs ® Channel 0
® Output type: Voltage ® Output range: +/- 10 V ® Reaction to CPU STOP: Shutdown)

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7.4 Expand the tag table to include analog signals

® Double-click the 'Tag table_sorting station' to open it.

® Add the global tags for the analog value processing to the "Tag table_sorting station". An
analog input B8 and an analog output U1 must be added.
(® U1 ® %QW64 ® B8 ® %IW64)

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7.5 Call the block in the organization block

® Open the "Main [OB1]" organization block with a double-click.

® Add the temporary tag 'Motor_speed_monitoring_Ret_Val' to the local tags of OB1.

These will be needed in order to interconnect the return value of the
"MOTOR_SPEEDCONTROL" function.
(® Temp ® Motor_speed_monitoring_Ret_Val ® Bool)

® Select the block title of OB1 and then click ' ' to insert a new Network 1 in front of the
other networks

(® )

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® Use drag-and-drop to move your "MOTOR_SPEEDCONTROL [FC10]" function onto the

green line in Network 1.

® Connect the contacts with the constants and global and local tags here as shown.

® Change the connection of output tag "Conveyor_motor_automatic_mode" in Network 2 to

'-Q3' (Conveyor motor -M1 variable speed) so that the conveyor motor is controlled taking
the analog speed setting into consideration.
(® -Q3)

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7.6 Save and compile the program

® To save your project, select the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu.

(® ® Program blocks ® )

® The "Info", "Compile" area shows which blocks were successfully compiled.

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7.7 Download the program

® After successful compilation, the complete controller with the created program including
the hardware configuration can, as described in the previous modules, be downloaded.

(® )

7.8 Monitor program blocks

® The desired block must be open for monitoring the downloaded program. The monitoring

can now be activated/deactivated by clicking the icon.

(® Main [OB1] ® )

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® The "MOTOR_SPEEDCONTROL" [FC10] function called in the "Main [OB1]" organization

block can be selected directly for "Open and monitor" after right-clicking and the program
code in the function can thus be monitored.
(® "MOTOR_SPEEDCONTROL" [FC10] ® Open and monitor)

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8 Checklist
No. Description Completed

1 Compiling successful and without error message

2 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
Pushbutton automatic stop not actuated (-S2 = 1)
3 Briefly press the automatic start pushbutton (-S1 = 1)
Sensor part at slide activated (-B4 = 1)
then Conveyor motor M1 variable speed (-Q3 = 1)
switches on and stays on.
The speed corresponds to the speed setpoint in the range +/-
50 rpm
Sensor part at end of conveyor activated (-B7 = 1) ® -Q3 = 0
4
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0) ® -Q3 =
5
0

6 Activate EMERGENCY OFF (-A1 = 0) ® -Q3 = 0

7 Manual mode (-S0 = 0) ® -Q3 = 0

8 Switch off station (-K0 = 0) ® -Q3 = 0

9 Cylinder not retracted (-B1 = 0) ® -Q3 = 0

10 Project successfully archived

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TIA Portal Module 010

Global Data Blocks
for the SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 313
2 Prerequisite....................................................................................................................................... 313
3 Required hardware and software ..................................................................................................... 314
4 Theory............................................................................................................................................... 315
4.1 Data blocks ............................................................................................................................... 315
4.2 Data types of the SIMATIC S7-1500 ........................................................................................ 316
4.3 Optimized blocks ...................................................................................................................... 317
4.4 Download without reinitialization .............................................................................................. 317
5 Task .................................................................................................................................................. 318
6 Planning ............................................................................................................................................ 318
6.1 Global data block for speed control and speed monitoring of the motor.................................. 318
6.2 Technology diagram ................................................................................................................. 318
6.3 Reference list ............................................................................................................................ 319
7 Structured step-by-step instructions ................................................................................................. 320
7.1 Retrieve an existing project ...................................................................................................... 320
7.2 Create the global data block "SPEED_MOTOR"...................................................................... 321
7.3 Access to data of the data block in the organization block....................................................... 325
7.4 Save and compile the program................................................................................................. 329
7.5 Download the program ............................................................................................................. 330
7.6 Monitor/modify values in data blocks........................................................................................ 330
7.7 Initialize setpoints/reset start values ......................................................................................... 331
7.8 Snapshots in data blocks.......................................................................................................... 333
7.9 Expand data block and download it without reinitialization ...................................................... 335
8 Checklist ........................................................................................................................................... 339

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GLOBAL DATA BLOCKS FOR THE

SIMATIC S7-1500
1 Goal
In this chapter, you will become acquainted with the use of global data blocks for the SIMATIC
S7-1500 with the TIA Portal programming tool.
The module explains the structure and creation of and access to global data blocks for the
SIMATIC S7-1500. It also shows the steps for creating a global data block in the TIA Portal
and for accessing this data in the program with read and write access.

2 Prerequisite
This chapter builds on the chapter Analog Values with the SIMATIC S7 CPU1516F-3 PN/DP.

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3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs and analog inputs and outputs should be fed out to a control
panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station Portal) as of V1X

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Data blocks
In contrast to logic blocks, data blocks contain no instructions. Rather, they serve as memory
for user data.
Data blocks thus contain variable data that is used by the user program. You can define the
structure of global data blocks as required.
Global data blocks store data that can be used by all other blocks (see Figure 1). Only the
associated function block should access instance data blocks. The maximum size of data
blocks varies depending on the utilized CPU.

Function_10
Global DB
Access for all blocks
(DB_Global)

Function_11

Function_ Instance DB Access only for

block_12 (DB_Instance) Function_data_block_12

Figure 1: Difference between global DB and instance DB.

Application examples for global data blocks are:

- Saving of information about a storage system. "Which product is located where?"
- Saving of recipes for particular products.
The data in data blocks is stored retentively in most cases. This data is then retained in the
event of a power failure or after a STOP/START of the CPU.

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4.2 Data types of the SIMATIC S7-1500

The SIMATIC S7-1500 has many different data types for representing different numerical
formats. A list of some of the elementary data types is given below.

Data type Size (bits) Range Example of constant entry

Bool 1 0 to 1 TRUE, FALSE, O, 1
Byte 8 16#00 to 16#FF 16#12, 16#AB
Word 16 16#0000 to 16#FFFF 16#ABCD, 16#0001
DWord 32 16#00000000 to 16#FFFFFFFF 16#02468ACE
Char 8 16#00 to 16#FF 'A', ‘r’, ‘@’
Sint 8 -128 to 127 123,-123
Int 16 -32,768 to 32,767 123, -123
Dint 32 -2,147,483,648 to 2,147,483,647 123, -123
USInt 8 0 to 255 123
Ulnt 16 0 to 65,535 123
UDInt 32 0 to 4,294,967,295 123
Real 32 +/-1.18 x 10 -38 to +/-3.40 x 10 38 123.456, -3.4, 1.2E+12
3.4E-3
LReal 64 +/-2.23 x 10 -308 to +/-1.79 x 10 308 12345.123456789
-1.2E+40
Time 32 T#-24d_20h_31 m_23s_648ms to T#5m_30s
T#24d_20h_31 m_23s_647ms 5#-2d
Saved as: -2,147,483,648 ms to T#1d_2h_15m_30x_45ms
+2,147,483,647 ms
String Variable 0 to 254 characters in byte size 'ABC'
Array With arrays, data of a uniform data
type is arranged one after the other
and addressed consecutively in the
address area. The properties of
each array element are identical
and are configured in the array tag.
Struct The STRUCT data type represents
a data structure that consists of a
fixed number of components of
different data types. Components of
STRUCT or ARRAY data type can
also be nested in a structure.
… For other data types, refer to the
online help.

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4.3 Optimized blocks

S7-1500 controllers have optimized data storage. In optimized blocks all tags are
automatically sorted based on their data type. The sorting ensures that data gaps between the
tags are minimized and the tags are stored in a manner that optimizes their access by the
controller.
– The tags are always accessed as fast as possible because the file storage by the
system is optimized and is independent of the declaration.
– There is no danger of inconsistencies due to incorrect, absolute accesses because
symbolic access is generally used.
– Declaration changes do not result in access errors because accesses by process
visualization systems, for example, occur symbolically.
– Individual tags can be selectively defined as retentive.
– No settings are needed or possible in the instance data block. Everything will be set in
the assigned FB (e.g., retentivity).
– Memory reserves in the data block enable changes to be made without loss of actual
values (download without reinitialization).

4.4 Download without reinitialization

To enable the subsequent editing of user programs that are already running in a CPU, the S7-
1500 controllers support the option of expanding the interfaces of optimized function or data
blocks during operation. You can download the modified blocks without switching the
controller to STOP mode and without affecting the actual values of previously downloaded
tags.

Figure 2: Download without reinitialization

The following steps can be performed while the controller is in RUN mode:
1. Activate "Download without reinitialization"
2. Insert newly defined tags in an existing block
3. Download expanded block to the controller
The newly defined tags are initialized. The existing tags retain their current value.
Prerequisite: a memory reserve must have been defined for the block beforehand and the
block with this memory reserve must have downloaded to the CPU.

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5 Task
In this chapter, the program from chapter Analog will be expanded to include a data block that
centrally provides the parameters for the two functions "MOTOR_SPEEDCONTROL“ [FC10]
and "MOTOR_ SPEEDMONITORING“ [FC11].

6 Planning
The data management and setpoint setting for the "MOTOR_SPEEDCONTROL" [FC10] and
"MOTOR_SPEEDMONITORING" [FC11] functions will be carried out using the global data
block "SPEED_MOTOR" [DB2].
This will be added to the "032-500_Analog_Values" project. This project must be retrieved
from the archive beforehand.
In the "Main" [OB1] organization block, the two functions "MOTOR_SPEEDCONTROL" [FC10]
and "MOTOR_SPEEDMONITORING" [FC11] must then be connected with the tags from
global data block "SPEED_MOTOR" [DB2].

6.1 Global data block for speed control and speed monitoring of the
motor
Speed setpoint and actual speed value will be created in Real data format (32-bit floating-point
number) as the first tags in the "SPEED_MOTOR" [DB2] data block. The speed setpoint is
thereby given the start value + 14 U/min
A structure (Struct) 'Positive_Speed' will then be created for monitoring the positive speed
limits.
This structure contains the 2 tags 'Threshold_Error' (start value + 15 rpm) and
'Threshold_Warning' (start value + 10 rpm) in Real data format (32-bit floating-point number)
and the 2 tags 'Error' and 'Warning' in Bool data format (binary number).
The structure (Struct) 'Positive_Speed' will then be inserted again as a copy and renamed to
'Negative_Speed' for monitoring the negative speed limits.
The 'Threshold_Error' tag is given the start value - 16 rpm and the 'Threshold_Warning' tag
the start value - 14 rpm.

6.2 Technology diagram

Here you see the technology diagram for the task.

Figure 3: Technology diagram

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Figure 4: Control panel

6.3 Reference list

The following signals are required as global operands for this task.

DI Type Identifier Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop OK NC

I 0.1 BOOL -K0 Main switch "ON" NO

Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/ automatic (1)
Auto = 1

I 0.3 BOOL -S1 Pushbutton automatic start NO

I 0.4 BOOL -S2 Pushbutton automatic stop NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO

I 1.3 BOOL -B7 Sensor part at end of conveyor NO

Sensor actual value speed +/-10V

IW64 BOOL -B8
corresponds to +/- 50 rpm

DO Type Identifier Function

Q 0.2 BOOL -Q3 Conveyor motor -M1 variable speed

Manipulated value speed of the motor in 2

QW 64 BOOL -U1
directions +/- 10V corresponds to +/- 50 rpm

Legend for reference list

DI Digital Input DO Digital Output

AI Analog Input AO Analog Output

I Input Q Output

NC Normally Closed

NO Normally Open

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can expand the "SCE_EN_032-500_Analog_Values_R1508.zap13" project
from chapter "SCE_EN_032-500 Analog Values", we must retrieve this project from the
archive. To retrieve an existing project that has been archived, you must select the
relevant archive with ® Project ® Retrieve in the project view. Confirm your selection
with Open.
(® Project ® Retrieve ® Select a .zap archive ® Open)

® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
(® Target directory ® OK)

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® Save the opened project under the name 032-600_Global_Data_Blocks.

(® Project ® Save as … ® 032-600_Global_Data_Blocks ® Save)

7.2 Create the global data block "SPEED_MOTOR"

® Select the 'Program blocks' folder of your CPU 1516F-3 PN/DP and then click "Add new
block" to create a new global data block there.

(® CPU_1516F [CPU 1516F-3 PN/DP] ® Add new block)

® Select in the next dialog and rename your new block to: "SPEED_MOTOR". Select
'Global DB' as the type. The number '2' will be automatically assigned. Select the "Add
new and open" check box. Click "OK".

(® ® Name: SPEED_MOTOR ® Type: Global DB ® Add new and open ® OK)

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® The "SPEED_MOTOR" data block is automatically displayed. Start by creating the

'Speed_Setpoint' and 'Speed_Actual_Value' tags shown here with their associated
comments. Select 'Real' as the data type. Also set a start value of 10.0 rpm for the
'Speed_Setpoint'.
(® Speed_Setpoint ® Real ® 14.0 ® Speed_Actual_Value ® Real)

Note: Be sure to use the correct data types.

® Next we create a tag structure 'Struct' so it can be duplicated later.

(® Struct)

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® Name the structure 'Positive_Speed' and enter a comment.

(® Positive_Speed)

® Create the tags for the speed monitoring below the structure as shown here.

Note: Be sure to use the correct data types.

® Then select the structure and copy it.

(® Copy)

® Paste the copied structure below the 'Positive_Speed' structure again.

(® Paste)

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® Rename the new structure to 'Negative_Speed' and enter a comment.

(® Negative_Speed)

Do not forget to click . The finished global data block "SPEED_MOTOR"

[DB2] is shown below. Check to verify that Retain is selected and the corresponding
start value is entered for all tags. The data will thus be retained in the data block even
after a power failure or a STOP/START of the CPU. The check boxes for 'Accessible from
HMI' and 'Visible in HMI' should also all have a check mark so that all tags in future
expansions of this project will be accessible by the visualization systems (HMI). We will
select the 'Setpoint' check box only for the default values in our data block.
(® )

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Note: The use of setpoints is described further below in the step-by-step instructions of the
module.

7.3 Access to data of the data block in the organization block

® Open the "Main [OB1]" organization block with a double-click.

® Delete the temporary tags in Main [OB1] that are no longer needed. Only the Boolean tag
'Motor_Speed_Control_Ret_Val' is still needed.
(® Delete)

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® Have the "SPEED_MOTOR" [DB2] data block and the "Main" [OB1] organization block
displayed side by side by clicking the ' ' icon to vertically split the editor area.

(® )

® Use drag-and-drop to move the tags needed for the interconnection from the
"SPEED_MOTOR" [DB2] data block onto the connections of the called functions and
function blocks in the "Main" [OB1] organization block. First we move the
'Speed_Actual_Value' tag onto the 'Actual_speed' output of the
"MOTOR_SPEEDMONITORING" [FC11] block.
(® Speed_Actual_Value)

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® Also connect the other contacts in Network 1 with tags from the "SPEED_MOTOR" [DB2]
data block as shown here.

® Connect the contacts in Network 2 with tags from the "SPEED_MOTOR" [DB2] data block
as shown here.

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® Connect the contacts in Network 3 with tags from the "SPEED_MOTOR" [DB2] data block
as shown here.

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7.4 Save and compile the program

® To save your project, click the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu.

(® ® Program blocks ® )

® The "Info", "Compile" area shows which blocks were successfully compiled.

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7.5 Download the program

® After successful compilation, the complete controller with the created program including
the hardware configuration can, as described in the previous modules, be downloaded.

(® )

7.6 Monitor/modify values in data blocks

® The desired block must be open for monitoring the tags of a downloaded data block. The

monitoring can then be activated/deactivated by clicking the icon.

(® SPEED_MOTOR [DB2] ® )

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® In the 'Monitor value' column, the values currently available in the CPU can be monitored.

® If your right-click on one of the values, the 'Modify' dialog for modifying this value opens
(® Modify ® Modify value: 14.0 ® OK)

7.7 Initialize setpoints/reset start values

® The setpoints can be initialized by clicking the ' ' icon. For the tags whose 'Setpoint'
check box is selected , the start value will then be applied as the current value.

(® )

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® All start values can be reset by clicking the icon.

(® )

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7.8 Snapshots in data blocks

® If you click the ' ' icon, a snapshot of the monitored values can be taken in order to
apply these values as start values or to transfer them back to the CPU later

(® ).

® Alternatively, values from the snapshot can be applied by clicking the ' ' icon for all

values or by clicking the ' ' icon for the start values only. Only the setpoints are needed
here in most cases

(® )

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® To transfer data captured in the snapshot back to the CPU, you must click ' '.

(® )

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® If you want to overwrite all setpoints with the start values, you can initiate this by clicking '

'. The values in the CPU for which the 'Setpoint' check box was not selected are
thereby retained.

(® )

7.9 Expand data block and download it without reinitialization

® To enable 'Download without reinitialization' for the "SPEED_MOTOR" [DB2] data block,

you must ' ' and then open the properties of the data block.

(® ® SPEED_MOTOR [DB2] ® Properties)

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® Select the 'Optimized block access' check box in the properties under 'General',
'Attributes'.
(® General ® Attributes ® Optimized block access)

® Assign a 'Retentive memory reserve' to the data block for 'Download without
reinitialization'.
(®Download without reinitialization ® Retentive memory reserve ® 10 bytes ® OK)

® Download your "SPEED_MOTOR" [DB] data block to the controller again and select '

'.

(®SPEED_MOTOR [DB] ® ® )

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® Then click the ' ' icon to activate download without reinitialization and confirm the
safety prompt with 'OK'.

(® ® OK)

® Next add any tag in your data block

(® Name: Value_test ® Data type: Real ® Start value: 99)

® Download your "SPEED_MOTOR" [DB] data block to the controller again.

(®SPEED_MOTOR [DB] ® ® Download)

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® If you click ' ' to monitor the block again, you will see that the monitored values have
not been overwritten with the start values.

(® )

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8 Checklist
No. Description Completed

1 Data block SPEED_MOTOR [DB2] successfully created.

2 Program changes made in Main [OB1].

3 Compiling successful and without error message

4 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
Pushbutton automatic stop not actuated (-S2 = 1)
5 Briefly press the automatic start pushbutton (-S1 = 1)
Sensor part at slide activated (-B4 = 1)
then Conveyor motor M1 variable speed (-Q3 = 1)
switches on and stays on.
The speed corresponds to the speed setpoint in the range +/-
50 rpm
Sensor part at end of conveyor activated (-B7 = 1) ® -Q3 = 0
6
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0) ® -Q3 =
7
0

8 Activate EMERGENCY OFF (-A1 = 0) ® -Q3 = 0

9 Manual mode (-S0 = 0) ® -Q3 = 0

10 Switch off station (-K0 = 0) ® -Q3 = 0

11 Cylinder not retracted (-B1 = 0) ® -Q3 = 0

12 Speed > Motor_speed_monitoring_error_max ® -Q3 = 0

13 Speed < Motor_speed_monitoring_error_min ® -Q3 = 0

14 Project successfully archived

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WinCC Advanced with
TP700 Comfort and SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 363
2 Prerequisite....................................................................................................................................... 363
3 Required hardware and software ..................................................................................................... 363
4 Theory............................................................................................................................................... 365
4.1 Process visualization ................................................................................................................ 365
4.2 SIMATIC HMI Panel TP700 Comfort........................................................................................ 365
4.2.1 Device description ............................................................................................................ 365
4.2.2 Memory concept ............................................................................................................... 367
4.2.3 Settings on the Touch Panel TP700 Comfort/Start Center .............................................. 369
4.2.4 Setting the date and time.................................................................................................. 370
4.2.5 Setting transfer properties and assigning the IP address................................................. 371
4.2.6 Calibrating the touch panel and rebooting........................................................................ 373
4.3 WinCC Advanced V1X programming software (TIA Portal V1X) ............................................. 374
4.3.1 Project............................................................................................................................... 375
4.3.2 Hardware configuration..................................................................................................... 375
4.3.3 Schedule the hardware ..................................................................................................... 376
4.3.4 Planning the screen structure ........................................................................................... 376
4.3.5 Planning of the screen structure ....................................................................................... 377
4.3.6 Basic settings for WinCC Advanced in the TIA Portal ...................................................... 378
4.3.7 Resetting the SIMATIC HMI Panel TP700 Comfort and setting the IP address .............. 379
4.3.8 WinCC user interface........................................................................................................ 381
4.3.9 Project tree........................................................................................................................ 382
4.3.10 Details view....................................................................................................................... 382
4.3.11 Menu bar and buttons ....................................................................................................... 382
4.3.12 Work area ......................................................................................................................... 383
4.3.13 Tools ................................................................................................................................. 383
4.3.14 Properties window ............................................................................................................ 384
4.3.15 Other tabs ......................................................................................................................... 384
5 Task .................................................................................................................................................. 385
6 PlanningProcess visualization .......................................................................................................... 385
6.1 Program description for the sorting station with speed control and speed monitoring of the
motor 385
6.2 Technology diagram ................................................................................................................. 386
6.3 Reference list ............................................................................................................................ 387
7 Structured step-by-step instructions ................................................................................................. 388
7.1 Retrieving an existing project.................................................................................................... 388
7.2 Adding a SIMATIC HMI Panel TP700 Comfort......................................................................... 389
7.3 HMI wizard for the TP700 Comfort Panel................................................................................. 391
7.4 Device configuration of the TP700 Comfort Panel ................................................................... 395

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7.4.1 Setting the IP address ...................................................................................................... 396

7.5 Compiling the CPU and panel and saving the project .............................................................. 397
7.6 Configuring the graphic display ................................................................................................ 398
7.7 Displaying a process value in an IO field.................................................................................. 401
7.8 Visualizing binary signals with animated rectangles ................................................................ 404
7.9 Symbol library ........................................................................................................................... 407
7.10 Connections and HMI tags ....................................................................................................... 410
7.11 .Downloading the CPU and panel ............................................................................................ 412
7.12 Process visualization in the simulation ..................................................................................... 415
7.13 Switches and buttons for the process operation....................................................................... 416
7.14 Adapting the headers in the template....................................................................................... 431
7.15 Bar graph .................................................................................................................................. 441
7.16 Alarms....................................................................................................................................... 447
7.16.1 General alarm settings...................................................................................................... 447
7.16.2 Alarm window.................................................................................................................... 448
7.16.3 Alarm indicator .................................................................................................................. 450
7.16.4 Alarms for system diagnostics of CPU 1516F .................................................................. 451
7.16.5 Alarm class settings .......................................................................................................... 453
7.16.6 System events .................................................................................................................. 453
7.16.7 Controller alarms............................................................................................................... 454
7.16.8 Analog alarms ................................................................................................................... 454
7.16.9 Discrete alarms ................................................................................................................. 455
7.17 Remote control of the TP700 Comfort Panel............................................................................ 459
7.17.1 Activating web services for Runtime................................................................................. 459
7.17.2 WinCC Internet settings in the TP700 Comfort Panel ...................................................... 460
7.17.3 Starting remote access to the TP700 Comfort Panel ....................................................... 462
8 Checklist ........................................................................................................................................... 464

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PROCESS VISUALIZATION WITH THE SIMATIC

HMI PANEL TP700 COMFORT AND WINCC
ADVANCED
1 Goal
In this chapter, you will become acquainted with the basics of process visualization and the
use of a SIMATIC HMI Panel TP700 Comfort together with the SIMATIC S7-1500 and the TIA
Portal programming tool.
The module explains the configuring of a SIMATIC HMI Panel TP700 Comfort, the creating of
the connection to the SIMATIC S7-1500 and the read and write access to CPU data from the
SIMATIC HMI Panel TP700 Comfort.

2 Prerequisite
This chapter builds on the chapter "Global data blocks with SIMATIC S7 CPU 1516F-3
PN/DP". You can use the following project for this chapter, for example: Data Block.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 WinCC Advanced software in TIA Portal – as of V1X

4 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs and analog inputs and outputs should be fed out to a panel.

5 SIMATIC HMI Panel TP700 Comfort

6 Ethernet connection between engineering station and controller and

between controller and TP700 Comfort control panel

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2 SIMATIC STEP 7
Professional (TIA Portal)
as of V13

1 Engineering station

3 WinCC Advanced
(TIA Portal) as of V13

6 Ethernet connection

4 SIMATIC S7-1500 controller Control panel

6 Ethernet connection

5 SIMATIC HMI Panel TP700 Comfort

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4 Theory
4.1 Process visualization
Production processes are becoming more and more complex and greater demands are being
placed on the functionality of machinery and plants. For this reason, the operator needs a
high-performance tool to control and monitor production plants. An HMI (Human Machine
Interface) system represents the interface between the human being (operator) and the
process (machine/plant). The controller has the actual control over the process. There is
therefore an interface between the operator and WinCC (on the HMI panel) and an interface
between WinCC and the controller.

SIMATIC HMI Comfort Panels and WinCC undertake the following tasks:
• Representing processes with a clear screen structure
The process is represented on the HMI device. If, for example, a state changes in the process,
the display is updated on the HMI device. The process can be represented clearly structured
on multiple screens.
• Operating processes
The operator can operate the process using the graphical user interface. The operator can, for
example, enter a setpoint for the controller or start a motor.
• Outputting alarms
If critical process states occur in the process, an alarm is triggered automatically; for example,
when a specified limit is exceeded.
• Logging process values and alarms
The HMI system can log alarms and process values. You can document the process history in
this way. As a result, you still have access to older production data even at a later time.
• Documenting process values and alarms
The HMI system can print out alarms and process values as reports. For example, you can
output the production data at the end of a shift.
• Managing process parameters and machine parameters in recipes
The HMI system can store parameters for processes and machines in recipes. You can
transfer these parameters, for example, from the HMI device to the controller in a single step
in order to change production to another product type.
• User management
Certain rights can be granted to the devices and the possible operator inputs can be limited for
certain users.

4.2 SIMATIC HMI Panel TP700 Comfort

4.2.1 Device description

The SIMATIC HMI Comfort Panels product line includes touch panels (operated by a touch
screen), key panels (operated by a keyboard) and key & touch panels (operated by a
keyboard and touch screen).
The SIMATIC HMI Comfort Panels cover all requirements described in Chapter 3.1. The
following is also optionally possible:
– Support for operation through help texts
– User-specific expansion of functionality through VBScript

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– Microsoft Excel/Word/PDF Viewer for displaying documents

– Remote access to the user interface of the Comfort Panel via Ethernet from the web
browser of another HMI device or any PC through the WinCC/Sm@rtServer option
– Recording of operations in an audit trail with electronic signature through the
WinCC/Audit option
– Uninterruptible power supply (UPS) with USB support
This document explains these HMI devices using the TP700 Comfort as an example.

Figure 1: TP700 Comfort

The WinCC Advanced V1X (TIA Portal V1X) software is required for configuration and
programming. This software is included in the product package of the SCE Trainer Packet
"SIMATIC HMI TP700 COMFORT PANEL"!
Notes:

Because all devices in this series have similar functions, it would also be possible to work
through the chapters of this document with a different device version in this series.

WinCC Advanced Runtime Simulation can also be used to represent the TP700 Touch
Panel on the PC (included in the product package of the SCE Trainer Package SIMATIC
HMI TP700 COMFORT PANEL).

Front view of the TP700 Comfort

③ Touchscreen display
Rear view of the TP700 Comfort

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① Rating plate
② Slots for SD memory cards
Interfaces of the TP700 Comfort

① Connection for power supply

② Connection for equipotential bonding (ground)
③ PROFIBUS (Sub-D RS422/485)
④ 2x USB type A
⑤ PROFINET (LAN), 10/100 Mbit, 2 ports
⑥ Audio Line IN/OUT
⑦ USB type Mini-B

4.2.2 Memory concept

The HMI devices can use the following types memory:
– Internal memory
– System memory card
– Memory card
– USB mass storage connected to the USB port
Internal memory
The following data is stored here:
– Operating system
– Project file
– License keys
– User management
– Recipes
Note: Cyclic write access is not permitted for the internal memory because this reduces
the life expectancy of the internal memory and thus the service life of the HMI device.
You should preferably use external memory cards, such as the SIMATIC HMI Memory
Card, if possible, in order to prolong the service life of the HMI device for the storage of
data records and for logs.

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Memory card
The following data is stored here:
– Logs
– Backups
– Recipes
You can use commercially available memory cards in "SD(IO / HC)" or "MMC" format as the
memory card. For reasons of data consistency, use of a SIMATIC HMI Memory Card as the
memory card is recommended.
System memory card
The system memory card is part of the service concept of the HMI devices and helps to
reduce downtimes.
When you activate the service concept, all data is transferred from the internal memory of the
HMI device to the system memory card. In this way, if the HMI device fails, the system
memory card can simply be inserted into the replacement device.
Only the SIMATIC HMI Memory Card with 2 GB or more memory is permitted as the system
memory card. Other memory cards are not recognized by the HMI device as a system
memory card.
Slots for memory card and system memory card

① Slot for memory card in "SD(IO / HC)" or "MMC" format

② Slot for system memory card
③ Locking slide

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4.2.3 Settings on the Touch Panel TP700 Comfort/Start Center

A few important settings must be made directly on the Touch Panel TP700 Comfort.
The Touch Panel TP700 runs on the Windows CE operating system and can be operated, like
all touch panels, directly on the screen. For better operation, you should use a touch pen or
connect a mouse to the panel's USB port.
After the panel starts, the desktop containing the standard icons and the 'Start Center'
window appear. The version of the images present on the panel is also displayed in this
window.
Buttons in the Start Center:
Transfer: The data transfer becomes activate (Connecting to host …) and the panel waits for
the configuration data to download from WinCC Advanced to the PC.
Start: Runtime is started and the process visualization appears on the panel. The panel is
often set up so that the start occurs automatically after a few seconds.
Settings: The Windows CE settings dialog opens. Settings for the panel can be made here.
Taskbar: The Start bar of Windows CE opens.

® Select ® "Settings" in the "Start Center" directly after switching on the voltage supply
and the start of the panel.

Note: The selection of "Settings" must occur fast enough, and before the automatic
"Start" of Runtime.

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4.2.4 Setting the date and time

® Select from the icons in order to set the date and time.

® Set the date, current time and time zone.® Close and confirm the dialog with "OK".

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4.2.5 Setting transfer properties and assigning the IP address

® Select the icon in order to open the transfer settings.

® Select "Automatic". The transfer will then be started from the WinCC Advanced software.
® Select Ethernet "PN/IE" as the transfer channel. Press the " " button ® to
set the IP address on the panel and to make or check the network settings.

Notes:
To set the MPI or PROFIBUS address on the panel, select the MPI or PROFIBUS
interface and then press the Properties button to make or check the bus settings.

The settings in the Transfer Settings window have nothing to do with the connection
settings in the project. This means, for example, that data can be transferred between the
TP700 panel and WinCC Advanced using the Ethernet interface, and communication
between the panel and the SIMATIC S7 controller can take place via the PROFIBUS
interface.

In our example, data is transferred between the TP700 panel and WinCC Advanced and
communication takes place between the panel and the SIMATIC S7 controller via the
Ethernet interface.

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® Double-click the Ethernet interface in the network settings to select it.

® In the "IP Address" tab, select the "Specify an IP address" option and set the IP address
and subnet mask. ® Close and confirm the dialog with "OK".

® Click to close the network settings.

® Click "OK" to accept the transfer settings.

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4.2.6 Calibrating the touch panel and rebooting

® Select the icon in order to open the basic settings of the touch panel.

® Select the "Touch" tab ® Start the calibration there with "Recalibrate".

® Follow the instructions on the touch panel and press on the center of the target as
accurately as possible.

® To conclude the calibration operation, tap on the touch display of the panel again.

® Now select the "Reboot" option in the "Device" tab.

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® Press the "Reboot" button.

4.3 WinCC Advanced V1X programming software (TIA Portal V1X)

The WinCC Advanced V1X software (TIA Portal V1X) is the programming tool for the following
visualization systems:
- WinCC Runtime Advanced for PC-based single-user systems with licenses for 128, 512,
2k, 4k as well as 8k Power Tags (tags with a process interface)
- SIMATIC Comfort Panels
- SIMATIC Mobile Panels
- SIMATIC Multi Panels
- SIMATIC Panels of predecessor generations (Series 70, 170, 270)
- SIMATIC Basic Panels

With WinCC Advanced V1X you have the following functions for creating HMI (Human
Machine Interface) systems:
- Configuration and parameter assignment of the hardware
- Specification of communication and creation of a connection to a PLC
- Creation and design of screens with hierarchical structure
- Creation of internal and external variables
- Creation of alarms and alarm views
- Creation of logs and display of logs in the form of trends and tables
- Creation of recipes and recipe views
- Creation and printing of reports
- Creation of user-defined functions with Visual Basic Scripting
- Testing, commissioning and servicing with operational/diagnostic functions
- Remote operation via the optional WinCC Smart Server

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– Recording of operations in an audit trail with electronic signature

through the WinCC/Audit option
- Documentation
Support is provided for all functions through detailed online help.

4.3.1 Project
To implement a solution for an automation and visualization task, you create a project in the
TIA Portal. A project in the TIA Portal contains the configuration data for the configuration and
networking of devices as well as the programs and the configuration of the visualization.

4.3.2 Hardware configuration

The hardware configuration contains the configuration of the devices consisting of the
automation system hardware, the intelligent field devices and the visualization hardware, e.g.
panels as HMI (Human Machine Interface) systems. The configuration of the networks
specifies the communication between the various hardware components. The individual
hardware components are inserted in the hardware configuration from catalogs.
The hardware of automation systems comprises controllers (CPUs) with signal modules for
input and output signals (SMs) and communication and interface modules (CP, IM). Other
power supply modules (PS) and power modules (PM) are also available for supplying the
modules with energy.
The signal modules and intelligent field devices connect the input and output data of the
process to be automated and visualized to the automation system.
The visualization, in turn, accesses the data in the automation system.

Visualization

Central structure

Actuators/sensors

Figure 2: Example of hardware configuration with centralized and distributed structures and process
visualization

The hardware configuration enables the downloading of automation and visualization solutions
to the automation system and access to the connected signal modules by the controller.

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4.3.3 Schedule the hardware

Before you can configure the hardware, you must plan it (hardware planning). In general, you
begin by selecting which controllers are needed and how many. Next you select the
communication modules and signal modules. The selection of signal modules is based on the
number and type of inputs and outputs needed. As the final step, a power supply that ensures
that the necessary power is supplied must be selected for each controller or field device.
The functionality required and the ambient conditions are of vital importance for planning the
hardware configuration. For example, the temperature range in the application area
sometimes limits the devices available for selection. Fail-safe operation might be another
requirement, for example.
The TIA Selection Tool (automation technology ® select TIA Selection Tool and follow the
instructions) provides you support.
Notes:
· TIA Selection Tool requires Java.
· Online research: If more than one manual is available, you should look for the
description "Device Manual", "Product Manual" or simply "Manual" (as opposed to
"Function Manual", "List Manual", "System Manual", etc.) in order to find the device
specifications.
Figure 2 (see above) shows an automation structure that contains both centralized and
distributed structures.
Centralized and distributed uses are also possible for the visualization. Panels are often used
for distributed local operation. These can communication with the controller via Ethernet,
WLAN or fieldbus. For centralized operation and monitoring, PCs can also be used. They are
usually connected to the controller via Ethernet.
The TIA Selection Tool (automation technology ® select TIA Selection Tool and follow the
instructions, requires Java) also supports you when selecting the panels.

4.3.4 Planning the screen structure

After selection of a device for the visualization, the screen structure must be planned. For this
purpose, you should collect, group and structure the information to be displayed. A screen
structure, such as shown by way of example in Figure 3, should be derived from this. The
point of entry into the screen structure is always guaranteed by a so-called root screen.

Figure 3: Example of the screen structure

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The screen structure should be chosen to optimally support navigation by the user through the
information distributed among the screens for operation and monitoring of the process.
The following questions can aid you in this:
Which mental model of the process should be observed for the information display?
Which data belong together?
Which data belong in which order?
Which data belong to which actions/processes?
Is there cross-action data and the like?
Which data are key data, which are supplementary data?

4.3.5 Planning of the screen structure

Every individual screen must be planned. For the information display, its use by people must
also be considered. It is helpful here to observe design principles such as the law of proximity,
law of similarity and law of symmetry. The following rules of thumb derived from the design
principles can also aid in structuring screens:
® Form groups of data blocks

® Uniform division of the overall screen into work information, status or system information
and controller information

® Observe the average distribution of attention on the screen as a function of reading

direction.

® Use alignment as a design principle (align numbers, column headings same as column
content)

® Make effective use of a maximum of 30 – 40% of the available space: place as little
information as possible and as much as necessary

® Use codings sparingly (for example, color, bold text, brightness, shape, outline, pattern,
flashing)

® Subdivide numbers: Subdivide numbers with more than 4 digits in groups of 2, 3 or 4 (for
example, 66 234)

® Select numbers preferentially when listing objects, properties, etc.

® Use and position designations uniformly, use short words if possible

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4.3.6 Basic settings for WinCC Advanced in the TIA Portal

Users can specify their own default settings for certain settings in the TIA Portal. The path to
the settings for the visualization is shown here.
® In the project view, select the ® "Options" menu and then ® "Settings".

® Under ® "Visualization" in "Settings", select the desired default settings for the
appearance of the user interface.

Note: Keep the default settings for the visualization here.

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4.3.7 Resetting the SIMATIC HMI Panel TP700 Comfort and setting the IP
address
The SIMATIC HMI Panel TP700 Comfort can be reset directly in the TIA Portal. A new IP
address can also be assigned to the panel here.
To do so, select the Totally Integrated Automation Portal, which is opened here with a double-
click.
( ® TIA Portal V1X)
® Then, select ®"Online & Diagnostics" and open ®"Project View".

® In the project tree, select the network adapter of your computer under ® "Online
access". If you click ® "Update accessible devices" here, you will see the IP address (if
previously set) or the MAC address (if IP address not yet assigned) of the connected
SIMATIC HMI Comfort Panel ® Select ® "Online & Diagnostics" here.

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® To reset the panel, select the ® "Reset to factory settings" function and click ® "Reset".

Note: For resetting to factory settings, "Runtime" should not yet be started in the panel
and the "Start Center" should be displayed.

® Confirm the prompt asking if you really want to reset the module with ® "Yes".

® Before you can assign the IP address, you must wait until the panel has finished
resetting. Afterwards, you must select ® "Update accessible devices" and ® "Online &
diagnostics" of your panel again. To assign the IP address, select the ® "Assign IP
address" function here. Enter the following IP address here, for example: ® IP address:
192.168.0.10 ® Subnet mask 255.255.255.0. Click ® "Assign IP address" and this new
address will be assigned to your SIMATIC HMI Panel TP700 Comfort.

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® If the IP address was not successfully assigned, you will receive a message in the ®
"Info" window under ® "General".

Note: The IP address of the SIMATIC HMI Panel TP700 Comfort can also be set using
he Windows CE operating system of the panel.

4.3.8 WinCC user interface

Project tree Menu bar and buttons Work area Tools

Details view Properties window

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4.3.9 Project tree

The project tree window is the central control point for project editing. All components and all
available editors of a project are displayed in a tree structure in the project window and can be
opened there.
Each editor is assigned a symbol that enables you to identify the associated objects. Only
elements supported by the selected HMI device are displayed in the project window.
You can access the HMI device settings in the project window.

4.3.10 Details view

The details view displays the contents or additional information on the objects selected in the
project tree.

4.3.11 Menu bar and buttons

In the menus and toolbars, you will find frequently used functions you need to configure your
HMI device. If a corresponding editor is active, editor-specific menu commands and toolbars
are displayed.
If you point to a command with the mouse, a corresponding tooltip is provided for each
function.

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4.3.12 Work area

You edit the objects of the project in the work area. All other WinCC elements are arranged
around the working area.
In the work area, you edit the project data either in tabular form (for example, tags), or
graphically (for example, process screens).
A toolbar is located in the upper part of the work area. Here, you can select, for example, the
font, font color and functions such as rotate, align, etc.

4.3.13 Tools
The Tools window contains a selection of objects is provided that you can insert into your
screens, such as graphic objects and operator controls. In addition, the Tools window contains
graphics with preassembled graphic objects and collections of faceplates.
Objects are moved to the working area via "drag and drop".

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4.3.14 Properties window

In the properties window, you edit the properties of the objects selected in the work area (e.g.
the color of screen objects). The window is available only in certain editors.
The properties of the selected object are displayed arranged by category in the properties
window. As soon as you exit an input field, the value changes take effect. If you enter an
invalid value, it is highlighted in color. The tool tip gives you information about the valid value
range, for example.
In addition, animations (e.g. change of color at a signal state change in the PLC) and events
(e.g. change of screen when a button is released) are configured for a selected object in the
properties window.

4.3.15 Other tabs

Settings for the work area such as the level selection and grid functions can be made in the
layout window.
Animations, instructions, tasks and libraries of the select object can be selected using
additional tabs.

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5 Task
In this chapter, process visualization will be added to the program from chapter Data_Blocks.
This will enable you to better monitor the process flow and operate the process more
effectively.

6 PlanningProcess visualization
A Touch Panel TP700 Comfort is to be used for the process visualization.
The programming device, a SIMATIC S7-1500 controller and the Touch Panel TP700 Comfort
are interconnected via the Ethernet interface.
The basic configuration is to be performed using the wizard in the TIA Portal V1X. All system
screens are to be created in the process.
In an overview screen "Overview of sorting station", the process will be represented by the
conveyor and sensors. Conveyor speed and the count of plastic workpieces will also be
displayed here.
In this screen, it is also to be possible to select the operating mode, start and stop in automatic
mode and reset the counter.
The actual speed of the motor will be graphically displayed in another screen titled "Motor
Speed". The setpoint speed can also be specified here.
The "Plastic Magazine" will be created in a first step.
An alarm line, date/time and the plant states "Emergency Stop ok/triggered", "Main switch
ON/OFF" and "Automatic started/stopped" are to be displayed in the header of all screens.
The footer contains a button that can be used to return to the start screen and a button to exit
Runtime.
The alarm system is also to be configured.
System events are to be displayed on the panel and the CPU and limit violations of the motor
speed and the main switch monitored.
The alarms will be displayed in the alarm line of the header and shown automatically in alarm
windows when errors/warnings occur.
Remote control of the Touch Panel TP700 Comfort is activated via the web server.

6.1 Program description for the sorting station with speed control
and speed monitoring of the motor
The "MOTOR_AUTO" [FB1] function block controls a conveyor in automatic mode.
The Memory_automatic_start_stop is latched with the Start_command but only if the reset
conditions are not present.
The Memory_automatic_start_stop is to be reset if a Stop_command is pending or safety
shutoff is active or automatic mode is not activated from the visualization.
The Conveyor_motor_automatic_mode output is activated when
Memory_automatic_start_stop is set, the enable conditions are met and
Memory_conveyor_start_stop is set.
To save energy, the conveyor should only run when a part is present.
For this reason, the Memory_conveyor_start_stop is set when Sensor_chute_occupied signals
a part and reset when Sensor_end_of_conveyor produces a negative edge or safety shutoff is
active or automatic mode is not activated (manual mode).

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Because the Sensor_end_of_conveyor is not able to be mounted directly at the end of the
conveyor, signal stretching of the Sensor_end_of_conveyor signal is programmed.
The magazine for plastic holds only five parts. For this reason, the parts will be counted at the
end of the conveyor. When the magazine contains five parts, automatic mode is to be
stopped. After the magazine has been emptied, automatic mode will be restarted with the
Start_command once the counter has been reset from the visualization.
The speed setting is made at an input of the "SPEED_MOTORCONTROL" [FC10] function in
revolutions per minute (range: +/- 50 rpm).
First, the function first checks for correct entry of the speed setpoint in the range +/- 50 rpm.
If the speed setpoint is outside the range +/- 50 rpm, the value 0 will be output at the speed
manipulated value output. The return value of the function (Ret_Val) will be assigned the value
TRUE (1).
If the speed setting is within the range +/- 50 rpm, this value will first be normalized to the
range 0…1 and then scaled to +/- 27648 with data type 16-bit integer (Int) for output as the
speed manipulated value at the analog output.
In the "SPEED_MOTORMONITORING" [FC11] function, the actual value will be made
available to B8 as an analog value and queried at an input of the
"SPEED_MOTORMONITORING" [FC11] function.
The actual speed value will be scaled to revolutions per minute (range: +/- 50 rpm) and made
available at an output.
The following four limits can be specified for the block inputs in order to monitor them in the
function:
Speed > SPEED_MOTOR_monitoring_error_max
Speed > SPEED_MOTOR_monitoring_warning_max
Speed < SPEED_MOTOR_monitoring_warning_min
Speed < SPEED_MOTOR_monitoring_error_min
If a high or low limit is violated, the value TRUE (1) is assigned to the corresponding output bit.
If a fault is present, the protective tripping of the "MOTOR_AUTO" [FB1] function block is to be
tripped.
The speed setpoint and the actual speed value as well as the positive and negative error and
warning limits are created in the data block "SPEED_MOTOR" [DB2], as are the error and
warning bits.
The setpoint and actual value of the counter for the plastic parts will be specified and
displayed in the global data block "MAGAZINE_PLASTIC" [DB3]. These values are
interconnected with the "MOTOR_AUTO" [FB1] function block using an input for the setpoint
setting and an output for the actual value display.

6.2 Technology diagram

Here, you see the technology diagram of the plant for the task.

Figure 4: Technology diagram

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Figure 5: Control panel

6.3 Reference list

The following signals are required as global operands for this task.

DI Type Identifier Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop OK NC
I 0.1 BOOL -K0 Main switch "ON" NO
Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/ automatic (1)
Auto = 1

I 0.3 BOOL -S1 Pushbutton "Automatic Start" NO

I 0.4 BOOL -S2 Pushbutton "Automatic Stop" NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO
I 1.3 BOOL -B7 Sensor part at end of conveyor NO

Sensor actual value speed of the motor +/-10V

IW64 BOOL -B8
corresponds to +/- 50 rpm

DO Type Identifier Function

Q 0.2 BOOL -Q3 Conveyor motor M1 variable speed

Manipulated value speed of the motor in two

QW 64 BOOL -U1
directions +/-10V corresponds to +/-50 rpm

Legend for reference list

DI Digital input DO Digital output

AI Analog input AO Analog output

I Input O Output

NC Normally Closed

NO NO Normally Open

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
follow the individual instructions in the steps below.

7.1 Retrieving an existing project

® Before you can expand the "SCE_EN_032-600_Global_Data_Blocks_R1508.zap13"
project from chapter "SCE_EN_032-600_Global_Data_Blocks", you must retrieve this
project from the archive. To retrieve an existing project that has been archived, you must
select the relevant archive with ® Project ® Retrieve in the project view. Confirm your
selection with "Open".
( ® Project ® Retrieve ® Select a .zap archive … ® Open)

® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
( ® Target directory … ® OK)

® Save the opened project under the name 042-201_WinCC_Advanced_TP700_CPU

1516F.
( ® Project ® Save as … ®042-201_WinCC_Advanced_TP700_CPU 1516F ® Save)

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7.2 Adding a SIMATIC HMI Panel TP700 Comfort

® To create a new panel in the project, go to the portal view. In the portal, select the menu
command ® "Devices & networks" and ® "Add new device".

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® Now, select the device version as follows: ® "HMI" ® "SIMATIC Comfort Panel" ® "7"
Display" ®"TP700 Comfort" and the correct order number of your panel, here, for
example, ® 6AV2 124-0GC01-0AX0

® Enter "Panel TP700 Comfort" as the device name and ® select the check box "Start

device wizard". Click the button here.

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7.3 HMI wizard for the TP700 Comfort Panel

The TIA Portal now creates the desired panel and automatically starts the HMI wizard for the
TP700 Comfort Panel This helps in specifying a few basic settings for the panel.
® A prompt for the PLC connections appears first. Choose your previously configured CPU
1516F as the communication partner.

® In order to connect your panel to the CPU, select the "Ethernet" interface.® Confirm
your selection by clicking " "

® Under "Screen layout" you can change the default background color of your panel. ®
Select the "Page header" check box with screen title "Date/time" and "Logo".®
Confirm your selection by clicking " ".

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® In the "Alarms" section, you can specify the alarms that are to be displayed in a window.
Select all 3 alarm types (with the option "Top alarm line" for unacknowledged
alarms) ® Confirm your selection by clicking " ".

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® The "Screen navigation" section shows the screen structure with the screen names of
the last created project, in which the start screen is the first screen shown on the left.
® By clicking a screen name, you can easily assign a new name ® By clicking , you

can insert new pictures in the hierarchy ®By clicking " ", you can delete
selected screens.

® Use this method to create the screen structure shown below with the corresponding
screen names. ® Confirm your selection by clicking " ".

® In the "System screens" section, you can select previously preset views for system
functions and automatically insert them. ®Enable all system screens with "Select all"
® Confirm your selection by clicking " ".

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® In the "System buttons" section, you will find the four freely selectable buttons for Exit

(Runtime), Log on , Language and Start screen . You can place these
buttons on the provided button areas "Left", "Bottom" or "Right" using drag-and-drop.

® Enable only the "Button area" "Bottom". ® Insert the button for the "Start screen"

on the left and the button for Runtime "Exit" on the right. ® Confirm your selection

by clicking " "

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7.4 Device configuration of the TP700 Comfort Panel

® The TIA Portal now switches automatically to the project view and displays the start
screen of our visualization there.

® In order to configure our panel, select "Panel TP700 Comfort" in the project tree and
double-click it to open its "Device configuration".

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7.4.1 Setting the IP address

® Double-click the Ethernet interface of the panel in the Device view.

® In the ® "Properties" under General, open the ® "PROFINET interface [X1]" menu
command and select the ® "Ethernet addresses" entry there.

® Set the IP address 192.168.0.10 under IP protocol.

Note: The subnet mask was previously set in the settings of the CPU 1516F and is
applied automatically to the panel.

® To obtain an overview of the assigned addresses within a project, you can click the ® "

" icon in the ®"Network view". If you click ® , the "HMI connection"
between the CPU and panel that you previously created in the wizard will be displayed.

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7.5 Compiling the CPU and panel and saving the project

® To compile all blocks, click the "CPU_1516F" folder and select the icon for compiling
in the menu. To compile the panel, click the "Panel TP700 Comfort" folder and select the

icon for compiling in the menu. You can save your project by clicking the
button in the menu.

(® CPU_1516F ® ® Panel TP700 Comfort ® ® )

® The 'Info' area then indicates whether compiling was successful or whether warnings or
errors occurred.

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7.6 Configuring the graphic display

® After successful compilation, you want to lay out the first screen for the visualization. To
do this, first open the ® "Overview of sorting system" screen by double-clicking it.

® Many objects such as the screen change buttons were already created by the wizard.
The text filed in the center of the screen is to be removed by right-clicking it and
selecting ® "Delete" in the displayed dialog.

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® From Tools, select ® "Graphic display" under ® "Basic objects". The mouse pointer
changes so that you can now draw an area for displaying a graphic in the work area.

® You can double-click the graphic display area to have its properties displayed. Select the

® "Create graphic from file" icon ® in the ® "General" sub-item.

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Note: There are four sub-items for the properties of the objects.

- Properties for static settings of the object.

- Animation for dynamic settings of the object.

- Events if actions are to be triggered from objects.

- Texts for the multilingual display within an object.

® In the displayed dialog, select the Picture ® "Open"

® Select the "Foerderband_Conveyor.bmp" graphic for the display and click ® "Apply".

Note: The generated graphic is stored in the "Languages & Resources" path under
"Project graphics".

® Position the graphic with the mouse in such a way that the positions and sizes shown
below are entered ® under "Layout" ® in the properties. Select the ® "Fit graphic to
object size" option to adapt the size.

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7.7 Displaying a process value in an IO field

® You first want to insert a display of the actual value of the current speed below the
conveyor motor. To do this, select the ® "Program blocks" of the ® "CPU_1516F" and
the ® "SPEED_MOTOR[DB2]" data block there. Then drag the ® "Actual speed value"
tag from the ® "Detail view" to our "Overview of sorting station" screen.

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® The connection to the tag in the PLC has already been created in the "Properties" of the
IO field under "General", "Process". The "Display format" is set to "Decimal". Now, all
you have to do is change the "Format pattern" to ® "s999.99" and the "Type" of the field
to ® "Output".

Note: The format pattern s999.99 means that the display will include three places in front
of the decimal point two places after the decimal point and a sign.

® In the "Properties" under "Appearance", we change the "Color" of the "Background" to ®

"Blue".

® Under "Text format" in "Properties", change the "Horizontal" setting of "Alignment" to ®

"Right".

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® Under "Layout" in the "Properties", change ® "Position & Size" as illustrated here so that
the IO field will be displayed below the conveyor motor.

® For the description, use drag-and-drop to insert a ® "Text field" before and after
the IO field from ® "Basic objects" in "Tools". Type ® "Actual speed value" and ® "rpm"
there.

® Next, select the three objects ® IO field ® text field "Actual speed value" ® and text

field "rpm" in that order and then click on the ® "Align selected objects on top"

function in the toolbar of the work area. Save your project by clicking .

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7.8 Visualizing binary signals with animated rectangles

® For the visualization of the sensors, you want to start with sensor "-B4" at the slide. To
allow you to draw and position the rectangle better, first change the zoom factor
to ® "300%".

® Next, use "drag-and-drop" to move a rectangle from ® "Basic objects" in Tools to

the position of sensor "-B4".

® Draw the correctly sized and positioned rectangle with the mouse or set the ® "Position
& Size" under "Layout" in "Properties" as shown here. The sensor will then be displayed
below the designation "-B4".

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® In "Properties" under "Appearance", change the "Color" of the "Background" to ® "Gray"

and the "Width" of the "Border" to ® "0".

® Now change to the "Animation" tab and select "Display" and click
® "Add new animation" .

® In the displayed dialog, select ® "Appearance" and click ® "OK".

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® To establish the connection to the global tag in the CPU, select ® "PLC tags" under ®
"CPU_1516F" and below that
the ® "Tag_table_sorting_station". Next, drag the "-B4" tag from the ® "Detail view" to
the "Name" field for the "Tag".

® In the "Appearance" of the "Display", add an area with the value ® "1" (signal state
"High") and change the "Background color" to ® "Green".

As shown in the previous steps, create a display for each of the following sensors:
® "-B1", ® "-B2", ® "-B5", ® "-B6" and ® "-B7".
® Also insert an additional binary display below the motor M1 and connect it to the global
tag ® "-B3". For the description, insert a text field ® "-B3 Motor active" in front of it.

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7.9 Symbol library

® In order to show that the conveyor is being controlled, use drag-and-drop to move the

"Symbol library" object from ® "Elements" in Tools onto the conveyor.

® The symbol library contains a number of simple and more complex graphic elements.
Under "General" in "Properties", select the "Category" ® "Arrow". Select an arrow

pointing in the opposing direction here ® .

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® Under "Appearance" in "Properties", change the "Style" of the arrow to ® "Solid" and the
"Color" of the "Foreground" to ® "Green".

® Now change to the "Animation" tab and select "Display" and click ® "Add new
animation" .

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® In the displayed dialog, select ® "Visibility" and click ® "OK".

® To establish the connection to the global tag in the CPU, select ® "PLC tags" under ®
"CPU_1516F" and below that ® "Tag_table_sorting_station". Next, drag the "-Q3" tag
from the ® "Detail view" to inside the "Tag" field. In addition, select ® "Single bit" as the
type of evaluation.

® Next, duplicate the arrow from the symbol library with all its properties using ®
"Copy" and "Paste".

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7.10 Connections and HMI tags

® Before you download the configuration to the TP700 Comfort Panel, you should check
the connection to the CPU 1516F. To do so, double-click ® "Connections" in ® "Panel
TP700 Comfort" to select it. In the displayed view, you can check the IP addresses and
the connection settings. It is important that the check box for Online is selected.

Note: If access protection has been activated for the CPU 1516F, the access password
for the panel can also be entered here.

® To access the HMI tags, you must double-click the ® "Default tag table" in the ® "HMI
tags" folder in ® "Panel TP700 Comfort" to open it. All tags created by drag-and-drop
have been entered here.

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® In the default tag table, you can check which tags in the CPU 1516F will be accessed.
You can also made additional settings.
The "Acquisition cycle" of our tags is to be accelerated from 1 second to 100

milliseconds here. To do so, click the ® selection field and select a new acquisition
cycle ® "100 ms" by double-clicking it.

® You can make the settings of other tags using the "Autocomplete" function by selecting
the lower right corner of the first entry with the mouse and dragging over the other
entries.

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7.11 .Downloading the CPU and panel

® Before the project is downloaded to the CPU and the panel, compile the CPU and panel
again and save the project.

(® CPU_1516F ® ® Panel TP700 Comfort ® ® )

® After successful compilation, the complete controller with the created program including
the hardware configuration can be downloaded, as described in the previous modules.

(® )

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® To download the visualization to the panel, proceed in a similar way. Select the ® "Panel
TP700 Comfort [TP700 Comfort]" folder and click the icon

® "Download to device".

® The manager for configuring the connection properties (extended download) opens.
First, the interface must be correctly selected. This happens in three steps.

® Type of the PG/PC interface ® PN/IE

® PG/PC interface ® here, for example: Intel(R) Ethernet Connection I217-LM

® Connection to interface/subnet ® "PN/IE_1"

The ® "Show all compatible devices" check box must then be selected. The search for

devices in the network is started by clicking the ® button.

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® If your panel is shown in the "Compatible devices in target subnet" list, it must be
selected and the download started.
(® Panel TP700 Comfort ® "Download")

® You first obtain a preview. Confirm the prompt ® "Overwrite all" and continue with ®
"Load".

Note: The symbol should be visible in every line of the "Load preview". You can find
additional information in the "Message" column.

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7.12 Process visualization in the simulation

For a connection to be set up between the runtime simulation on the PG/PC and the S7-1500
CPU, first the PG/PC interface has to be set to TCP/IP.

No. Procedure:

Open the Control Panel

1
· with "Start > Control Panel"
(Start menu for easy access to programs under Windows XP),
· or via "Start > Settings > Control Panel"
(with class Start menu as is the case in previous Windows versions).

In the Control Panel, double-click the icon ”Set PG/PC Interface".

2

Set the following parameters in the "Access Path" tab:

3
1. For the access point of the application, select "S7ONLINE [STEP 7]"
from the drop-down list.
2. From the list of interface parameter assignment used, select the
interface "TCP/IP(Auto) -> with your network adapter that is connected
directly with the Panel and the controller, e.g., 3Com EtherLink XL.
3. Then click OK and confirm the next message with OK.

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® Select "Panel TP700 Comfort" and click the

® "Start simulation” button.

® The process visualization will be implemented completely on the PC with a connection to

the process data in the CPU 1516F. To close the simulation, you can select the ®
button for "Exit Runtime" in the application or simply close the window by clicking
®" ".

7.13 Switches and buttons for the process operation

® To have an interface to the process operation available in the PLC, select ® "Add new
block" in the "Program blocks" folder in "CPU_1516F" and create a global data block

"OPERATION_HMI".

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® In the "OPERATION_HMI" data block, create the following four tags of data type BOOL:
® "Mode selection", ® "Automatic_Start", ® "Automatic_Stop" and ®
"Reset_Counter_Plastic". The start value of the "Automatic_Stop" tag
is preset with ® "true".

® The "MOTOR_AUTO[FB1]" function block is now expanded to include an input tag ®

"Reset_Workpiece_Counter_Plastic" of type ® "Bool". This tag is moved onto the ® "R"
input of the "CTUD" counter in network 2 using drag-and-drop.

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® The call of the function block "MOTOR_AUTO[FB1]" must be updated in the "Main[OB1]"

block. This is done by clicking the icon ® "Update inconsistent block calls".

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® In network 3 of the "Main[OB1]" block, drag an ® "OR" in front of the input tag ®
"Start_command".

® The second free input of the ® "OR" is connected to the ® "Automatic_Start" tag from
the "OPERATION_HMI" data block.

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® In network 3 of the "Main[OB1]" block, drag an ® "AND" in front of the input tag ®
"Stop_command".

® The second free input of the ® "AND" is connected to the ® "Automatic_Stop" tag from
the "OPERATION_HMI" data block.

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® The input tag ® "Automatic_mode_active" is connected to the ® "Mode selection" tag

from the "OPERATION_HMI" data block.

® The input tag ® "Reset_part_counter_plastic" is connected to the ®

"Reset_counter_plastic" tag from the "OPERATION_HMI" data block.

® Compile the CPU again and save the project.

(® CPU_1516F ® ® )

® You download the modified program including the hardware configuration to the CPU

1516F. ( ® )

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® In order to implement a pushbutton that resets the workpiece counter for the plastic
parts, use drag-and-drop to move the ®"Button" object from ® "Elements" in
"Tools" to a location below the plastic parts storage.

® Under "General" in "Properties", enter ® "Reset" as the label.

® Under "Appearance" in "Properties", change the "Color" of the "Background" to ®

"Blue".

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® The functionality must now be configured as a pushbutton. For this, change to the
"Events" menu, select ® "Press" as the event and ® "<Add function>".

® Under "System functions", select "Bit processing" as the function and select ®
"SetBitWhileButtonPressed" there.

® For the process connection, select the ® "Program blocks" of the ® "CPU_1516F" and
the ® "OPERATION_HMI[DB4]" data block there. Then drag the
®"Reset_counter_plastic" tag from the ® "Detail view" into the field for "Tag
(input/output)".

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® As shown previously in the document, now insert a text ® "Plastic parts counter" above
the button and a display of the ® "Plastic_parts_actual" tag from the
"MAGAZINE_PLASTIC[DB3]" block to the left of the button.

® In order to implement the pushbutton, use drag-and-drop to move the ®"Button" object
from ® "Elements" in "Tools" to a location at the top next to the button for the screen
change.

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® Under "General" in "Properties", change the "Mode" to ® "Graphics and text". To do this,
open the selection dialog for ® "Graphic when button is not pressed" by clicking the
icon.

® Then click the icon for "Create graphic from file" and select the "Pushbutton-Round-
G_Off_256c.bmp" file from the "SCE_EN_042-201_Screens" folder by double-clicking it.

® In exactly the same way, select the "Pushbutton-Round-G_On_256c.bmp" file from the
"SCE_EN_042-201_Screens" folder for the "Graphic when button is pressed".

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Note: The generated graphics are stored in the "Languages & Resources" path under
"Project graphics".

® Under "Layout" in "Properties", adapt the size of the button under ® Position & Size.

® The pushbutton functionality is realized here again as event ® "Press" with "System
function" ® "SetBitWhileButtonPressed". The ® "Automatic_Start" tag from the data
block ® "OPERATION_HMI[DB4]" is used for the process connection.

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® As shown in the last steps, a "button" for the Stop button is inserted. The files
"Pushbutton-Stop_Off_256c.bmp" and "Pushbutton-Stop_On_256c" from the
"SCE_EN_042-201_Screens" folder are used as graphics.

® The functionality as a normally-closed switch is implemented with two events. The first
event is ® "Press" with "System function" ® "ResetBit" and the second event ®
"Release" with "System function" ® "SetBit". The ® "Automatic_Stop" tag from the data
block ® "OPERATION_HMI[DB4]" is used for the process connection in both cases.

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® In order to implement the mode switch, use drag-and-drop to move the ®"Switch"
object from ® "Elements" in "Tools" to a location at the top between the buttons for the
screen change and the Start button.

® Under "General" in "Properties", select the "Show label" ® option. Next, enter the
texts ® "Auto" for the "ON" state and ® "Manual" for the "OFF" state. The ® "Mode
selection" tag from the data block ® "OPERATION_HMI[DB4]" is used for the process
connection.

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® Under "Layout" in "Properties", adapt the size of the mode switch under ®Position &
Size.

® Now compile the CPU and save the project.

( ® Panel TP700 Comfort ® ® )

® Afterwards, download the changed visualization to the panel.

(® )

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7.14 Adapting the headers in the template

® The plant states are to be shown overall in the header. "Template_1" for our header and
footer was already created by the wizard when the panel was created. The footer
contains the system buttons and a logo, date and time as well as the "Screen title" text
field was previously created in the header.

® You would now like to adapt the screen title to the dimensions specified here under
"Layout" in "Properties" in ® "Position & Size".

® Delete the logo on the left in the header by selecting the ® graphic display for the LOGO
with the right mouse button and clicking ® "Delete".

® In the "Panel TP700 Comfort", open the ® "Text and Graphic lists" folder.

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® Under "Graphic lists", create a ® "Graphic_List_Warning" with ® selection "Bit(0,1)".

® Click the icon for "Value 0" to open the selection dialog for the graphics stored under
"Project graphics" in the "Language & Resources" path. Click the icon for "Create

graphic from file" and select the "Warning.bmp" file from the "SCE_EN_042-
201_Screens" folder by double-clicking it. This file is stored in the "Languages &
Resources" path under "Project graphics".

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® The graphic that you want to assign to "Value 1" is already stored in the "Languages &
Resources" path under "Project graphics". After clicking the ® icon, you can select
the ®"Logo of Panel TP700 Comfort" file directly.

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® Now change to the "Text lists" and create the following three text lists:® "Text
list_Emergency stop" ® "Text list_Main switch" and ® "Text list_Automatic". Use the ®
selection "Bit(0,1)" in each case.

® Make the following assignments in "Text list_Emergency stop": "Value 0" ®

"EMERGENCY STOP triggered" and ® "Value 1" ® "EMERGENCY STOP OK".

® Make the desired assignments in "Text list_Main switch": "Value 0" ® "Main switch OFF"
and ® "Value 1" ® "Main switch ON".

® Make the following assignments in "Text list_Automatic": "Value 0" ® "Automatic

stopped" and ® "Value 1" ® "Automatic started".

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® Back in "Template_1" for our header, use drag-and-drop to move the ® "Graphic IO

field" object from ® "Elements" in Tools to the top left corner.

® Under "General" in "Properties", change the "Mode" to ® "Output".

Then open the selection dialog for ® "Graphic list" by clicking the icon. Select the
"Graphic list_Warning" you just created.

® To establish the connection to the global tag in the CPU, select ® "PLC tags" under ®
"CPU_1516F" and below that ® "Tag_table_sorting_station". Now drag the
® "-A1" tag from the "Detail view" into the "Tag" field In addition, select ® "Bit number
0" as the type of evaluation.

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® Under "Layout" in "Properties", adapt the size of the "Graphic IO field" under ® "Position
& Size".

® To display the status of the EMERGENCY STOP in the header, use drag-and-drop to
move the ® "Symbolic IO field" object from ® "Elements" in Tools to the right of the
"Graphic IO field".

® Under "General" in "Properties", change the "Mode" to ® "Output". Next, open the
selection dialog for ® "Text list" by clicking the icon. Select the "Text list_Emergency
stop" you just created.

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® To establish the connection to the global tag in the CPU, select ® "PLC tags" under ®
"CPU_1516F" and below that ® "Tag_table_sorting_station". Now drag the
® "-A1" tag from the "Detail view" into the "Tag" field and also select ® "Bit number 0"

® Under "Layout" in "Properties", adapt the size of the "Graphic IO field" under ® "Position
& Size".

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® Repeat the preceding steps again for the text lists ® "Text list_Main switch" and ® "Text
list_Automatic" to insert these left of the date and time directly one beneath the other.

® The "Text list_Main switch" is connected using the ® "-K0" tag from
Tag_table_sorting_station".

® The "Text list_Automatic" is connected using the ® "-Memory_Automatic_Start_Stop"

tag from "MOTOR_AUTO_DB1[DB1]".

® Under "Appearance" in "Properties", change the "Color" of the "Background" for ®"Text
list_Main switch" and ® "Text list_Automatic" to ® "Gray".

® For ® "Text list_Main switch" and ® "Text list_Automatic", change to the "Animation"
tab and select "Display" and click ® "Add new animation" .

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® In the displayed dialog, select ® "Appearance" and click ® "OK".

® In "Appearance" of both "Symbolic IO fields", add an area with the value ® "1" (signal
state "High") and change the "Background color" to ® "Green".

® The "Text list_Main switch" is connected using the ® "-K0" tag from
Tag_table_sorting_station".

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® The "Text list_Automatic" is connected using the

® "-Memory_Automatic_Start_Stop" tag from "MOTOR_AUTO_DB1[DB1]".

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® In the default tag table, the "Acquisition cycle" of all tags is also to be accelerated from 1
second to 100 milliseconds here.

® Before the project is downloaded to the CPU and the panel, compile the CPU and panel

again and save the project. ( ® CPU_1516F ® ® Panel TP700 Comfort ® ®

® After successful compilation, the complete controller with the created program including
the hardware configuration can be downloaded, as described in the previous modules.

(® )

® To download the visualization to the panel, proceed in a similar way. Select the ® "Panel
TP700 Comfort [TP700 Comfort]" folder and click the icon

® "Download to device".

7.15 Bar graph

® You would like to specify the setpoint for the speed control of the motor and display the
actual value. To do this, open the ® "SPEED MOTOR" screen by double-clicking it.

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® The text field in the center of the screen is to be removed by right-clicking it and
selecting ® "Delete" in the displayed dialog.

® In order to graphically display the actual speed value, use drag-and-drop to move the

®"Bar" object from ® "Elements" in "Tools" to the center of the screen.

® Under "General" in "Properties", change the "Maximum scale value" to ® 50 and the
"Minimum scale value" to ® -50.

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® For the process connection, select the ® "Program blocks" of the ® "CPU_1516F" and
the ® "SPEED_MOTOR[DB2]" data block there. Then drag the ®"Actual speed value"
tag from the ® "Detail view" into the field for "Process tag".

® Under "Scales" in "Properties", select ® "Show scale". Under "Divisions" select ® 2.

Under "Marks label" select ® 1. Under "Interval", select ® 10.

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® Under "Label" in "Properties", select ® "Label". Under "Unit" select ® rpm. Under
"Decimal places", select ® 2.

® Under "Layout" in "Properties", adapt the position and size of the bar under ® "Position

& Size". Above the bar diagram, insert a ® "Text field" for the description with text
® "Actual speed value".

® In order to specify the speed setpoint, move the ®"IO field" object from ®
"Elements" in "Tools" to a location above and to the right of the bar display.

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® Under "General" in "Properties" keep the "Type" as ®"Input/Output" and change the
"Format pattern" to ® s99.99.

® For the process connection, select the ® "Program blocks" of the ® "CPU_1516F" and
the ® "SPEED_MOTOR[DB2]" data block there.
Now drag the ®"Speed setpoint" tag from the ® "Detail view" into the field for "Tag".

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® Under "Appearance" in "Properties", change the "Color" of the "Background" to ®

"Blue".

® Under "Text format" in "Properties", change the "Horizontal" setting of "Alignment" to ®

"Right".

® Under "Layout" in "Properties", adapt the position and size of the IO field under ®
"Position & Size".

® Above the bar diagram, insert a ® "Text field" for the description with text ®
"Speed setpoint".

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® In the default tag table, the "Acquisition cycle" of the newly created
"SPEED_MOTOR_speed setpoint" tag is again changed from 1 second to 100
milliseconds.

® Before the visualization is downloaded to the panel, compile the panel again and save
the project.

(® Panel TP700 Comfort ® ® )

® Select the ® "Panel TP700 Comfort [TP700 Comfort]" folder and click the icon®
"Download to device".

7.16 Alarms
When you created the TP700 Comfort Panel using the wizard, you created a pair of alarm
windows at the same time. You should now look these over in more detail.

7.16.1 General alarm settings

® You first want to make a pair of settings for the display of alarms in Runtime. To do this,
double-click the® "Runtime settings" folder in ® "Panel TP700 Comfort" to select it.
Under "General" in "Alarms", select ® "Colors of alarm classes". Under "System
events", change ® display duration in seconds to "10". Under "Controller alarms", check
whether the "System diagnostics" check box is selected .

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7.16.2 Alarm window

® In order for the alarm window to be shown in the foreground in every screen, there is a
® "Global screen" in the ® "Screen management" folder in ® "Panel TP700 Comfort".
Open this with a double-click. An alarm window ® "System events" has already been
created in this screen. Under "General" in "Properties", "Pending alarms" of
"System" alarm class are already activated.

® System events will thus automatically be displayed for ten seconds in Runtime.

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® As a second alarm window in the "Global screen" there is ® "Pending alarms". Under
"General" in "Properties", activate "Pending alarms" and "Unacknowledged
alarms". Activate "Errors", "Warnings" and "No Acknowledgment" as alarm
classes.

Note: You will create alarm classes of types "Errors" and "Warnings" in the panel itself in
the following steps. The alarm class of the "No acknowledgment" type is produced
automatically by the settings for the system diagnostics in the CPU 1516F.

® Under "Miscellaneous" in "Properties", change the "Name" to ® "Alarm

window_pending_not_acknowledged".

® Under "Mode" in "Properties", change the "Title" to ® "Pending/not acknowledged

alarms".

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7.16.3 Alarm indicator

® In addition to the alarm windows there is an ® "Alarm indicator" in the "Global screen".
This is used so that an alarm window that was closed by the user is displayed again.
Under "General" in "Properties", activate the alarm classes "Errors: Pending alarms",
"Errors: Acknowledged", "Warnings: Pending alarms" and "No Acknowledgment:
Pending alarms".

® In ® "Events", the display of the alarm window "Alarm

window_pending_not_acknowledged" with function "ShowMessageWindow" has already
been stored for "Click" and "Click when flashing".

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7.16.4 Alarms for system diagnostics of CPU 1516F

® Open the "Device configuration" of the "CPU_1516F" and select the ® "System
diagnostics" menu under ® "General" in ® "Properties".
System diagnostics is always activated for devices of the SIMATIC S7-1500 series.
Under ® "Alarm setting", you see which alarm classes are being used. Here, the alarm
class is "No Acknowledgment". These alarm classes are referenced in turn by the HMI
systems in the alarm windows and for the other settings for the alarms.

® Select the analog output module ® "AQ4xU/I" and activate ® "Diagnostics" ®

"Missing voltage supply L+" for all channels under ® "Outputs" in ® Properties.

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® Before the project is downloaded to the CPU and the panel, compile the CPU and panel
again and save the project.

( ® CPU_1516F ® ® Panel TP700 Comfort ® ® )

® After successful compilation, the complete controller with the created program including
the hardware configuration can be downloaded, as described in the previous modules.

( ® CPU_1516F ® )

® To download the visualization to the panel, proceed in a similar way. Select the ® "Panel

TP700 Comfort [TP700 Comfort]" folder and click the icon ® "Download to device".

® Alarms for system diagnostics of the CPU 1516F are now automatically displayed in the
alarm window "Pending/Unacknowledged alarms". Details and help texts can be
displayed and alarms can be acknowledged if necessary in this alarm window. If the
alarm window has been closed, it can be displayed again by clicking the displayed

alarm indicator. This example shows a failure of the supply voltage for the
"AQ4xU/I" module.

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7.16.5 Alarm class settings

® The item ® "HMI alarms" is available in the ® "Panel TP700 Comfort" for configuring
the alarm system and creating individual alarms. Open this with a double-click. The
alarm classes we are using have already been created in the menu command "Alarm
classes" but these can also be changed. For alarm class ® "Warnings", change the
background color for the "Incoming" and "Outgoing" states to ® "Yellow".

7.16.6 System events

® With the menu command "System events", you can have these automatically imported
by clicking ® "Yes".

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7.16.7 Controller alarms

® The controller alarms have already been created with the menu command "Controller
alarms".

7.16.8 Analog alarms

® You can monitor tags to determine whether they are within limits in "Analog alarms".
Create a new alarm by clicking "Add". For monitoring purposes, select the ® "Default
tag table" in ® "Panel TP700 Comfort" and drag the ®
"SPEED_MOTOR_actual_speed_value" tag that is to be monitored from the ® "Detail
view" into the field for "Trigger tag". Drag the variable
limit®"SPEED_MOTOR_positive_speed_error limit" from the ® "Detail view" into the
field for "Limit".

® Enter the text ® "Error limit exceeded positive motor speed", select the "Alarm class" ®
"Errors" and "Mode" ® "High". Create the three other alarms of alarm classes
"Warnings" and "Errors" shown below in the same way.

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7.16.9 Discrete alarms

® Before you can create discrete alarms in the panel, you need a global tag with at least
16 bits in the CPU 1516F. You will use this tag to trigger the discrete alarms from the
PLC. In "CPU 1516F", open the data block ® "OPERATION_HMI[DB4]" in the®
"Program blocks" folder and create a global tag ® "Group alarms 01" of data type ®
"Word" there.

® In the ® "Program blocks" folder, click ® "Add new block" to create ® ®

"Discrete alarm_assignment".

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® In the "Discrete alarm_assignment" function, create a local input tag ®

"DiscreteAlarmX0" of data type ® "Bool" and a local output tag ® "GroupAlarms01" of

data type ® "Word". In the first network, program a single assignment of the ®
"DiscreteAlarmX0" tag to Bit X0 in the ® "GroupAlarms01" tag.

Note: The "Tag1.%X0" syntax is referred to as Slice access in the TIA Portal. This
enables access to the individual bits of a tag of data type Byte, Word or DWord: If you
need additional information about this, search for the term "Slice" in the online help for
STEP 7 Professional V1X.

® Open the ® "Main[OB1]" block from the "Program blocks" folder and call the ®
"Discrete_alarm_assignment[FC1]" function in ® "Network 4". Connect the input of the
"Discrete_alarm_assignment[FC1]" function to the inverted global tag ®
"-K0" / %I0.1 / Station "ON"(no) from the "Tag_table_sorting_station". Connect the
output of the "Discrete_alarm_assignment[FC1]" function to the global tag ®
"GroupAlarms01" from the data block "OPERATION_HMI[DB4]".

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® Return to ® "HMI alarms" ® "Discrete alarms" in the "Panel TP700 Comfort". Create a
new alarm by clicking ® "Add". Select the ® "GroupAlarms01" tag you just created from
the "OPERATION_HMI[DB4] data block as the "Trigger tag". Enter the text ® "Main
switch OFF" in the "Alarm text" column, select the "Alarm class" ® "Warnings" and
"Trigger bit" ® "0". In the "Trigger address" column, "OPERATION_HMI.
GroupAlarms01.x0" is now displayed.

® The alarm display is also adapted in "Template_1" in the "Screen management" folder.
Under "General" in "Properties", activate ® "Pending alarms". Activate ® "Errors",
® "Warnings" and ® "No Acknowledgment" as alarm classes.

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® nder "Miscellaneous" in "Properties", change the "Name" to ® "Alarm line".

® Before the project is downloaded to the CPU and the panel, compile the CPU and panel
again and save the project.

(® CPU_1516F ® ® Panel TP700 Comfort ® ® )

® After successful compilation, the complete controller with the created program including
the hardware configuration can be downloaded, as described in the previous modules.

(® CPU_1516F ® )

® To download the visualization to the panel, proceed in a similar way. Select the ® "Panel

TP700 Comfort [TP700 Comfort]" folder and click the icon® "Download to device".

® Analog alarms and discrete alarms for system are now automatically displayed in the
alarm window "Pending/Unacknowledged alarms" and in the "Alarm line". Details and
help texts can be displayed and alarms can be acknowledged if necessary in the alarm

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window. If the alarm window has been closed, it can be displayed again by clicking the
displayed alarm indicator. Various alarm classes appear in different colors.

7.17 Remote control of the TP700 Comfort Panel

7.17.1 Activating web services for Runtime

® To enable remote control, double-click the ® "Runtime settings" in the configuration for
the ® Panel TP700 Comfort to open them. The ® "Start Sm@rtServer" option is
activated for ® "Layout" under "Remote control" and the ® "HTML pages" option is
activated under "Diagnostics".

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7.17.2 WinCC Internet settings in the TP700 Comfort Panel

® Settings must also be made directly on the panel. Select ® "Settings" in the "Start
Center" directly after switching on the voltage supply and the start of the panel.

Note: The selection of "Settings" must occur fast enough, and before the automatic
"Start" of Runtime.

® Select from the icons in order to make the web server settings.

® With menu command "Web Server", first select the "Start automatically after booting"
option and click on ® "User Administration".

® Assign the administrator password in the "Password" field ® "100", confirm it in the
"Confirm Password" field ® "100" and apply it with ® "Apply".

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® With menu command "Remote", first select the "Start automatically after booting"
option and click ® "Change settings".

® Also assign ® "100" for Password1 and ® "100" for Password2 and put this into effect
with ® "Apply".

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7.17.3 Starting remote access to the TP700 Comfort Panel

® To start the remote access to your panel, enter the IP address of the in your browser
® "192.168.0.10".

Note: A current installation of Java Runtime Environment is required for secure access to
the web services of the TP700 Comfort Panel.

® Enter the password that was previously set in the panel ® "100".

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® You then have the option of monitoring, and operating the panel remotely and even
changing the settings in Windows CE of the device.

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8 Checklist
No. Description Completed

1 Program changes successfully performed in the CPU 1516F

2 CPU 1516F successfully compiled without error message

3 CPU 1516F successfully downloaded without error message

Process visualization for the Touch Panel TP700 Comfort

4
successfully created
Touch Panel TP700 Comfort successfully compiled without
5
error message
Touch Panel TP700 Comfort successfully downloaded without
6
error message
Switch on station (-K0 = 1)
Cylinder retracted/Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (in the panel)
Pushbutton automatic stop not actuated (-S2 = 1)
7 Briefly press the automatic start pushbutton (in the panel)
Sensor part at slide activated (-B4 = 1)
then conveyor motor -M1 variable speed (-Q3 = 1) switches
on and remains active
The speed corresponds to the speed setpoint in the range +/-
50 rpm
Sensor part at end of conveyor activated (-B7 = 1) ® -Q3 = 0
8
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0) ® -Q3 =
9
0

10 Activate EMERGENCY OFF (-A1 = 0) ® -Q3 = 0

11 Manual mode (in the panel)® -Q3 = 0

12 Switch off station (-K0 = 0) ® -Q3 = 0

13 Cylinder not retracted (-B1 = 0) ® -Q3 = 0

14 Speed > SPEED_MOTOR_monitoring_error_max ® -Q3 = 0

15 Speed < SPEED_MOTOR_monitoring_error_min ® -Q3 = 0

16 Values and alarms are displayed in the panel.

17 Project successfully archived

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TIA Portal Module 012

PID Controller
for SIMATIC S7-1500

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Table of contents
1 Goal .................................................................................................................................................. 467
2 Prerequisite....................................................................................................................................... 467
3 Required hardware and software ..................................................................................................... 467
4 Theory............................................................................................................................................... 468
4.1 Tasks of closed loop controls ................................................................................................... 468
4.2 Components of a control loop................................................................................................... 468
4.3 Step function for analysis of controlled systems....................................................................... 470
4.4 Controlled systems with self-regulation .................................................................................... 471
4.4.1 Proportional system without time delay ............................................................................ 471
4.4.2 Proportional system with time delay ................................................................................. 472
4.4.3 Proportional system with two time delays......................................................................... 473
4.4.4 Proportional system with n time delays ............................................................................ 474
4.5 Systems without self-regulation ................................................................................................ 475
4.6 Basic types of continuous controllers ....................................................................................... 476
4.6.1 The proportional controller (P controller) .......................................................................... 477
4.6.2 The integral controller (I controller)................................................................................... 478
4.6.3 The PI controller................................................................................................................ 479
4.6.4 The derivative controller (D controller) ............................................................................. 480
4.6.5 The PID controller ............................................................................................................. 480
4.7 Controller tuning using the oscillation test ................................................................................ 481
4.8 Controller tuning with Tu-Tg approximation ............................................................................... 482
4.8.1 Tuning the PI controller according to the Ziegler-Nichols method.................................... 482
4.8.2 Tuning the PI controller according to the Chien, Hrones and Reswick method ............... 483
4.9 Digital controllers ...................................................................................................................... 483
5 Task .................................................................................................................................................. 485
6 Planning ............................................................................................................................................ 485
6.1 PID_Compact closed-loop control block................................................................................... 485
6.2 Technology diagram ................................................................................................................. 486
6.3 Reference list ............................................................................................................................ 486
7 Structured step-by-step instructions ................................................................................................. 487
7.1 Retrieve an existing project ...................................................................................................... 487
7.2 Call PID_Compact controller in a cyclic interrupt OB ............................................................... 488
7.3 Save and compile the program................................................................................................. 494
7.4 Download the program ............................................................................................................. 495
7.5 Monitor PID_Compact .............................................................................................................. 496
7.6 PID_Compact pretuning ........................................................................................................... 497
7.7 PID_Compact fine tuning.......................................................................................................... 499
8 Checklist ........................................................................................................................................... 502

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PID Controller for SIMATIC S7-1500

1 Goal
In this chapter, you will become acquainted with the use of software PID controllers for the
SIMATIC S7-1500 with the TIA Portal programming tool.
The module explains the call-up, connection, configuration and optimization of a PID controller
for the SIMATIC S7-1500. It also shows the steps for calling the PID controller in the TIA
Portal and integrating it into a user program.

2 Prerequisite
This chapter builds on the chapter Analog Values with the SIMATIC S7 CPU1516F-3 PN/DP.
You can use the following project for this chapter, for example: Analog

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs and analog inputs and outputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station Portal) as of V1X

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Tasks of closed loop controls
Closed loop control is a process in which the value of a variable is generated and maintained
continuously through an intervention based on measurements of this variable.
This produces an action path that takes place in a closed loop – the control loop – because
the process runs based on measurements of a variable that is, in turn, influenced by itself.
The variable to be controlled is continuously measured and compared with another preset
variable of the same type. Depending on the result of this comparison, an adjustment of the
variable to be controlled to the value of the preset variable is made.
Diagrammatic representation of a
closed loop control

Comparing
Controlling Actuator
element
element

Measuring
device
Setpoint
temperature

4.2 Components of a control loop

The fundamental concepts of closed loop controls are explained in detail in the following.
An overview based on a diagram is presented here to start.

Loop controller

YR Y Final Controlled
W Comparing e Controlling Actuator X
element element controlling system
element

r Measuring
device

1. The controlled variable x

This is the actual "target" of the closed-loop control, namely the variable that is to be
influenced or kept constant. In our example, this would be the room temperature. The
instantaneous value of the controlled variable at a particular time is called the "actual value" at
this time.

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2. The feedback variable r

In a control loop, the controlled variable is continuously checked to enable a response to
unwanted changes. The measured quantity proportional to the controlled variable is called the
feedback variable. In the "Heating" example, it would correspond to the measured voltage of
the inside thermometer.
3. The disturbance variable z
The disturbance variable is the variable that influences the controlled variable in an unwanted
way and moves it away from the current setpoint. In the case of fixed setpoint control, this
control is only necessary in the first place due to the existence of the disturbance variable. In
the examined heating system, this would be, for example, the outside temperature or any
other variable that causes the room temperature to move away from its ideal value.
4. The setpoint w
The setpoint at a given time is the value that the controlled variable should ideally have at this
time. Note that the setpoint may vary continuously in a slave control. In our example, the
setpoint would be the currently desired room temperature.
5. The comparing element
This is the point at which the current measured value of the controlled variable and the
instantaneous value of the reference variable are compared. In most cases, both variables are
measured voltages. The difference between the two variables is the "system error " e. This is
passed to the controlling element and evaluated there (see below).
6. The controlling element
The controlling element is the actual heart of a closed loop control. It evaluates the system
error, thus the information regarding whether, how and how much the controlled variable
deviates from the current setpoint, as an input variable and derives from this the "Controller
output variable" YR, which is ultimately used to influence the controlled variable. In the
heating system example, the controller output variable would be the voltage for the mixer
motor.
The manner in which the controlling element determines the controller output variable from the
system error is the main criterion of the closed-loop control.
7. The actuator
The actuator is, so to speak, the "executive organ" of the closed loop control. It receives
information from the controlling element in the form of the controller output variable indicating
how the controlled variable is to be influenced and translates this into a change of the
"manipulated variable". In our example, this would be the mixer motor controller.
8. The final controlling element
This is the element of the control loop that influences the controlled variable (more or less
directly) as a function of the manipulated variable Y. In the example, this would be the
combination of the mixer, heating lines and radiators. The adjustment of the mixer (the
manipulated variable) is made by the mixer motor (actuator) and influences the room
temperature by means of the water temperature.
9. The controlled system
The controlled system is the system containing the variable to be controlled, thus the living
space in the heating example.
10. The dead time
The dead time refers to the time that elapses from a change in the controller output variable
until there is a measurable response in the controlled system. In the example, this would be
the time between a change in the voltage for the mixer motor and a measurable change in the
room temperature resulting from this.

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4.3 Step function for analysis of controlled systems

To analyze the response of controlled systems, controllers and control loops, a uniform
function for the input signal is used – the step function.
Depending on whether a control loop element or the entire control loop is being analyzed, the
controlled variable x(t), the manipulated variable y(t), the reference variable w(t) or the
disturbance variable z(t) can be assigned the step function. The input signal is often
designated xe(t) and the output signal xa(t).

xe(t)

for t < 0

xe(t)
xeo
xeo for t > 0

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4.4 Controlled systems with self-regulation

4.4.1 Proportional system without time delay

This controlled system is called a P system for short.

xe(t)

sudden change of the input variable at i t0

Xa(t)

Controlled variable/manipulated
variable:

Kss: Proportional coefficient for a

manipulated variable change:

Controlled variable/disturbance variable:

Ksz: Proportional value for a disturbance

variable change

Range: yh = ymax - ymin

Control range: xh = xmax - xmin

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4.4.2 Proportional system with time delay

This controlled system is called a P-T1 system for short.

Differential equation for a general input signal xe(t):

TS • xa(t) + xa(t) = KPS • xe(t)
Solution of the differential equation for a step function at the input (step response)
xa(t) = KPS (1-e-t/TS) • xeo
xa (t = ∞) = KPS • xeo
TS: Time constant

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4.4.3 Proportional system with two time delays

This system is called a P-T2 system for short.

Xa(t)
Tg
Xa

Tu

Tu: Delay time Tg: Compensation time

The system is generated through the reaction-free series connection of two P-T1
systems that have the time constants TS1 and TS2.

Controllability of P-Tn systems:

Tu Tu Tu
easily still controllable difficult to control
Tg controllable Tg
Tg

With the increasing ratio Tu/Tg, the system becomes less and less controllable.

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4.4.4 Proportional system with n time delays

This controlled system is called a P-Tn system for short.
The time response is described by an nth order differential equation. The step response
characteristic is similar to that of the P-T2 system. The time response is described by Tu and
Tg.
Substitute: An approximate substitution for the system with many delays is the series
connection of a P-T1 system with a dead time system.
The following applies: Tt » Tu and TS » Tg.

Xa(t)
TS
Xa

P-Tn

(P-T1) - Tt

Tt

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4.5 Systems without self-regulation

This controlled system is called an I system for short.

After a disturbance, the controlled variable continues increasing steadily without striving for a
fixed final value.

xe(t) xa(t)

xeo

to to
Example: Level control
For a tank with discharge outlet, whose incoming and outgoing flow rates are the same, there
is a constant fill height. If the incoming or outgoing flow rate changes, the liquid level rises or
falls. The level changes faster as the difference between the incoming flow rate and outgoing
flow rate increases.
It is clear from this example that, in practice, the integral action has a limit in most cases. The
controlled variable increases or decreases only until a system-inherent limit value is reached.
A tank runs over or drains dry, pressure reaches the system maximum or minimum, etc.
The figure shows the time response of an I system to a step change in the input variable as
well as the derived block diagram:

ymax

Block diagram

tt00

xmax

Ti

t0
If the step function at the input changes to a function xe(t), then

integrating controlled system

KIS: Integral coefficient of the controlled system

* Figure from SAMSON Technical Information - L102 Controllers and Controlled Systems,
Edition: August 2000 (http://www.samson.de/pdf_en/l102en.pdf)

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4.6 Basic types of continuous controllers

Discrete controllers that only switch one or two manipulated variables on and off have the
advantage of simplicity. Both the controller itself and the actuator and final controlling element are
simpler in nature and thus less expensive than continuous controllers.

Discrete controllers have several disadvantages, however. For one thing, when large loads such
as large electric motors or cooling units must be switched, high load peaks may occur at switch-
on and overload the power supply, for example. For this reason, these often do not switch
between "Off" and "On" but instead between full power ("full load") and a significantly lower power
of the actuator or final controlling element ("base load"). Still, even with this improvement, a
discrete closed-loop control is unsuitable for numerous applications. Consider an automobile
engine whose speed is discreetly controlled. There would then be nothing between idle and full
throttle. Apart from the fact that it would probably be impossible to properly transfer the forces
from a sudden full-throttle to the road via the tires, such a vehicle would probably be unsuitable
for road traffic.

Continuous controllers are therefore used for such applications. Theoretically, hardly any limits
are placed on the mathematical relationship that establishes the controlling element between the
system error and controller output variable. In practice, however, three classic basic types are
differentiated. These will be described in more detail in the following.

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4.6.1 The proportional controller (P controller)

The manipulated variable y of a P controller is proportional to the measured error e. From this
can be deducted that a P controller reacts to any deviation without lag and only generates a
manipulated variable in case of system deviation.
The proportional pressure controller illustrated in the figure compares the force FS of the
setpoint spring with the force FB created in the elastic metal bellows by the pressure p2. When
the forces are off balance, the lever pivots about point D. This changes the position of the
valve plug –and, hence, the pressure p2 to be controlled –until a new equilibrium of forces is
restored.
The dynamic behavior of the P controller after a step change in the error variable is shown in
the figure. The amplitude of the manipulated variable y is determined by the error e and the
proportional-action coefficient Kp.
To keep the control deviation as small as possible, as large a proportional-action coefficient as
possible must be selected. An increase in the factor causes the controller to react faster, but if
the value is too high there is a risk of overshooting and a large "hunting" tendency of the
controller.

Metal bellows

Setpoint spring

KP

y = KP · e

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You see the response of the P controller in the diagram.

Controlled
variable

Setpoint

Deviation
Actual value

Time

The advantages of this controller type lie, on the one hand, in its simplicity (in the simplest
case, it can be implemented electronically with just a resistor) and, on the other hand, in its
very prompt reaction compared to other controller types.
The main disadvantage of the P controller is its permanent system deviation. That is, the
setpoint is never fully reached even over the long term. This disadvantage as well as the not
yet ideal response speed cannot be minimized to a satisfactory extent through a larger
proportional-action coefficient, because this leads to overshooting by the controller, or in other
words an overreaction. In the worst case, the controller goes into a permanent oscillation in
which the controlled variable is periodically moved away from the setpoint by the controller
itself instead of by the manipulated variable.
The problem of permanent control deviation is best solved by an additional integral controller.

4.6.2 The integral controller (I controller)

Integral control action is used to fully correct system deviations at any operating point. As long
as the error is nonzero, the integral action will cause the value of the manipulated variable to
change. Only when reference variable and controlled variable are equally large –at the latest,
though, when the manipulated variable reaches its system specific limit value (Umax, pmax,
etc.)– is the control process balanced.
Mathematics expresses integral action as follows: the value of the manipulated variable is
changed proportional to the integral of the error e.

with

How rapidly the manipulated variable increases/decreases depends on the error and the
integral time.

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emax

Block diagram
t1
t2

ymax

t1 t2

4.6.3 The PI controller

PI controllers are often employed in practice. In this combination, one P and one I controller
are connected in parallel.
If properly designed, they combine the advantages of both controller types (stability and
rapidity; no steady-state error), so that their disadvantages are compensated for at the same
time.

P
PI

emax

Block diagram

t1
t2

ymax

Tn

t1 t2

The dynamic behavior is marked by the proportional-action coefficient Kp and the reset time
Tn. Due to the proportional component, the manipulated variable immediately reacts to any
error signal e, while the integral component starts gaining influence only after some time. Tn
represents the time that elapses until the I component generates the same control amplitude
that is generated by the P component (Kp) from the start. As with I controllers, the reset time
Tn must be reduced if the integral-action component is to be amplified.

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Controller dimensioning:
By adjusting the Kp and Tn values, oscillation of the controlled variable can be reduced,
however, at the expense of control dynamics.
PI controller applications: Fast control loops allowing no steady-state error
Examples: pressure, temperature. ratio control, etc.

4.6.4 The derivative controller (D controller)

D controllers generate the manipulated variable from the rate of change of the error and not –
–as P controllers –– from their amplitude. Therefore, they react much faster than P controllers:
even if the error is small, derivative controllers generate– by anticipation, so to speak –large
control amplitudes as soon as a change in amplitude occurs. A steady-state error signal,
however, is not recognized by D controllers, because regardless of how big the error, its rate
of change is zero. Therefore, derivative-only controllers are rarely used in practice. They are
usually found in combination with other control elements, mostly in combination with
proportional control.

4.6.5 The PID controller

If a D component is added to PI controllers, the result is an extremely versatile PID controller.
As with PD controllers, the added D component –if properly tuned –causes the controlled
variable to reach its setpoint more quickly, thus reaching steady state more rapidly.

PID I

emax

Block diagram
t1
t2

ymax

t1 t2

with

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4.7 Controller tuning using the oscillation test

For a satisfactory control result, the selection of a suitable controller is an important aspect. It
is even more important that the control parameters Kp. Tn and TV be appropriately adjusted to
the system response. Mostly, the adjustment of the controller parameters remains a
compromise between a very stable, but also very slow control loop and a very dynamic, but
irregular control response which may easily result in oscillation, making the control loop
instable in the end.
For nonlinear systems that should always work in the same operating point, e.g. fixed setpoint
control, the controller parameters must be adapted to the system response at this particular
operating point. If a fixed operating point cannot be defined, such as with follow-up control
systems ñ, the controller must be adjusted to ensure a sufficiently rapid and stable control
result within the entire operating range.
In practice, controllers are usually tuned on the basis of values gained by experience.
Should these not be available, however, the system response must be analyzed in detail,
followed by the application of several theoretical or practical tuning approaches in order to
determine the proper control parameters.
One approach is a method first proposed by Ziegler and Nichols, the so-called ultimate
method. It provides simple tuning that can be applied in many cases. This method, however,
can only be applied to controlled systems that allow sustained oscillation of the controlled
variable.

For this method, proceed as follows:

- At the controller, set Kp and Tv to the lowest value and Tn to the highest value (smallest
possible influence of the controller).

- Adjust the controlled system manually to the desired operating point (start up control loop).

- Set the manipulated variable of the controller to the manually adjusted value and switch to
automatic operating mode.

- Continue to increase Kp (decrease Xp) until the controlled variable encounters harmonic
oscillation. If possible, small step changes in the setpoint should be made during the Kp
adjustment to cause the control loop to oscillate.

- Take down the adjusted Kp value as critical proportional-action coefficient Kp,crit.

Determine the time span for one full oscillation amplitude as Tcrit, if necessary by taking
the time of several oscillations and calculating their average.

- Multiply the values of Kp,crit and Tcrit by the values according to the table and enter the
determined values for Kp, Tn and Tv at the controller.

Kp Tn Tv

P 0.50 x Kp. crit. - -

PI 0.45 x Kp. crit. 0.85 x T crit. -

PID 0.59 x Kp. crit. 0.50 x T crit. 0.12 x T crit.

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4.8 Controller tuning with Tu-Tg approximation

The tuning of the controlled systems will be performed here using the example of a PT2
system.
Tu-Tg approximation
The Ziegler-Nichols method and the Chien, Hrones and Reswick method are based on the T u-
Tg approximation in which the transfer coefficient of the system Ks, delay time Tu and
balancing time Tg parameters are determined from the system step response.
The tuning rules, which are described below, are the result of experiments using analog
computer simulations.
P-TN systems can be described with sufficient accuracy with a so-called Tu-Tg approximation,
that is, through approximation using a P-T1-TL system.
The starting point is the system step response with input step height K. The required
parameters (transfer coefficient of the system Ks, delay time Tu and balancing time Tg) are
determined as shown in the figure.
The transfer function must be measured up to the final steady-stated value (K*Ks) so that the
transfer coefficient of the system Ks required for the calculation can be determined.
The main advantage of this method is that the approximation can also be used when an
analytical description of the system is not possible.

x/%

K*KS

Turning point

Tu Tg t/sec

Figure: Tu-Tg-Approximation

4.8.1 Tuning the PI controller according to the Ziegler-Nichols method

Based on experiments on P-T1-TL systems, Ziegler and Nichols have identified the following
optimal controller adjustments for fixed setpoint control:

Tg
KPR = 0.9
KSTu

TN = 3.33 Tu

Use of these tuning values generally results in very good response to disturbances.

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4.8.2 Tuning the PI controller according to the Chien, Hrones and Reswick
method
Both the response to disturbances and response to setpoint changes were examined in order
to achieve the most favorable controller parameters. Different values are yielded for the two
cases. In addition, two different adjustments are specified in each case that meets different
control performance requirements.
This resulted in the following adjustments:
· For response to disturbances:
Aperiodic transient reaction 20 % overshoot minimum
with the shortest duration oscillation period

Tg Tg
KPR = 0.6 KPR = 0.7
KSTu KSTu

T N = 4 Tu TN = 2.3 Tu

· For response to setpoint changes:

Aperiodic transient reaction 20 % overshoot minimum

with the shortest duration oscillation period

Tg Tg
KPR = 0.35 KPR = 0.6
KSTu KSTu

TN = 1.2 Tg TN = Tg

4.9 Digital controllers

Up to now, the main focus was on analog controllers, in other words, controllers that use the
system error, which exists as an analog value, to derive the controller output variable in an
analog manner. The diagram of this type of control loop is now well-known:

Comparing Analog
controller System
element

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Often, however, it is advantageous to perform the actual evaluation of the system error
digitally. For one thing, the relationship between the system error and controller output
variable can be defined much more flexibly when it can be defined by an algorithm or formula
that can be used in each case to program a computer than when it has to be implemented in
the form of an analog circuit. For another, digital technology enables significantly greater
integration of circuits so that multiple controllers can be accommodated in the smallest space.
Finally, by dividing the computing time when there is a sufficient amount of computing
capacity, it is even possible to use an individual computer as a controller for multiple control
loops.
To enable digital processing of the variables, both the reference variable and the feedback
variable are first converted to digital values in an analog-to-digital converter (ADC). These are
then subtracted from one another by a digital comparing element and the difference is passed
to the digital controlling element. Its controller output variable is then converted back to an
analog value in a digital-to-analog converter (DAC). From the outside, the combined unit of
converters, comparing element and controlling element resembles an analog controller.
We will examine the structure of a digital controller based on a diagram:

Comparing Digital
ADC element controller DAC System

ADC

The advantages resulting from digital implementation of the controller are accompanied by
various problems. For this reason, the size of some variables related to the digital controller
must be chosen large enough to prevent the accuracy of the closed loop control from suffering
too much from digitization.

Quality criteria for digital computers are:

– The quantization resolution of the digital-to-analog converter
This specifies how fine the continuous value range is digitally mapped. The chosen
resolution must be high enough that none of the finer points important for the closed loop
control are lost.
– The sampling rate of the analog-to-digital converter.
This is the frequency at which the analog values present at the converter are measured
and digitized. This must be high enough that the controller can also still respond to step
changes in the controlled variable in a timely manner.
– The cycle time
Unlike an analog closed-loop controller, each digital computer works in clock cycles. The
speed of the utilized computer must be high enough that a significant change of the
controlled variable cannot occur during a single clock cycle (in which the output value is
calculated and no input value is queried).

The performance of the digital controller must be high enough that its response is apparently
as prompt and precise as an analog controller.

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5 Task
In this chapter, a PID controller for speed control will be added to the program from chapter
Analog. The call-up of the "MOTOR_SPEEDCONTROL" [FC10] function must be deleted for
this.

6 Planning
The PID_Compact technology object is available in the TIA Portal for closed loop controls.
For closed-loop control of the motor speed, this technology object replaces the
"MOTOR_SPEEDCONTROL" [FC10] block.
This will be carried out as an expansion of the "032-500_Analog_Values_" project. This project
must be retrieved from the archive beforehand.
The call-up of the "MOTOR_SPEEDCONTROL" [FC10] function must be deleted in the "Main"
[OB1] organization block before the technology object can be called and connected in a cyclic
interrupt OB.
The PID_Compact technology object must then be configured and commissioned.

6.1 PID_Compact closed-loop control block

The PID_Compact technology object provides a PID controller with integrated tuning for
proportional-action final controlling elements.
The following operating modes are possible:
– Inactive
– Pretuning
– Fine tuning
– Automatic mode
– Manual mode
– Substitute output value with error monitoring
Here, the connection, parameter assignment and commissioning of this controller will be for
automatic mode
During commissioning we will use the integrated tuning algorithms and record the control
response of the controlled system.
The PID_Compact technology object is always called from a cyclic interrupt OB whose fixed
set cycle time is 50 ms here.
The speed setpoint is set as a constant at the "Setpoint" input of the PID_Compact technology
object in revolutions per minute (range: +/- 50 rpm). The data type is 32-bit floating-point
number (Real).
The actual speed value -B8 (sensor actual value speed of the motor +/-10V corresponds to +/-
50 rpm) will be entered at the "Input_PER" input.
The output of the controller "Output_PER" will then be connected directly with signal -U1
(manipulated value speed of the motor in 2 directions +/- 10V corresponds to +/- 50 rpm).
The controller will only be active as long as output -Q3 (conveyor motor -M1 variable speed) is
set. If this is not set, the controller will be deactivated by connection of the "Reset" input.

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6.2 Technology diagram

Here you see the technology diagram for the task.

Figure 1: Technology diagram

Figure 2: Control panel

6.3 Reference list

The following signals are required as global operands for this task.

DI Type Identifier Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop OK NC

I 0.1 BOOL -K0 Main switch "ON" NO
Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/ automatic (1)
Auto = 1

I 0.3 BOOL -S1 Pushbutton automatic start NO

I 0.4 BOOL -S2 Pushbutton automatic stop NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO
I 1.3 BOOL -B7 Sensor part at end of conveyor NO

Sensor actual value speed of the motor +/-10V

IW64 BOOL -B8
corresponds to +/- 50 rpm

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DO Type Identifier Function

Q 0.2 BOOL -Q3 Conveyor motor -M1 variable speed

Manipulated value speed of the motor in 2

QW 64 BOOL -U1
directions +/- 10V corresponds to +/- 50 rpm

Legend for reference list

DI Digital Input DO Digital Output

AI Analog Input AO Analog Output

I Input Q Output

NC Normally Closed

NO Normally Open

7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

® Before we can expand the "SCE_EN_032-500_Analog_Values_R1508.zap13" project
from chapter "SCE_EN_032-500_Analog_Values", we must retrieve this project from the
archive. To retrieve an existing project that has been archived, you must select the
relevant archive with ® Project ® Retrieve in the project view. Confirm your selection
with Open.
(® Project ® Retrieve ® Select a .zap archive ® Open)

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® The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
(® Target directory ® OK)

® Save the opened project under the name 052-300_PID_Controller.

(® Project ® Save as … ® 052-300_PID_Controller ® Save)

7.2 Call PID_Compact controller in a cyclic interrupt OB

® Open the "Main [OB1]" organization block with a double-click.

® Delete Network 2 with the no longer needed call-up of the "MOTOR_SPEEDCONTROL"

[FC10] function.
(® Network 2 ® Delete)

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® We need a cyclic interrupt OB for calling the PID_Compact controller. Therefore, select
the 'Add new block' item in the Program blocks folder.
(® Program blocks ® Add new block)

® Select in the next dialog and rename the cyclic interrupt OB to: "Cyclic interrupt
50ms". Set the language to FBD and assign "50000 µs" as the cyclic time. Select the
"Add new and open" check box. Click "OK".

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(® ® Name: Cyclic interrupt 50ms ® Language: FBD ® Cyclic time (ms): 50000 ®
Add new and open ® OK)

® The block is then directly opened. Enter meaningful comments and move the
'PID_Compact' technology object to Network 1 using drag-and-drop.
(® Technology ® PID Control ® Compact PID ® PID_Compact)

® Assign a name for the instance data block and apply it with OK.
(® PID_Compact_Motor_Speed ® OK)

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® Expand the view of the block by clicking the ' ' arrow. Interconnect this block as shown
here with setpoint (constant: 15.0), actual value (global tag "-B8"), manipulated variable
(global tag "-U1") and Reset input for deactivating the controller (global tag "-Q3"). Negate

the 'Reset' input. The configuration mask ' ’ of the controller can then be opened.

(® ® 15.0 ® "-B8" ® "-U1" ® -Q3 ® ® )

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® There are 2 views for configuration of the controller: Parameter view and Functional view.
Here we will use the easier-to-understand 'Functional view'.
(® Functional view)

® In the 'Basic settings', the 'Controller type' and the interconnection of the 'Input / output
parameters' are entered. Set the values as shown here.
(® Basic settings® Controller type ® Input / output parameters)

® In 'Process value settings' we scale to the range +/- 50 rpm and define the 'Process value
limits' of +/- 45 rpm.
(® Process value settings ® Process value limits ® Process value scaling)

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® In the 'Advanced settings', a process value monitoring would be possible but we don't
want to deal with that here.
(® Advanced settings ® Process value monitoring)

® In the 'Advanced settings' for 'PWM' (pulse width modulation), we will leave the default
values since the output for this is not needed in our project.
(® Advanced settings ® PWM)

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® In the 'Advanced settings', we define the 'Output value limits' of 0.0 % to 100.0 %.
(® Advanced settings ® Output value limits)

® In the 'Advanced settings', you will now also find a manual setting of the 'PID parameters'.
Once we have changed the controller structure to 'PI', the configuration window is closed

by clicking and we receive a finished product with a functional PID controller. This
should, however, still be commissioned and tuned online during operation.

(® Advanced settings ® PID Parameters ® Controller structure: PI ® )

7.3 Save and compile the program

® To save your project, click the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu.

(® ® Program blocks ® )

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7.4 Download the program

® After successful compilation, the complete controller with the created program including
the hardware configuration can, as described in the previous modules, be downloaded.

(® )

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7.5 Monitor PID_Compact

® Click the Monitoring on/off icon to monitor the state of the blocks and tags when
testing the program. At the first start of the CPU, however, the 'PID_Compact' controller is

not yet tuned. We still have to start the tuning by clicking the ' ' icon.

(® Cyclic interrupt 50ms [OB30] ® ® PID_Compact ® )

® If we click under 'Measurement', the values of the setpoint (Setpoint), actual

value (ScaledInput) and manipulated variable (Output) can be displayed and monitored in
a diagram.
(® )

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® The measurement can be stopped again by clicking ' '.

(® )

7.6 PID_Compact pretuning

The pretuning determines the process response to a step change of the output value and
searches for the turning point. The PID parameters are calculated from the maximum slope
and the dead time of the controlled system. The optimal PID parameters are obtained when
you perform pretuning and fine tuning.
The more stable the actual value is, the easier and more accurately the PID parameters can
be determined. Actual value noise is acceptable as long as the actual value rise is significantly
greater than the noise. This is most likely the case in "Inactive" or "Manual mode" operating
mode. The PID parameters are backed up before they are recalculated.

The following requirements must be met:

– The "PID_Compact" instruction is called in a cyclic interrupt OB.
– ManualEnable = FALSE
– Reset = FALSE
– PID_Compact is in "Manual mode", "Inactive" or "Automatic mode" operating mode.
– The setpoint and actual value are within the configured limits (see "Process value
monitoring" configuration).
– The difference between setpoint and actual value is greater than 30 % of the difference
between the process value high limit and low limit.
– The difference between setpoint and actual value is > 50 % of the setpoint.
® 'Pretuning' is selected as the 'Tuning mode' and this is then started.
(® Tuning mode ® Pretuning ® )

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® The pretuning starts. The current work steps and any errors that occur are shown in the
"Tuning status" field. The progress bar shows the progress of the current work step.

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7.7 PID_Compact fine tuning

The fine tuning generates a constant, limited oscillation of the actual value. The PID
parameters are optimized for the operating point based on the amplitude and frequency of this
oscillation. All PID parameters are recalculated from the results. The PID parameters resulting
from fine tuning generally produce a better response to setpoint changes and disturbances
than the PID parameters from pretuning. The optimal PID parameters are obtained when you
perform pretuning and fine tuning.
PID_Compact automatically attempts to generate an oscillation that is greater than the actual
value noise. The fine tuning is influenced only slightly by the stability of the actual value. The
PID parameters are backed up before they are recalculated.
The following requirements must be met:
– The "PID_Compact" instruction is called in a cyclic interrupt OB.
– ManualEnable = FALSE
– Reset = FALSE
– The setpoint and actual value are within the configured limits.
– The control loop is stable at the operating point. The operating point is reached when the
actual value is equal to the setpoint.
– No disturbances are expected.
– PID_Compact is in "Manual mode", "Inactive" or "Automatic mode" operating mode.

The fine tuning runs as follows when started in automatic mode:

When you want to improve the existing PID parameters by tuning them, start the fine tuning
from automatic mode.
PID_Compact uses the existing PID parameters for controlling until the control loop is stable
and the requirements for fine tuning are met. Only then does the fine tuning start.
The fine tuning runs as follows when started in inactive or manual mode:
When the requirements for pretuning are met, pretuning is started. PID_Compact uses the
determined PID parameters for controlling until the control loop is stable and the requirements
for fine tuning are met. Only then does the fine tuning start. If pretuning is not possible,
PID_Compact responds as configured in Response to error.
If the actual value is already too close to the setpoint for pretuning, an attempt is made to
reach the setpoint with minimum or maximum output value. This can cause increased
overshoot.

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® 'Fine tuning' is selected as the 'Tuning mode' and this is then started.
(® Tuning mode ® Fine tuning ® )

® The fine tuning starts. The current work steps and any errors that occur are shown in the
"Tuning status" field. If the self-tuning was completed without error message, the PID
parameters have been tuned. The PID controller switches to automatic mode and uses
the tuned parameters. The tuned PID parameters are retained at a Power ON and restart
of the CPU. You can download the PID parameters from the CPU to your project with the

' ' button.

(® )

® The PID parameters in the configuration can be displayed by clicking ' '.

(® )

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® As the final step, the online connection should be disconnected and the complete project
should be saved.

(® ® )

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8 Checklist
No. Description Completed

Cyclic interrupt OB Cyclic interrupt 50ms [OB30] successfully

1
created.
PID_Compact controller in cyclic interrupt OB Cyclic interrupt
2
50ms [OB30] called and connected.

3 Configuration of the PID_Compact controller performed.

4 Compiling successful and without error message

5 Download successful and without error message

6 Pretuning successful and without error message

7 Fine tuning successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
Pushbutton automatic stop not actuated (-S2 = 1)
8 Briefly press the automatic start pushbutton (-S1 = 1)
Sensor part at slide activated (-B4 = 1)
then Conveyor motor -M1 variable speed (-Q3 = 1)
switches on and stays on.
The speed corresponds to the speed setpoint in the range +/-
50 rpm
Sensor part at end of conveyor activated (-B7 = 1) ® -Q3 = 0
9
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0) ® -Q3 =
10
0

11 Activate EMERGENCY OFF (-A1 = 0) ® -Q3 = 0

12 Manual mode (-S0 = 0) ® -Q3 = 0

13 Switch off station (-K0 = 0) ® -Q3 = 0

14 Cylinder not retracted (-B1 = 0) ® -Q3 = 0

15 Speed > Motor_speed_monitoring_error_max ® -Q3 = 0

16 Speed < Motor_speed_monitoring_error_min ® -Q3 = 0

17 Project successfully archived

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Siemens Automation Cooperates with Education | 05/2017

TIA Portal Module 013

Frequency converter G120 on PROFINET
with SIMATIC S7-1500

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Table of contents
1 Objective ........................................................................................................................................... 506
2 Requirement ..................................................................................................................................... 506
3 Required hardware and software ..................................................................................................... 506
4 Theory............................................................................................................................................... 508
4.1 SINAMICS G120 frequency converter...................................................................................... 508
4.2 Components for configuring SINAMICS G120 ......................................................................... 508
4.2.1 Control Units CU250S-2 ...............................................................................................................508
4.2.2 Operator Panels ............................................................................................................................509
4.2.3 Memory cards for Control Unit (optional) ....................................................................................510
4.2.4 Brake Relay ...................................................................................................................................510
4.2.5 Safe Brake Relay ..........................................................................................................................510
4.2.6 PM240-2 Power Modules .............................................................................................................510
4.2.7 PM250 Power Modules ................................................................................................................511
4.2.8 Line filter.........................................................................................................................................511
4.2.9 Line reactor....................................................................................................................................511
4.2.10 Output reactor................................................................................................................................512
4.2.11 Sine-wave filter ..............................................................................................................................512
4.2.12 Braking resistor..............................................................................................................................512
4.3 Parameter assignment of the SINAMICS G120 ....................................................................... 513
4.3.1 Display parameters .......................................................................................................................513
4.3.2 Adjustable parameters..................................................................................................................513
4.3.3 P0010 Drive commissioning parameter filter ..............................................................................513
4.3.4 P0015 Macro drive unit.................................................................................................................514
4.3.5 Changeability depending on the converter state ........................................................................514
4.3.6 BICO technology ...........................................................................................................................515
4.3.7 Control Data Set (CDS) and Drive Data Set (DDS) ...................................................................516
4.4 Commissioning of the SINAMICS G120 frequency converter.................................................. 516
4.4.1 Restoring factory settings through a parameter reset ................................................................517
4.4.2 Basic commissioning ....................................................................................................................517
4.5 PROFINET interface of the SINAMICS G120, CU250S-2 PN Vector ...................................... 517
4.5.1 Telegrams......................................................................................................................................518
4.5.2 Assignment of the process data (PZD) for the SINAMICS G120 with Standard Telegram 1 .518
4.5.3 Control word 1 (STW1).................................................................................................................518
4.5.4 Status word 1 (ZSW1) ..................................................................................................................519
4.5.5 Main setpoint (HSW/NSOLL_A; 16-bit) .......................................................................................520
4.5.6 The main actual value (HIW/NIST_A; 16-bit)..............................................................................520
4.5.7 Layout of the request telegram in double-word format...............................................................521

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4.5.8 Layout of the response telegram in double-word format............................................................521

4.6 SINAMICS Startdrive commissioning tool for SINAMICS G120............................................... 522
4.6.1 Resetting frequency converters and setting the IP address ......................................................522
5 Task .................................................................................................................................................. 525
6 Planning ............................................................................................................................................ 526
6.1 Technology schematic diagram ................................................................................................ 527
6.2 Reference table ........................................................................................................................ 527
7 Structured step-by-step instructions ................................................................................................. 528
7.1 Retrieving an existing project.................................................................................................... 528
7.2 Creating a frequency converter in the TIA Portal ..................................................................... 529
7.3 Assigning parameters with the commissioning wizard ............................................................. 537
7.4 Testing and commissioning with control panel ......................................................................... 544
7.5 Creating a program for controlling the frequency converter ..................................................... 547
7.6 Loading the program in SIMATIC S7 CPU 1516F-3 PN/DP .................................................... 555
7.7 Diagnostics of SIMATIC S7 CPU 1516F-3 PN/DP ................................................................... 556
7.8 Diagnostics with SINAMICS Startdrive ..................................................................................... 557
7.9 Checklist ................................................................................................................................... 560

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Frequency Converter G120 with Control

Unit CU250S-2 PN Vector on PROFINET
with SIMATIC S7-1500
1 Objective
In this chapter you learn how a frequency converter SINAMICS G120 with the Control Unit
CU250S-2 PN Vector and together with a CPU1516F-3 PN/DP on PROFINET is put into
operation.
The module explains the basic commissioning of the frequency converter SINAMICS G120
with the SINAMICS Startdrive software in the TIA Portal.
Subsequently we show step-by-step how the frequency converter SINAMICS G120 can be
controlled and monitored from the program of the CPU1516F-3 PN/DP.

2 Requirement
This chapter is based on chapter "Global data blocks for SIMATIC S7 CPU1516F-3 PN/DP".
In order to carry out this chapter you can for example, use the following project: Data Block.

3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)
2 SIMATIC STEP 7 Professional software in TIA Portal – as of V1X
3 SINAMICS Startdrive software in TIA Portal – as of V1X
4 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –
Firmware as of V1.6 with memory card and 16DI/16DO
Note: The digital inputs should be fed out to a control panel.
5 SINAMICS G120 frequency converter with:
- Control Unit CU250S-2 PN as of Firmware 4.6
- Power Module PM240-2
- IOP Intelligent Operator Panel
- Induction motor
6 Ethernet connection between engineering station and controller and
between controller and frequency converter

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2 SIMATIC STEP 7
Professional (TIA Portal)
as of V13

1 Engineering station

3 SINAMICS Startdrive
(TIA Portal) as of V13
6 Ethernet connection

4 SIMATIC S7-1500 controller Control panel

6 Ethernet connection

5 G120 frequency converter with:

- Control Unit CU250S-2 PN
- Power Module PM240-2
- IOP Intelligent Operator Panel
- Induction motor

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4 Theory
4.1 SINAMICS G120 frequency converter
Each SINAMICS G120 converter consists of a Control Unit (CU) and a Power Module (PM).
• The Control Unit controls and monitors the Power Module and the connected motor.
• The Power Modules contain rectifiers and converters for motors in a
power range of 0.37 kW to 250 kW.

Note: More detailed information about the frequency converter G120 with Control Unit
CU250S-2 PN Vector is available in the manuals. In this module the frequency converter
SINAMICS G120 is used as a PROFINET IO device.

4.2 Components for configuring SINAMICS G120

4.2.1 Control Units CU250S-2

The Control Units CU250S-2 differ with regard to their type of fieldbus connections. There are
Control Units CU250S-2 with:
● RS485 interface for USS, Modbus RTU
● PROFIBUS interface
● RS485 interface for PROFINET, Ethernet/IP
● CANopen interface
All the Control Units have an EEPROM in order for power-failure-proof storage of the
configuration data.
The used Control Unit CU250S-2 Vector has a PROFINET interface with two ports that
supports the PROFIdrive, PROFIsafe and PROFIenergy profiles.
In addition, for example, HTL or TTL encoders and temperature sensors can be connected
directly to a 15-pin encoder interface and DRIVE-CLiQ-compatible encoders as well as
sensor modules to a DRIVE-CLiQ interface of the Control Unit.
The Control Unit supports the following functions of Safety Integrated (SIL 3, PL e, Cat. 3):

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● Safe Torque Off (STO)

● Safe Stop 1 (SS1) with and without speed monitoring
● Safe Brake Control (SBC)
● Safely Limited Speed (SLS)
● Safe Direction (SDI)
Safe Speed Monitor (SSM)
● PROFIsafe communication to a higher-level control unit
Various control methods are available in order to meet the wide range of requirements in
drive technology:
● U/f characteristic curves
● Flux current control
● Vector regulation with and without encoders
The following special functions can be used with this Control Unit:
● Basic positioning function with EPOS
● Energy recovery capability through Efficient Infeed Technology (only PM250 Power
Modules)
Terminals with digital and analog as well as safe inputs and outputs are available.

4.2.2 Operator Panels

The Operator Panels are used to commission, diagnose and control the converter as well as
to back up and transfer the converter settings.

The Intelligent Operator Panel (IOP) is available for snapping onto the Control Unit or as a
hand-held unit with a connecting line to the Control Unit. The IOP enables operator control and
diagnostics of the converter.

The BOP-2 is an Operator Panel for snapping onto the Control Unit. The BOP-2 has a two-line
display for diagnostics and operator control of the converter.
Note: For further information on the Operator Panels, please refer to the manuals:

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4.2.3 Memory cards for Control Unit (optional)

The SD or MMC memory cards can be optionally used to back up the converter settings.
It is possible to store up to 100 parameter sets. This can be done by using the SINAMICS
Startdrive software.
A firmware update/downgrade is only possible by using a memory card.
If you use the "Basic positioner" function or the extended safety functions, a memory card with
a valid license has to be inserted into the Control Unit.
Note: A memory card is not required during operation.

4.2.4 Brake Relay

The Brake Relay provides a switch contact (NO contact) to control the motor brake solenoid.

4.2.5 Safe Brake Relay

The Safe Brake Relay controls a 24-V motor brake and monitors the brake control for short-
circuits and wire breaks.

4.2.6 PM240-2 Power Modules

PM240-2 Power Modules have a brake chopper (four-quadrant applications) and are suitable
for a wide range of applications in general mechanical engineering. The PM240-2 Power
Modules are available without a filter or with integrated Class A line filter.

The PM240-2 Power Module is available for the following voltage and power range:
● 1-phase/3-phase 200 VAC ... 240 VAC 0.55 kW ... 4.0 kW
● 3-phase 200 VAC ... 240 VAC 5.5 kW ... 7.5 kW

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● 3-phase 380 VAC ... 480 V 0.55 kW ... 250 kW

● 3-phase 500 VAC ... 690 VAC 11 kW ... 132 kW

Note: If frequency converters are not put into operation for a longer period, the DC link
capacitors have to be formed in accordance with the specifications in the operating
instructions.

4.2.7 PM250 Power Modules

PM250 Power Modules are suitable for identical applications as the PM240 Power Modules.
Any brake energy occurring can be fed back directly into the power network (four-quadrant
applications – no brake chopper required). The PM250 Power Modules are available without a
filter or with integrated Class A line filter.

The PM250 Power Module is available for the following voltage and power range:
● 3-phase 380 VAC - 480 VAC ±10% 7.5 kW to 90 kW

Note: If frequency converters are not put into operation for a longer period, the DC link
capacitors have to be formed in accordance with the specifications in the operating
instructions.

4.2.8 Line filter

A line filter allows the converter to reach a higher radio interference category. An external filter
is not required for converters with built-in line filter.

4.2.9 Line reactor

The line reactor supports overvoltage protection, flattens the harmonics in the power network
and bridges commutation notches.

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4.2.10 Output reactor

Output reactors reduce the voltage load of the motor windings as well as the load of the
converter through capacitive charge/discharge currents in the lines. An output reactor is
required for shielded motor lines greater than 50 m or unshielded motor lines greater than 100
m.

4.2.11 Sine-wave filter

The sine-wave filter at the output of the converter limits the voltage gradient and the peak
voltages at the motor motor winding. The maximum permissible motor supply line length
increases to 300 m. An output reactor becomes superfluous.

4.2.12 Braking resistor

The braking resistor allows rapid braking of loads with a high moment of inertia.
The Power Module controls the braking resistor through its integrated brake chopper.

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4.3 Parameter assignment of the SINAMICS G120

There are two main types of parameters:
● Display parameters
● Adjustable parameters

4.3.1 Display parameters

Display parameters allow the reading of the internal measured quantities of the converter and
motor. The Operator Panel and SINAMICS Startdrive represent the display parameters with a
preceding "r". For example, r0027 is the parameter for the output current of the converter.

4.3.2 Adjustable parameters

Adjustable parameters are the parameters that you use to adjust the converter to your
application. When you change the value of an adjustable parameter, you also change the
behavior of the converter. Adjustable parameters are represented with a preceding "p". For
example, p1082 is the parameter for adjusting the maximum speed of the motor.
The following section displays some particularly important adjustable parameters.
Note: Further information on the parameters is available in the list manual.

4.3.3 P0010 Drive commissioning parameter filter

Parameter P0010 filters parameters so that only the parameters assigned to a specific
function group can be selected. This means, for example, that the parameters required for
quick commissioning are displayed in order. The following settings are available:
• P0010 = 0: Ready
In order to start up the converter, the P0010 has to be set to 0.
• P0010 = 1: Quick commissioning
• P0010 = 2: Power unit startup
• P0010 = 3: Motor startup
• P0010 = 4: Encoder startup
• P0010 = 5: Technological application/units
• P0010 = 11: Function modules
• P0010 = 15: Data records
• P0010 = 17: Basic positioning startup
• P0010 = 25: Position control startup
• P0010 = 29: Only Siemens-internal
• P0010 = 30: Parameter reset
• P0010 = 39: Only Siemens-internal
• P0010 = 49: Only Siemens-internal
• P0010 = 95: Safety Integrated startup
By setting p3900 unequal to 0, the quick commissioning is complete, and this parameter is set
automatically to 0.

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4.3.4 P0015 Macro drive unit

With the parameter P0015 you select command and setpoint sources of the converter by
executing the corresponding macro files.
After the value has changed, the further changing of parameters is blocked as long as the
macro is being executed. The status is displayed in r3996. Changing is not possible until
r3996 = 0 again.
When a specific macro is executed, the correspondingly programmed settings are carried out
and become effective.
For example, Macro 7: "Fieldbus with data record changeover"

DI 3 = 0 Control via PROFIdrive Telegram 1

DI 3 = 1 Fieldbus is not active
DI 3 = 0 No function
5 DI 0
DI 3 = 1 Jog 1
DI 3 = 0 No function
6 DI 1
DI 3 = 1 Jog 2
7 DI 2 Acknowledge fault
Control and setpoint DI 3 = 0 Telegram 1
8 DI 3
switchover DI 3 = 1 Jogging

DI 3 = 0
Telegram 1, PZD2
Speed setpoint
Jogging 1 or 2 DI 3 = 1
Speed setpoint
18 DO 0 Fault
19
20
21 DO 1 Warning
22
12 AO 0 Actual speed value
26 AO 1 Actual current value

Note: Information about further macros is available in the operating instructions of the
respective Control Unit.

4.3.5 Changeability depending on the converter state

"P"-parameters can furthermore only be changed depending on the status of the converter.
For example, the parameter p1120 Ramp-function generator ramp-up time (with the attribute
"C(1), U, T" in the parameter list) can only be changed in the quick commissioning "C", when
P0010 = 1, in the ready state "T" or during operation "U" .

Status Description
C(*) Quick commissioning (P0010 = *)
U Operation (drive running)
T Drive ready-to-start

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4.3.6 BICO technology

A converter corresponding to the latest state-of-the-art has to offer the possibility to freely
interconnect internal and external signals (setpoints or actual values as well as control and
status signals).
This interconnection has to offer a high degree of flexibility so that the converter can be easily
adapted to new applications.
The BICO technology and macros are used to meet these requirements.
By using the BICO technology the process data can be interconnected freely while using the
"default" parameter assignment of the converter.
Here all the values that can be interconnected freely are defined as "connectors", for example,
frequency setpoint, actual frequency value, actual current value, etc.
All the digital signals that can be interconnected freely are defined as "binectors", for example,
status of a digital input, ON/OFF, message function at limit violations, etc.
A converter contains numerous input and output variables as well as variables within the
control system that can be interconnected. Therefore it is possible to adapt the converter to
the various requirements by using the BICO technology.

Binectors
A binector is a digital (binary) signal without any units that can have either the value 0 or 1.
Binectors always reference functions. They are divided into binector inputs (BI) and binector
outputs (BO).
The binector input is always identified with a "P"-parameter (for example, P0840 BI:
ON/OFF1), whereas the binector output is always represented with an "r"-parameter (for
example, r1025 BO: FF status).

Example
Combination of the command ON/OFF1 with selection of a fixed frequency.

BI: ON/OFF1
BO: FF status P0840
Function Function
r1025 (1025.0)
P0840 = 1025.0
Binector output (BO) à Binector input (BI)
When a fixed frequency is selected, the fixed frequency status bit (r1025) is changed internally
from 0 to 1.
The source for the command ON/OFF1 is the parameter P0840 (default DI0). When the fixed
frequency status bit is connected as the source for P0840 (P0840 = 1025), the converter starts
by activating a fixed frequency and stops with OFF1 for deactivation of the fixed frequency.

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Connectors
A connector (16 or 32 bits) has a value that can contain a normalized variable (dimensionless)
or also a variable with assigned units.
Connectors always reference functions. They are divided into connector inputs (CI) and
connector outputs (CO). In essence the same applies as for binectors: The connector inputs
are identified by a "P"-parameter (for example P0771 CI: AO (analog output)), whereas the
connector outputs are always represented with an "r"-parameter (for example r0021 CO:
Actual frequency).

Example
Interconnection of the parameter r0755 (display analog input) with an internal value (main
frequency setpoint). To this purpose the CO parameter r0755 (scaled analog input) has to be
interconnected with the CI parameter P1070 (main setpoint).
CI: Main setpoint
CO: Actual AI after scaling [4000 h] P1070
Function Function
r0755 (755[0])
P1070 = (755[0])
(Connector output (CO) à Connector input (CI)

Note: For further details please refer to the list manual.

4.3.7 Control Data Set (CDS) and Drive Data Set (DDS)
Drive engineering has applications in which simutaneous changeover of multiple parameters
with external signals is needed during operation.
To enable this, certain parameters have been organized into groups. These so-called data
sets are:
● Control Data Set (CDS)
● Drive Data Set (DDS)
Note: For more details, refer to the list manual and the operating instructions.

4.4 Commissioning of the SINAMICS G120 frequency converter

A converter of the type G120 always consists of the Power Module and the Control Unit. After
the initial latching in of the Control Unit at the Power Module and switching on of the supply
voltage, the Power Module is recognized by the Control Unit. If it is a compatible Power
Module, the data are stored in the Control Unit.
Commissioning of the converter G120 is usually carried out in the following steps:
● Resetting to factory settings
● Basic commissioning
– Quick commissioning
– Calculation of the motor/control data
– Optimization of the speed control
● Further settings for commissioning
– Optional: Motor data identification
Startup of the application
– Commissioning of fail-safe functions (only with fail-safe applications)

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4.4.1 Restoring factory settings through a parameter reset

The factory setting can be effected via the SINAMICS Startdrive software, via a menu function
in the Intelligent Operator Panel (IOP) or via a direct parameter input.
Procedure for "Reset parameters":
p0010 = 30
p0970 = 1
P0970 = 0 is automatically set at the end of the calculations.
Through a factory setting via P0970, the original values of all the converter parameters can be
restored. These values are designated with "Factory Setting" in the list manual.
The following parameters remain unchanged after a reset to factory settings:
● P0014 Storage mode
● Communication parameters (for example PROFIBUS and PROFINET settings)
● Power-Module-dependent data

4.4.2 Basic commissioning

Basic commissioning should always be carried out by using the commissioning wizard via the
SINAMICS Startdrive software or the Intelligent Operator Panel (IOP).
Alternatively, quick commissioning (P0010 = 1) can also be carried out by direct entry of the
parameters. However, this procedure is not advisable.
Notes: Commissioning by using the commissioning wizard via the SINAMICS Startdrive
software is described in Chapter 6 of this document.
For information about carrying out commissioning by using the commissioning wizard via the
Intelligent Operator Panel (IOP) please refer to the operating instructions of the IOP.

4.5 PROFINET interface of the SINAMICS G120, CU250S-2 PN Vector

The frequency converter can be integrated into an Ethernet network at the PROFINET
interface X150 with the two ports P1 and P2. Now:
● The parameter assignment and diagnostics of the frequency converter via Ethernet can be
carried out by using the SINAMICS Startdrive software in the TIA Portal.
● The converter can be integrated into a PROFINET network.

In PROFINET IO operation, the converter supports the following functions:

● IO-RT: Real-time communication (as used in this document.)
● IO-IRT: Isochronous real-time communication
● MRP: Media redundancy when used in a network with ring topology
● MRPD: Media redundancy requirement: IRT when used in a network with ring topology
● Diagnostic interrupts in accordance with the error classes specified in the PROFIdrive profile

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4.5.1 Telegrams
Various telegrams, whose process data lengths and contents differ, are available for selection
for IO-RT communication with the frequency converter.
The simplest telegram, set as the standard, is the Standard Telegram 1.

4.5.2 Assignment of the process data (PZD) for the SINAMICS G120 with
Standard Telegram 1
Control words and setpoints (PLC -> SINAMICS) and status words and actual values
(SINAMICS -> PLC) can be transferred with the process data. The structure of the PZD area
is as follows for Telegram 1, for a coupling via PROFINET:
PZD1 PZD2
Request telegram Control word Main setpoint
(PLC -> SINAMICS) (STW1) (NSOLL_A)
Response telegram Status word Main actual value
(SINAMICS -> PLC) (ZSW1) (NIST_A)

4.5.3 Control word 1 (STW1)

Bit Significance Comments Signal inter-

Telegram 20 All other connection
telegrams in the inverter
0 0 = OFF1 The motor brakes with the ramp-down time P0840[0] =
p1121 of the ramp-function generator. The r2090.0
inverter switches off the motor at standstill.
0 → 1 = ON The inverter goes into the “ready” state. If,
in addition bit 3 = 1, then the inverter
switches on the motor.
1 0 = OFF2 Switch off the motor immediately, the motor P0844[0] =
then coasts down to a standstill. r2090.1
1 = No OFF2 The motor can be switched od (ON
command).
2 0 = Quick stop (OFF3) Quick Stopp: The motor brakes with the P0848[0] =
OFF3 rampdown time p1135 don to r2090.2
standstill.
1 = No Quick Stopp (OFF3) The motor can be switched on (ON
command).
3 0 = Inhibit operation Immediately switch-off motor (cancel P0852[0]
Pulses). =r2090.3
1 = Enable operation Switch-on motor (pulses can be enabled).
4 0 = Disable RFG sperren The inverter immediately sets ist ramp- p1140[0] =
function generator output to 0. r2090.4
1 = Do not disable RFG The ramp-function generator can be
enabled.
5 0 = Stop RFG The output of the ramp-function generator P1141[0]=
Stopps at the actual value. r2090.5
1 = Enable RFG The output of the ramp-function generator
follows the setpoint.
6 0 = Inhibit setpoint The inverter brakes the motor with the P1142[0]=
ramp-down time p1121 of the ramp-function r02090.6
generator.
1 = Enable setpoint Motor accelerates with the ramp-up time
p1120 to the setpoint.
7 0 → 1 = Acknowledge faults Acknowledge fault. If the ON command is p2103[0] =
still active, the inverter switches to „closing r2139.7

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lockout“ state.
8, 9 Reserved
10 0 = No control via PLC Inverter ignores the process data from the P0854[0]=
fieldbus. r2090.10
1 = Control via PLC Control via fieldbus, inverter accepts the
process data from the fieldbus.
11 1 = Direction reversal Invert setpoint in the inverter. p1113[0] =
r2090.11
12 Not used
13 ---1) 1 = MOP up Increase the setpoint saved in the motorized P1035[0] =
potentiometer. r2090.13
14 ---1) 1 = MOP Reduce the setpoint saved in the motorized P1036[0]=
down potentiometer. r2090.14
15 CDS bit 0 Reserved Changes over between settings for different P0810 =
operation interfaces (command data sets). r2090.15
1) If you change over from another telegram to telegram 20, then the assignment
of the previous telegram is kept.

4.5.4 Status word 1 (ZSW1)

Bit Significance Comments Signal inter-

Telegram 20 All other connection
telegrams in the inverter
0 1 = Ready to start Power supply switched on; electronics P2080[0] =
initialized; pulses locked. r0899.0
1 1 = Ready Motor is switched on (ON/OFF1 = 1), no p2080[1] =
fault is active. With the command “Enable r0899.1
operation” (STW1.3), the inverter switches
on the motor
2 1 = Operation enabled Motor follows setpoint. See control word 1, p2080[2] =
bit 3 r0899.2
3 1 = Fault active The inverter has a fault. Acknowledge fault p2080[3] =
using STW1.7. r2139.3
4 1 = OFF2 inactive Coast down to standstill is not active. p2080[4] =
r0899.4
5 1 = OFF3 inactive Quick Stopp is not active p2080[5] =
r0899.5
6 1 = Closing lockout active It is only possible to switch on the motor p2080[6] =
after an OFF1 followed by ON. r0899.6
7 1 = alarm active Motor remains switched on; no p2080[7] =
acknowledgement is necessary. r2139.7
8 1 = Speed deviation within the Setpoint/actual value deviation within the p2080[8] =
tolerance range tolerance range. r2197.7
9 1 = Master control requested The automation system is requested to p2080[9] =
accept the inverter control. r0899.9
10 1 = Comparison speed reached or Speed is greater than or equal to the p2080[10] =
exceeded corresponding maximum speed. r2199.1
11 1 = current or 1 = torque limit Comparison value for current or torque has p2080[11] =
torque limit reached been reached or exceeded. r0056.13/
reached r1407.7
12 ---1) 1 = Holding Signal to open and close a motor holding p2080[12] =
brake open brake. r0899.12
13 0 = Alarm, motor overtemperature __ p2080[13] =
r2135.14
14 1 = Motor 0 = Motor rotates Internal inverter actual value > 0 p2080[14] =
rotates counterclockwise Internal inverter actual value < 0 r2197.3
clockwise
15 1 = CDS 0 = Alarm, p2080[15] =
display inverter thermal r0836.0/
overload r2135.15

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2) If you change over from another telegram to telegram 20, then the assignment
of the previous telegram is kept.

4.5.5 Main setpoint (HSW/NSOLL_A; 16-bit)

The main setpoint is a 16-bit word in which the required speed is transferred to the converter.
The setpoint is transferred as an integer with preceding sign (-32768 to 32767). The value
16384 (4000 Hex) corresponds to +100%.
The value 100% is defined at a particular rotary speed by means of the parameter P2000
(reference speed). The speed that is to correspond to a setpoint of 100% via the interface is
entered in this parameter.
The speed of the converter is calculated as follows:
n= (HSW x P2000)/16384

Note: The parameter P2000 (reference speed) is automatically calculated for Drive Data Set 0
during motor startup and set to the value of parameter P1082 (maximum speed).

4.5.6 The main actual value (HIW/NIST_A; 16-bit)

The main actual value is a 16-bit word through which the actual speed of the converter is
transferred. The normalization of this value corresponds to that of the setpoint.
n= (HIW x P2000)/16384

Note: The parameter P2000 (reference speed) is automatically calculated for Drive Data Set 0
during motor startup and set to the value of parameter P1082 (maximum speed).

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4.5.7 Layout of the request telegram in double-word format

The request telegram is sent to the SINAMICS G120 in double-word format.
The layout of the bits is shown in the table.

Control word Main setpoint

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

QB 256 QB 257 QB 258 QB 259

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

4.5.8 Layout of the response telegram in double-word format

The response telegram is returned by the SINAMICS G120 in double-word format.
The layout of the bits is shown in the table.

Status word Main actual value

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

IB 256 IB 257 IB 258 IB 259

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Note: A data block in which the data are stored temporarily is used for the request telegram
and for the response telegram in the control program. The telegrams are mapped there
respectively in a structure that is created by means of the PLC data types.

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4.6 SINAMICS Startdrive commissioning tool for SINAMICS G120

The most recent version of the SINAMICS Startdrive commissioning software can be
downloaded from the Website:
support.industry.siemens.com .

SINAMICS Startdrive is a tool integrated in TIA Portal and corresponds to the familiar
TIA Portal in its structure and handling.
The SINAMICS Startdrive extension contains the data and views for the SINAMICS G120
frequency converters already supported there.
This enables easy parameter assignment and commissioning of the frequency converters. A
wide range of functions and aids are available for diagnostics and troubleshooting.

4.6.1 Resetting frequency converters and setting the IP address

A new IP address can be directly assigned to the Control Unit of the frequency converter with
SINAMICS Startdrive in TIA Portal. The Control Unit can now be reset.
® To do so select the Totally Integrated Automation Portal, which is opened with a double-
click. (® TIA Portal V1X )

® Then select the item ® "Online & Diagnostics" and open the ® "Project view".

® In the project tree select the network card of your computer under ® "Online access".
When you click ® "Update accessible devices", you see the IP address (if already set) or
the MAC address (if the IP address has not yet been assigned) of the Control Unit of the
connected SINAMICS G120 frequency converter®. Select ® "Online & diagnostics".

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® Before you reassign the IP address, we recommend that you first reset the PROFINET
interface parameters. To do so select the function ® "Resetting the PROFINET interface
parameters" and click ® "Reset".

® Answer the prompt whether you really want to reset with ® "Yes".

® Successful resetting can be checked in the messages in the ® "Info" window ®

"General".

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® Then once again select ® "Update accessible devices" and then ® "Online &
diagnostics" of your frequency converter. To assign the IP address, select the function ®
"Assign IP address". Enter the following IP address at this point: ® IP address:
192.168.0.6 ® Subnet mask: 255.255.255.0. Click ® "Assign IP address" and this new
address is assigned to the Control Unit of your frequency converter.

® The successful assignment of the IP address is shown again as a message in the window
® "Info" ® "General".

® Before you can now carry out resetting of the frequency converter to the factory setting
you have to once again select ® "Update accessible devices" and the ® "Online &
Diagnostics" of your frequency converter. In order to reset the frequency converter to
factory settings, select ® "Restore factory resetting" under ® "Backing up/reset" and
click ® "Start".

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® Select the option "Save factory setting in EEPROM" so that the parameters of the
factory setting are loaded from the EEPROM into the RAM of the device after switching
off and on - and not the data of an old project. Confirm the prompt whether you really
want to reset with ® "OK".

Note: The communication settings such as the IP address and the subnet mask are
retained when the frequency converter is set to the factory setting.

5 Task
In the following section the project from the chapter "SCE_EN_032-600_Global_Data_Blocks"
is to be supplemented by a frequency converter G120 with Control Unit CU250S-2 PN.
Controlling of the belt motor via analog values is now replaced by the controlling of the
frequency converter via PROFINET. Monitoring of the actual speed value is also effected via
PROFINET.

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6 Planning
The conveyor belt driven by an induction motor will now be controlled via a frequency
converter with a variable speed.
This frequency converter has to created, configured and commissioned in the project.
The parameter assignment of the frequency converter is done offline with the SINAMICS
Startdrive software, whereby the commissioning wizard is used.
Here the motor data of the induction motor are taken from the rating plate of the motor and
entered manually.
In this project the following induction motor is wired in Delta mode and operated single-phase
with 230V.

Figure 1: Rating plate of induction motor

A diagram of the two connection types can be found on the inside of the terminal box cover of
most motors:
• Star connection (Y)
• Delta connection (Δ)

Figure 2: Star connection/delta connection

The frequency converter SINAMICS G120 receives the start command and speed
specification in the following via PROFINET from the SIMATIC S7-1500. The actual speed
value is also read out of the SINAMICS G120 frequency converter via PROFINET and is
monitored for the high and low limits in the SIMATIC S7-1500.
A "Frequency converter" data block [DB4] is created in the control program in which the data
are stored temporarily for the request telegram and the response telegram. The telegrams are
created there by means of the PLC data types and are mapped respectively in a structure.
In the "Main" organization block [OB1] you copy the actual values from the converter into the
"Frequency converter" data block [DB4] and the setpoints from the data into the converter.
Finally the data created in the "Frequency converter" data block [DB4] can be accessed when
calling up the functions and function blocks.

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6.1 Technology schematic diagram

At this point you see the technology schematic diagram for the task.

Figure 3: Technology schematic diagram

Figure 4: Operator panel

6.2 Reference table

The following signals are required as global operands for this task.

DI Type ID Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop ok NC

I 0.1 BOOL -K0 Main switch "ON" NO

Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/automatic (1)
Auto=1

I 0.3 BOOL -S1 Pushbutton automatic start NO

I 0.4 BOOL -S2 Pushbutton automatic stop NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO

I 1.3 BOOL -B7 Sensor part at end of conveyor NO

Telegram 1 receive process data from G120

ID256 STRUCT PZD_IN_G120_01
conveyor1

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DO Type ID Function

Telegram 1 send process data to G120

OD256 STRUCT PZD_OUT_G120_01
conveyor1

Legend for reference list

DI Digital input DO Digital output

AI Analog input AO Analog output

I Input O Output

NC Normally Closed

NO Normally Open

7 Structured step-by-step instructions

You can find instructions on how to perform planning below. If you already have a good
understanding of everything, it is sufficient to focus on the numbered steps. Otherwise, simply
follow the steps of the instructions illustrated below.

7.1 Retrieving an existing project

® Before we can extend the project: Data Block " from the chapter Data Block, we have to
retrieve it. To retrieve an existing project you have to select the respective archive in the
project view under ® Project ® Retrieve. Confirm your selection with Open.
( ® Project ® Retrieve ® Selection of a .zap archive ® Open )

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® Next, the target directory in which the retrieved project is to be stored can be selected.
Confirm your selection with "OK".
( ® Target directory ® OK )

® Save the opened project under the name 062-101 Frequency converter G120 and S7-
1500.
( ® Project ® Save as … ® 062-101 Frequency converter G120 and S7-1500 ® Save )

7.2 Creating a frequency converter in the TIA Portal

® In order to network the Control Unit of the SINAMICS G120 with the CPU1516F-3 PN/DP
you have to change to the 'Network view'. At this point the desired 'CU250S-2 PN Vector'
can be dragged-and-dropped into the network view.
( ® Devices & networks ® Network view ® Drives & starters ® SINAMICS drives ®
SINAMICS G120 ® Control units® CU250S-2 PN Vector ® Article No.:
6SL3246-0BA22-1FA0 ® Version 4.7 ).

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® Connect the Ethernet interfaces of the Control Unit of the G120 and the CPU1516F-3 PN

with the mouse. ( ® Ethernet ® Ethernet )

® Set an IP address suitable for the CPU in the properties of the 'PROFINET interface [X1]'
of the 'G120'.
( ® G120 CU250S-2 PN Vector ® PROFINET interface [X1] ® Properties ® Ethernet
addresses ® IP protocol ® IP address: 192.168.0.6 )

® The device name is entered under 'General'.

( ® General ® Name: Drive_G120_conveyor )

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Note: This name is applied automatically as the PROFINET device name under the
'PROFINET' point for the 'PROFINET interface' of the 'G120 CU250S-2 PN-Vector'.
Settings for the 'IO cycle' such as the 'Update time' and 'Watchdog time' can also be set
for this device.
(® Advanced options ® Real time settings ® IO cycle ® Update time ® Watchdog time)

® The 'Standard Telegram 1' is specified for the 'Cyclic data exchange' between the PLC
and the frequency converter.
( ® PROFINET interface [X1] ® Cyclic data exchange ® Actual value: Standard
Telegram 1® Setpoint: Standard Telegram 1 )

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® For the address ranges, select 'I 256…259' and 'O 256 … 259'.
( ® PROFINET interface [X1] ® Cyclic data exchange ® Actual value ® Start address
I 256 ® Setpoint ® Start address O 256 )

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® Change to the 'Device view' from 'Drive_G120_conveyor'. There the used Power Module,
for example 'PM240-2 IP20 FSA U 1/3 AC200 0.75kW', is selected and assigned to the
'Drive_G120_conveyor'.
( ® Device view ® Drive_G120_conveyor ® PM 240-2 IP20 FSA U 1/3 AC200 0.75kW )

® Save the project with the existing settings.

(® )

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® Download the device configuration with the frequency converter G120 as the device to

the 'CPU_1516F [CPU1516F-3 PN/DP]' by clicking the ' Download to device' icon.

( ®CPU_1516F [CPU1516F-3 PN/DP] ® )

® The device name still has to be assigned to the frequency converter G120 as an IO
device of the CPU_1516F. To do so, select the 'PN/IE_1' network and select 'Assign
device name'.
( ® PN/IE_1 ® Assign device name )

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® In the subsequent dialog, the ''PG/PC interface' can be selected, before we select the
'Drive_G120_conveyor' and 'Assign name'.
( ® PROFINET device name: Drive_G120_conveyor ® SINAMICS G120 CU250S ®
Assign device name )

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Note: If several IO devices exist in the network, the device can be identified on the basis of
the imprinted MAC address.
® If too many components are displayed, the view can be filtered by clicking on 'Only show
devices of the same type'. If the device name was assigned successfully, this is indicated
by 'OK' in the status. ( ® Close )

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7.3 Assigning parameters with the commissioning wizard

® To assign the parameters of the frequency converter, double-click 'Parameter' of
'Drive_G120_conveyor‘ to open the parameters and start the 'Commissioning Wizard'.
( ® Drive_G120_conveyor ® Parameter ® Commissioning Wizard )

® In the subsequent dialog, select 'U/f control with linear characteristic' as the control type.
Keep the default selection for the function modules.
( ® U/f control with linear characteristic ® Next )

® For selection of the setpoint and command source, select the macro 7 'Fieldbus with data
set changeover'. ( ®[7] Fieldbus with data set changeover )

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® The selection of the macro '[7] Fieldbus with data set changeover' still has to be
confirmed with 'Accept'.
( ® Accept )

® The current interconnections of the IO terminals for the Macro 7 are now displayed.
( ® Next )

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® For the drive settings, select the 'IEC-Motor (50 Hz, SI units)' and 'Load duty cycle with
high overload for vector drives'.
( ® IEC-Motor (50 Hz, SI units) ® Load duty cycle with high overload for vector drives ®
Next )

Note: Further information about the settings is available in the tool tip text, the online help or in
the list manual.

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® In the subsequent dialog, select 'Induction motor' as the motor type and enter the motor
data in accordance with the specifications of the rating plate of the motor
( ® Enter motor data ® Induction motor ® Connection type: Delta ® … ® Next )

Note: Alternatively SIEMENS motors can also be selected directly via the order numbers.
® The following screenshot shows an example for the parameters for the current/speed
limiting and for the ramp-function generator.
( ® Next )

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® Select 'Standard drive' for the Technology application. Set the motor identification to
'Inhibited', and select 'Complete calculation' for calculating the motor parameters based
on parameter values from before.
( ® Standard drive ® Motor identification: Inhibited ® Complete calculation ® Next )

® Do not select an encoder at this point.

( ® Next )

® In the subsequent summary, all the settings are shown once more for checking. These
are applied by using the 'Finish' button.
( ® Finish )

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® Save the project once more before downloading the parameters into the

'Drive_G120_conveyor’‚ ‘. (® ® Drive_G120_conveyor ® )

® In the subsequent dialog, select 'PN/IE' as the PG/PC interface type, select the previously
set network adapters as the PG/PC interface and select 'PN/IE_1' as the connection of
the CPU to the subnet. Click 'Start search'.
( ® Type of the PG/PC interface: PN/IE ® PG/PC interface: …… ® Connection to
interface/subnet: PN/IE_1 ® Start search )

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® You should now see your 'SINAMICS drive' and be able to select it as the target device.
Click 'Load''. ( ® SINAMICS drive ® Load )

The configuration is compiled automatically and is displayed once more in an overview so

that you can check the steps to be carried out before loading. Now select ' Save the
parameterization in the EEPROM' and click 'Load'.
(® Save the parameterization in the EEPROM ® Load )

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Note: It is advisable to back up the parameters in the EEPROM as well, so that these are
retained in the case of a voltage drop

7.4 Testing and commissioning with control panel

® In order to test the current parameter assignment without PLC program, open the 'Control
panel' from the 'Commissioning' menu of the 'Drive_G120_conveyor'. Finally, click '

'.

( ® Drive_G120_conveyor ® Commissioning ® Control panel) (® )

® The first step is to 'Activate master control' in the control panel. The communication
between the PC and the converter will then be monitored It is necessary that successful
communication takes place at least every 10000 ms. Otherwise the motor stops and the
enables are reset.

( ®Master control: ® 10000 ms ® )

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® The drive enables first have to be set in order to start the motor . As a rule
this happens automatically. The drive can then be switched on .
( ® Switch on )

® Now the motor can be run at the selected speed or .

( ® Speed: 44 ® )

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® The drive can be switched off by clicking ' '. After completion of the test, it is necessary

to the master control.

(® ® )

® Confirm the prompt for deactivation with ' '.

(® )

® Finally, ' ' and save the project again ' '.

(® ® )

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7.5 Creating a program for controlling the frequency converter

® Before you adapt the program so that it can control the frequency converter, two 'PLC
data types' have to be created that correspond to the structure of the send and receive
Telegram 1.
( ® PLC data types® Add new data type )

® Change the name of the PLC data type to 'FU_Receive_Telegram1' and open it by
double-clicking it.
( ® FU_Receive_Telegram1 )

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® Create the tags shown below the same as in a data block. ( ® FU_Receive_Telegram1 )

® Create an additional PLC data type called 'FU_Send_Telegram1' and the tags shown
below.
( ® FU_Send_Telegram1 )

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Note: For some enable bits, the start value is already set to TRUE so that these do not have
to be set additionally in the program.
® Create the global data block 'FREQUENCY_CONVERTER' for the request and response
telegram.
( ®Add new block ® DB ® Global DB ® FREQUENCY_CONVERTER ® OK )

® Create the tag 'Send_G120_01' and select 'FU_SEND_Telegram1' as the data type.
( ® Send_G120_01 ® "FU_SEND_Telegram1" )

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® Create an additional tag 'Receive_G120_01' and select 'FU_RECEIVE_Telegram1' as the

data type. Provide comments for the two tags.
( ® Receive_G120_01 ® 'FU_ RECEIVE_Telegram1' )

® The data block can be created quickly and efficiently by using the PLC data types
'FU_SEND_Telegram1' and 'FU_RECEIVE_Telegram1', see representation.

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® The global PLC tags are created in a new tag table for the communication with the
frequency converter.
( ® Add new tag table )

® Change the name of the tag table to 'Tag_table_G120‘ and specify, as shown, two
structure tags 'PZD_IN_G120_01' and 'PZD_OUT_G120_01' using the PLC data types
'FU_RECEIVE_Telegram1' and 'FU_SEND_Telegram1'.
( ® PZD_IN_G120_01 ® 'FU_RECEIVE_Telegram1' ® PZD_OUT_G120_01®
'FU_SEND_Telegram1' )

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® The tags have been created in accordance with their structures by the use of the PLC
data types 'FU_SEND_Telegram1' and 'FU_RECEIVE_Telegram1'. Open the 'Main' block
[OB1].
( ® Main [OB1] )

® Insert two new networks at the beginning of the Main [OB1]. Drag-&-drop the 'Move'
command from the ''Instructions' under the 'Move operations' item into these networks.

(® ® ® Instructions ® Move operations ® Move ® Move )

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® Select the 'Tag_table_G120' in the project navigation. Now you can drag-&-drop the two
tags 'PZD_IN_G120_01' and 'PZD_OUT_G120_01' directly from the details view onto the
connections of the Move instructions.
( ® Tag_table_G120 ® PZD_IN_G120_01 ® PZD_OUT_G120_01 )

® Select the "FREQUENCY_CONVERTER [DB4]' data block in the project tree. You can
again drag-&-drop the two structure tags 'Send_G120_01' and 'Receive_G120_01'
directly from the details view onto the connections of the Move instructions.
( ® Send_IN_G120_01 ® Receive_OUT_G120_01 )

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® Open the structure of the tag 'Receive_G120_01' in the details view and from there drag-
&-drop the tag 'Receive_G120_01.XIST_A' to the connection 'Actual_speed_AI' of the
block 'MOTOR_SPEED_MONITORING'. ( ® Receive_G120_01.XIST_A )

® Drag the tag 'Send_G120_01.NSOLL_A' to the connection 'Setpoint_speed‘ of the block

'MOTOR_SPEEDCONTROL'.
( ® Send_G120_01.NSOLL_A )

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® As the activation command, drag the tag 'Send_G120_01.ON_OFF1' to the connection

'Conveyor_motor_automatic_mode' of the block 'MOTOR_AUTO'.
( ® Send_G120_01. ON_OFF1 )

7.6 Loading the program in SIMATIC S7 CPU 1516F-3 PN/DP

® Save the project once more before downloading the modified and created 'Program

blocks' to the CPU 1516F ' '.

(® ® Program blocks ® )

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7.7 Diagnostics of SIMATIC S7 CPU 1516F-3 PN/DP

® The block Main [OB1] can be monitored to diagnose the control of the converter from the

program. Monitoring is activated and deactivated by clicking the icon.

( ® Main [OB1] ® )

® The complete send and receive data of the communication with the converter ( control
words/status words/setpoint/actual value) are visible in the 'FREQUENCY_CONVERTER
[DB4]' data block. Monitoring can be activated and deactivated at this point as well by

clicking the icon.

( ® FREQUENCY_CONVERTER [DB4] ® )

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® The online network view lends itself to diagnostics of the PROFINET connection between
the CPU 1516F controller and the frequency converter.

( ® Devices & networks ® Network view ® )

7.8 Diagnostics with SINAMICS Startdrive

® The "Control/status words' can also be monitored in the frequency converter. This is
available under 'Online & Diagnostics'
( ® Drive_G120_conveyor ® Online & diagnostics ® Diagnostics ® Control/status word

® )

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® Under 'Drive enable signals' you also see the missing enables in order to be able to start
the motor.
( ® Drive enable signals )

® Under 'Active messages' you see pending faults and warnings. You can click the ' '
icon to acknowledge these.

( ® Active messages ® )

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® The values can also be monitored online in the 'Functional View' of 'Parameter'.
( ® Parameter ® Functional View )

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7.9 Checklist

No. Description Checked

Frequency converter SINAMICS G120 with Control Unit

1 CU250S-PN Vector created as distributed IO of the
CPU1516F- 3 PN/DP.
Device configuration with the frequency converter G120 as
2
device loaded successfully into the CPU1516F-3 PN/DP.
Device name of the Control Unit CU250S-PN Vector
3
assigned.
SINAMICS G120 frequency converter with induction motor
4
parameterized in SINAMICS Startdrive.
Parameter assignment successfully loaded from SINAMICS
5
Startdrive into the SINAMICS G120 frequency converter.
Induction motor tested successfully in operation with
6
SINAMICS G120 frequency converter via control panel.

7 Data block 'FREQUENCY_CONVERTER' [DB4] created.

8 Program changes carried out in Main [OB1].

Compiling and downloading of the program blocks is

9
successful and without error message.
Switch on system (-K0 = 1)
Cylinder retracted/feedback activated (-B1 = 1)
EMERGENCY STOP (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
10 Automatic stop pushbutton not actuated (-S2 = 1)
Briefly actuate automatic start pushbutton (-S1 = 1)
Sensor part at slide activated (-B4 = 1)
Then the induction motor is switched on via the frequency
converter and remains active ® Motor ON
Sensor at conveyor end activated (-B7 = 1) ® Motor OFF
11
(after 2 seconds)
Briefly actuate automatic stop pushbutton (-S2 = 0)® Motor
12
OFF

13 Activate EMERGENCY STOP (-A1 = 0)® Motor OFF

14 Operating mode manual (-S0 = 0)® Motor OFF

15 Switch off system (-K0 = 0)® Motor OFF

16 Cylinder not retracted (-B1 = 0)® Motor OFF

17 Project archived successfully.

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