Applications & Tools...Further Notes, Tips and Tricks, etc. 8 Literature 9 History 10. Warranty and Liability 4 ... - WinCC flexible 2008 - WinCC flexible ProAgent - (optional: WnCi

Applications & Tools

Answers for industry.

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Process diagnostics with SIMATIC S7-PDIAG and ProAgent based on LAD/FBD/STL and S7-GRAPH

WinCC flexible, ProAgent

Application Description December 2009

2 WinCC flexible Process Diagnostics

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Industry Automation and Drives Technologies Service & Support Portal

This article is taken from the Service Portal of Siemens AG, Industry Automation and Drives Technologies. The following link takes you directly to the download page of this document.

http://support.automation.siemens.com/WW/view/en/12139354

For questions about this document please use the following e-mail address:

[email protected]

http://support.automation.siemens.com/WW/view/en/12139354�

mailto:[email protected]�

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SIMATIC WinCC flexible Process Diagnostics

Process diagnostics with SIMATIC S7-PDIAG and ProAgent based on LAD/FBD/STL and S7-GRAPH

Automation Task

1

Automation Solution

2

Basics

3 Functional Mechanisms of this Application

4

Configuration

5

Startup of the Application

6

Operating the Application

7 Further Notes, Tips and Tricks, etc.

8

Literature

9

History

10

Warranty and Liability


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Warranty and Liability Note The Application Examples are not binding and do not claim to be complete

regarding the circuits shown, equipping and any eventuality. The application examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These application examples do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these application examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these application examples at any time without prior notice. If there are any deviations between the recommendations provided in this application example and other Siemens publications – e.g. Catalogs – the contents of the other documents have priority.

We do not accept any liability for the information contained in this document.

Any claims against us – based on whatever legal reason – resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Vertragspflichten”). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment.

It is not permissible to transfer or copy these application examples or excerpts of them without having prior authorization from Siemens Industry Sector in writing.

Table of Contents


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Table of Contents Warranty and Liability ................................................................................................. 4

1 Automation Task................................................................................................ 7

1.1 Overview .............................................................................................. 7 1.2 Requirements ....................................................................................... 8

2 Automation Solution ......................................................................................... 9

2.1 Overview of overall solution ................................................................. 9 2.2 Description of the core functionality ................................................... 11 2.2.1 Overview and description of the interface.......................................... 11 2.2.2 Structure of the control program ........................................................ 15 2.2.3 Sequence of the drilling process ........................................................ 16 2.3 Advantages of this solution ................................................................ 17 2.4 Hardware and software components used......................................... 18 2.5 Memory benchmark data of S7-PDIAG.............................................. 19

3 Basics ............................................................................................................... 20

3.1 What is diagnostics? .......................................................................... 20 3.2 Overview ............................................................................................ 20 3.3 Maintenance strategies ...................................................................... 21 3.4 Message concepts ............................................................................. 22 3.5 System and process diagnostics........................................................ 23 3.6 Session/functional sequence of process diagnostics......................... 25 3.7 Products and tools for process diagnostics ....................................... 26

4 Functional Mechanisms of this Application ................................................. 28

4.1 Monitoring with S7-PDIAG (procedures for generation time)............. 28 4.2 Monitoring with S7-GRAPH (procedures for generation time)........... 30 4.3 Principles and structures of process diagnostics ............................... 31 4.3.1 Diagnostics capability unit .................................................................. 31 4.3.2 Hierarchical units................................................................................ 32 4.4 Data structures ................................................................................... 33 4.4.1 “Unit” UDT .......................................................................................... 33 4.4.2 “Unit_s” UDT ...................................................................................... 35 4.4.3 Motion unit.......................................................................................... 35 4.5 Process diagnostics and reuseability ................................................. 36 4.6 Runtime connections.......................................................................... 36 4.6.1 Reporting............................................................................................ 37 4.6.2 Error analysis ..................................................................................... 39

5 Configuration ................................................................................................... 40

5.1 Configuration of an operand monitoring functions (S7-PDIAG)......... 40 5.1.1 Monitoring of individual signal ............................................................ 42 5.1.2 Monitoring of central release process (criteria analysis).................... 44 5.2 Configuration of an operand monitoring with S7-PDIAG ................... 47 5.2.1 Configuration of action monitoring ..................................................... 49 5.2.2 Configuration of motion screens ........................................................ 52 5.3 Configuration of sequence monitoring ............................................... 54 5.3.1 Configuration of the interlock condition.............................................. 55 5.3.2 Configuration of the supervision condition ......................................... 57 5.3.3 Configuration of the interlock and supervision messages.................. 57 5.4 Configuration of ProAgent.................................................................. 60 5.4.1 Integrating standard ProAgent screens in WinCC flexible ................. 60 5.4.2 Generating and compiling ProAgent .................................................. 61

Table of Contents


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6 Startup of the Application............................................................................... 62

6.1 Preparation......................................................................................... 62 6.2 Commissioning................................................................................... 62

7 Operating the Application............................................................................... 65

7.1 Overview ............................................................................................ 65 7.2 Description of fault-free process ........................................................ 66 7.3 Simulation of operand errors (criteria analysis) ................................. 67 7.4 Simulation of a general monitoring..................................................... 71 7.5 Simulation of motion errors (sequence sychronization) ..................... 74 7.5.1 Action monitoring................................................................................ 74 7.5.2 Startup monitoring .............................................................................. 80 7.5.3 Response monitoring ......................................................................... 80 7.5.4 Interlock monitoring ............................................................................ 81 7.6 Simulation of sequence errors ........................................................... 82 7.6.1 Interlock error ..................................................................................... 82 7.6.2 Supervision error ................................................................................ 83

8 Further Notes, Tips and Tricks, etc. .............................................................. 87

9 Literature .......................................................................................................... 89

9.1 Bibliography........................................................................................ 89 9.2 Internet Link Specifications ................................................................ 89

10 History............................................................................................................... 90

Automation Task

1.1 Overview


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Automation Task 11.1 Overview

Introduction

In order to yield a high productivity of machines and plants in modern production technology, the degree of automation and the complexity of the plants have increased considerably within recent years.

In addition, fierce competition leaves its mark which shows itself especially by increased time pressure in all operation phases, from the creation of the automation solution up to the maintenance of the production plants.

It is now decisive for plant/mechanical engineers and automation designers to guarantee high levels of availability for your plants and systems.

This is where process diagnostics is increasingly gaining significance. During all operating phases (especially during process run) process diagnostics makes it possible to report errors quickly as well as locating them as precisely as possible, and it provides support for its solution.

As a component of TIA, SIMATIC offers integrated and additional possible process diagnostics options as an essential system feature. Process diagnostics for SIMATIC is distributed across several products.

Overview of the automation task

The illustration below shows an example of an application case from production technology.

A drilling station is entirely controlled by a PLC. Some sections are additionally monitored by process diagnostics software.

The system is controlled and operated via operator screens.

Automation Task

1.2 Requirements


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Figure 1-1

M

P

Feed action

P

Drill motor

Clamp

CoolantSupply / disposal

Technologicalprocess

PLC

Controlsoftware

Processdiagnosticsmonitoring

software

HMI

Operator and monitoring

screens

Processdiagnostics

screens

1.2 Requirements

Based on the technology object drilling unit, the aim is to effectively minimize possible downtime in the case of faults.

As a result…

error states which are caused by the process have to be reliably detected. I.e. there are:

– errors in sensors (e.g. defects, pollution etc.).

– errors in mechanics (e.g. blockades due to wear and tear or external impact).

the causes are quickly and clearly displayed via the connected monitor.

the errors have to be localized without using a PG.

processes should be moved back to the productive state using the display device.

Automation Solution

2.1 Overview of overall solution


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Automation Solution 22.1 Overview of overall solution

Display

The following figure gives a schematic overview of the most important components of the solution.

Figure 2-2

PC or PG with- STEP 7- S7 PDIAG- S7 Graph- WinCC flexible 2008- WinCC flexible ProAgent- (optional:

WinCC fexible Runtime)

SIMATIC Multi Panelor comparable

PR

OF

IBU

S

CPU 317 2 DP or comparable(Optional: PLCSIM)

Overview

The task described can be easily tackled with the diagnostic functions contained in the SIMATIC. As an essential part of TIA, SIMATIC offers integrated system and process diagnostics functions.

Convenient tools and AddOns are available which allow an integrated solution from the controller up to the visualization in all operation phases.

In terms of technology, the example of the process diagnostics is closely related to already familiar examples which are delivered with the “single products” S7-PDIAG, S7-Graph and S7-HiGraph (drilling machine).

The procedure of the drilling process is controlled via a simple S7-Graph sequence. The actions from the S7-Graph are transferred to the LAD/FBD/STL blocks via flags which then control the outputs via the monitoring blocks.

The “system” is visualized with WinCC flexible and the respective Option package ProAgent.

Independent simulator blocks create a realistic time response and options to specifically trigger different aggregate errors for each aggregate.

The various error causes are also created in certain plant states via the WinCC flexible interface. The example offers different classifications of errors.

https://www.automation.siemens.com/mcms/human-machine-interface/de/visualisierungssoftware/wincc-flexible/wincc-flexible-optionen/wincc-flexible-proagent/Seiten/Default.aspx�

https://www.automation.siemens.com/mcms/human-machine-interface/de/visualisierungssoftware/wincc-flexible/wincc-flexible-optionen/wincc-flexible-proagent/Seiten/Default.aspx�

Automation Solution

2.1 Overview of overall solution


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Situation controlled with S7-PDIAG

– Signal/operand monitoring

– Motion monitoring

Situations controlled with S7-Graph

– Step monitoring

– Interlock monitoring

Once the errors were triggered the monitoring system reacts with diagnostic messages. The user will find the error location and the causes via the diagnostic screens. “Repairing” the error with subsequent manual operation and process synchronization will bring the “system” back to the productive state.

Topics not covered by this application

This application does not contain a description…

of the hardware configuration to be carried out.

for the creation of function blocks.

for the creation the WinCC flexible screens.

Basic knowledge of these topics is assumed.

Required knowledge

The following basic knowledge is assumed:

configuration of STEP7 projects

configuration of integrated WinCC flexible projects

configuration of S7-Graph blocks

configuration of PDIAG process diagnostic blocks (The precise configuration for the respective diagnostic option is only shown as an example.)

Automation Solution

2.2 Description of the core functionality


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2.2.1 Overview and description of the interface

Figure 2-3

The application example is structured in a way so that…

the state of the application example is displayed.

the drill model can be operated from the WinCC flexible interface (operation of the model).

the different fault scenarios can be simulated from the interface (error simulation).

the occurring errors can be diagnosed with ProAgent.

A precise description on the operation of the model can be found in chapter Operation of the Application in this documentation.

Automation Solution



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Components and function of the model

The figure and table below names the main components of the model and briefly explains its functions.

Figure 2-4

2

4

6

5

3

1

7 8

Table 2-1

No Component Function

1. Clamp Clamps the workpiece and therefore secures it against slipping.

2. Drill motor Sets the drill in rotary motion

3. Feed action Lowers and raises the drill with drill motor and fixture

4. Coolant/coolant pump Cools the workpiece during the drilling process (e.g. with drilling oil).

5. Oil pan (with drain) Collects the drilling oil

6. Drain/discharge pump Pumps the collected oil from the oil pan into the drain.

7. Hydraulics The supply unit hydraulics

Automation Solution



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Buttons for operating the model

The buttons for operating the application are labeled with the action which is triggered when pressing it, i.e. the label changes, depending on the state. The description of the buttons is in non-activated state.

Figure 2-5

The “on/off” cooling agent button turns the use of a coolant on or off.

The left button “Automatic” and “Manual” can toggle between automatic and manual mode. The red background color of the button displays the current operating mode.

The four middle buttons control the application.

– The “Reset Demo” button brings the drilling machine to a defined initial status, i.e. all errors and activated buttons are disabled and the initial step of the S7-GRAPH sequence is activated.

– The “Insert parts” button inserts a workpiece in the drilling machine or takes it out.

– The “Close safety screen” button opens or closes the safety screen.

– The “Start” button starts the drilling process when the safety screen is closed and no error is pending.

The “Diagnostics” button opens the ProAgent splash screen.

The “Change language” button switches among German, English and French.

The “Exit Runtime” button exits WinCC flexible Runtime.

Automation Solution



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Buttons for the simulation of errors

When activating an error via the buttons, the button of an error is highlighted in red and labeling changes from “0” to “1”. The listed errors are recorded as flags in the CPU and the error behavior will be simulated using simulation blocks.

Figure 2-6

The following errors can be triggered:

Pneumatic, hydraulic, voltage failure (Operand monitoring) The error simulates the failure of a supply unit (pneumatic, hydraulic, voltage). All supply units were recorded by a central release signal which is monitored.

Extraction system blocked (General monitoring) The error simulates a complete blockage of the oil pan drain. With the cooling turned on, this increases the filling level of the oil pan until the maximum value sensor of the oil pan triggers the error.

Feed limit switch defective or mechanism sluggish (Action monitoring) The error simulates a defective limit switch of the feed. The limit switch does not react when reaching the end position or the end position is not reached after a set time (10 seconds).

Feed jams in upper position (Startup monitoring) The error simulates a jammed feed, i.e. the end position is not left after activating the feed.

Clamping device can’t hold end pressure (Response monitoring) This error simulates a pressure loss of the clamp whilst it is clamping a workpiece, i.e. the clamping pressure is briefly (1 second) reached and then diminishes by a certain value.

Drill motor interlock Overheating (Interlock monitoring) The error simulates the triggering of the motor circuit breaker of the drill motor.

Safety screen open (Interlock error) The error is displayed and triggered when the safety screen is opened during the drilling process. This error is not operator-controllable.

Cooler pump pressure not reached (Supervision) The error simulates a defect in the cooling agent unit, so that the setpoint of the coolant pressure cannot be reached.

Automation Solution



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2.2.2 Structure of the control program

Figure 2-7

DB2

FB33

#ExtractionFB32

#Clamp#Drilling Unit# Coolant

pump

FB23

* PowersupplyFB22

* Hydraulic

DB44

FB21

* Pneumatic

FB13

# ExtractionFB12

# Clamp# Feed# Drilling motorDB10

FB10

* Initialization* Simulation

Release* Simulation

Aggregates* Error

Simulation

FB11

# Coolant

FB2

* CALL Releases

* CALLSeq_DrillUnit

* CALLDrillUnit

OB1

* CALL Simulation

* CALL DrillUnit

* CALL FB44

FB20

* Release

Simulation

FB44

* Error-detectio

DB45

#NAME?FB45

* First-value-capture

DB3FB3

* Sequencer

FB30

*Aggregates / Manual"

FB31

#Feed

Diagnosticablefunctions

DB

#NAME?FB

#Instanceof FB

* Functionof FB

Legend

S7-PDIAGDiagnosticblocks

The control program mainly consists of 5 parts.

Blocks for simulating the individual functions (FB 10 to F13) The simulation blocks were based on the behavior of real hardware. The blocks are controlled via the inputs and outputs of the CPU. The simulation blocks furthermore contain other inputs to simulate the different errors.

Blocks to release the process (FB20 to FB23) The blocks contain the monitoring of the external supply (e.g. power supply) and the general release for the process. To maintain clarity, the various supply units (power supply, pneumatic, hydraulic) were each summarized in individual FBs.

Blocks to control the process (FB30 –FB 33) The process blocks contain the logic for controlling the hardware units (e.g. feed, clamp). These blocks were created as diagnostics capability blocks. The process blocks do not contain functions for the sequence of the example.

A sequence block (FB3) The block was programmed with S7-GRAPH and contains the step chain for the correct sequence of the example. S7-GRAPH blocks have diagnostics capability by default; this is why no messages need to be configured.

S7-PDIAG Diagnostic blocks (FB44 and FB45) These blocks are independently created by S7-PDIAG during the configuration of the monitoring system.

Automation Solution



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2.2.3 Sequence of the drilling process

Figure 2-8

Initialization

Clamp

Drill motor

Coolant

Lower

Stop LowerRaise

Release

- All functions OFF

- Start button depressed- Safety screen closed

- Feed OFF- Coolant pump OFF

- Drill motor OFF

- Clamp ON

- Clamp pressure OK

- Drill motor ON

- Drill motor ON- Coolant OFF

- Drill motor ON- Coolant ON

- Coolant pump ON- Extractor pump ON

- Coolant pump ON- Extractor pump ON

1

1

- Feed LOWER

- Feed BOTTOM

- Feed TOP

- Feed RAISE

- Clamp OFF- Drill motor OFF- Coolant pump OFF- Extractor pump OFF

2

- Safety screen OPEN- Part REMOVED- Drill motor OFF- Clamp OPEN

- Feed TOP

2

…

Legend

Step

Transition

1 Jump lable

Automation Solution

2.3 Advantages of this solution


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2.3 Advantages of this solution

Use of PDIAG and ProAgent

The solution introduced here offers you the following advantages:

simple integration of process diagnostics in a control program by uniform data structures.

clear display of the process diagnostics by dividing the process diagnostics into units. (Also possible irrespective of the control program.)

uniform display of process diagnostics data through predefined diagnostic screens.

Use of S7-Graph

S7-Graph offers the following advantages:

graphic display of sequences.

sequence interlock and step monitoring already integrated, the respective logic can be individually configured.

the sequences always have diagnostics capability.

messages are already integrated, message texts can be individually adjusted.

Automation Solution

2.4 Hardware and software components used


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2.4 Hardware and software components used

The application was generated with the following components:

Hardware components

Table 2-2

Component Qty MLFB/order number Note

CPU 317-2 PN/DP 1 6ES7317-2EK13-0AB0 Simulated with S7-PLCSIM.

MP277 1 6AV6643-0CD01-1AX0 Simulated with WinCC flexible Runtime.

Standard software components

Table 2-3

Component Qty MLFB/order number Note

STEP 7 1 6ES7810-4CC08-0YA5

S7-PDIAG V5.3 SP4 1 6ES7840-0CC04-0YA5

S7-Graph V5.3 SP6 1 6ES7811-0CC06-0YA5

S7-PLCSIM V5.4 SP2 1 6ES7841-0CC05-0YA5 Only necessary when there is no hardware CPU.

WinCC flexible 2008 1 6AV6612-0AA51-3CA5

WinCC flexible ProAgent

1 6AV6618-7DB01-3AB0

Sample files and projects

The following list contains all files and projects that are used in this example.

Table 2-4

Component Note

WinCCflex_Diag_Drill.zip This zip file contains the sample project.

WinCCflex_Diag_Drill_DOKU_v2_d.pdf This document.

Automation Solution

2.5 Memory benchmark data of S7-PDIAG


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2.5 Memory benchmark data of S7-PDIAG

The option package generates different FBs and DBs from the monitoring configuration, as described in the previous chapters. Depending on the number of operands monitored and the additive options and parameters there is generally a memory requirement which is calculated from a basic requirements and a quasilinear increase.

Display

The graphic below shows the trend of dependence of an operand monitoring with initial value acquisition and time lag on the number of operands to be monitored.

Memory requirement for operand monitoring

012345678

0 2 4 6 8 10 12 14 16 18 20

Number of operands

Mem

ory

[kB

yte]

Fehlererkennungs-FB Fehlererkennungs-DB

Erstwerterfassungs-FB Erstwererfassungs-DB

The total for the basic requirement is at around 3k byte for an activated initial value acquisition and error detection, and increases by a memory requirement of around 200 bytes per operand.

Error detection FB Error detection DB

Initial val. acquis. FB Initial val. acquis. DB

Basics

3.1 What is diagnostics?


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Basics 33.1 What is diagnostics?

Diagnostics can be defined as the detection of a glitch by monitoring and evaluating the characteristic values of a system. If the evaluation of these characteristic values results in a critical value (fault detected) then the reason and the location of the state is determined and displayed.

3.2 Overview

Diagnostics includes the process chain of error detection, error localization and the identification of the cause of error. In the process, significant symptoms recorded by a monitoring unit are analyzed and the reasons responsible are filtered out with different strategies. The objective is the rapid containment of the error and the determination of the corresponding causes.

Figure 3-9

Cause(s)Cause(s)

FailureFailureError

Error

causes causes

causalursächlich

SymptomsSymptoms

SymptomsSymptoms

dis

pla

ys

char

act.

dis

pla

ys

char

act.

Error developmentError development

Error diagnosticsError diagnostics

Diagnostics tries to determine the causes on the basis on the detected error and based on the present symptoms. Due to the ambiguity between cause and effect which is often prevalent in real-life situation, the process can be particularly complex, because this calls for an extensive knowledge of process, experience and errors.

Basics

3.3 Maintenance strategies


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3.3 Maintenance strategies

The table below shows the different strategies for maintenance.

Figure 3-10

In case of failure

Preventive

Predictive

Error oriented

Time/model-based

State-based

Maintenancestrategy

Measure

Fast reporting,Detecting, help alleviate

Carry out plannedmaintenancereliably and correct

Timely andreasonable warning

Systemdiagnostics

Systemdiagnostics

Processdiagnostics

Processdiagnostics

Integrated in

e.g. IT Maintegrity byA&D SH2

Failure

In the case of a fault, meaning the failure of a unit, the respective tool or system feature has to display the error quickly, localize the cause as precisely as possible and be able to support the operator in remedying the error. The follow-up costs are the highest in this case, since downtime in the production process is often the case. This is the main task of the process and system diagnostics with their tools and AddOns for the different automation systems, which is the subject of this application.

Prevention

The preventive case is mainly based on a time model. Here, maintenance is specifically triggered, controlled and reliably carried out by logistic means, based on time intervals, operating hour counters, etc. The consequence may be a wasted service life of the respective aggregate because it could possibly work longer.

Prediction

The predictive case assumes a condition-based approach. This means in an ideal case, the operator is made aware of a fault to be expected in the near future by a timely and justified warning of the aggregate or system. This means there are hardly any extra costs anymore.

This case assumes extensive knowledge of the process, since a meaningful prediction makes a meaningful evaluation of n states or characteristic values necessary whose connection presents a critical value.

In future, the trend will also go in this direction in manufacturing industry because this can achieve the smallest follow-up costs.

Knowledge and status-oriented automatic diagnostic systems are only the beginning of an extensive use in manufacturing industry.

Basics

3.4 Message concepts


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3.4 Message concepts

Basis for any diagnostics is the possibility of a system to report an internal or external state to a superior unit.

Overview

The graphic below shows the different message processes which can be realized in the SIMATIC.

Figure 3-11

Bit message procedure

• Display device polls cyclically• no joint database• time stamp of display device

Message number procedure

• AS actively reports changes• joint database• time stamp of CPU

Block-relatedmessages

Symbol-relatedmessages

User-defineddiagnostics messages

• Program-synchronousentry in diagnostic buffer

• WR_USMSG message block• Display on PG• S7-300/400 systems

• Message of program-synchronousevents

• Message blocks:ALARM,ALARM_S(Q),ALARM_8

• Display in WinCC, WinCC flexiblevia Alarm_S(Q)

• S7-300/400 systems

• Program-asynchronousevents irrespective of events

• Configuration viasymbol table

• Display via WinCC• S7-400 systems

Procedure for processdiagnostics

HMI systemsWinCC or WinCC flexible

Bit message procedure

The HMI system asks the automation system cyclically whether the configured message bits have changed. When such a change is detected, the respective message is displayed on the message screen.

The configuration is in two steps because there is no joint data base.

1. Assignment by the program of the state to a message bit in accordance with an assignment list.

2. Configuration of the message texts on the HMI system according to the numbers in the assignment list.

Message number procedure

For the message number procedure the automation system actively sends a message to the HMI system via a block call when there are changes of the configured message bit.

Thanks to a joint database, the configuration is only single stage by directly assigning the respective message bit a message text in the CPU when configuring.

Of the three varieties in the message number procedure, the “block-related” messages are used for process diagnostics.

Basics

3.5 System and process diagnostics


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The main field of application of diagnostics is in the operation phase of a system or machine. It is usually applied when a fault leads to downtime or to an incorrect function of the system or machine (case of a fault).

The diagnostics of a cause of malfunction is normally distinguished by which components of a plant or machine are diagnosed. This is why two diagnostic possibilities are distinguished.

System diagnostics

Process diagnostics

System diagnostics

System diagnostics summarizes all monitoring functions which deal with the correct function of the components of the automation system itself.

Figure 3-12

“Normal“Program processing

Defined response to faultsvia error OB processing

Error causes• Programming error• Access error• Module failure• Channel error ....

Diagnostic bufferDiagnosing hardwareMonitoring/controlling variablesCPU-Meldefunktion

PG functions

Program response

Report system error

HMI device

PG

CPU

All S7-CPUs have an intelligent diagnostics system. The acquisition of diagnostic data through system diagnostics does not have to be programmed. It is integrated in the operating system of the CPU or in other diagnostics capability models by default and runs automatically. Even a display of system errors on HMI devices does not require any or only very small configuration effort.

Errors occurring are temporarily stored in the diagnostic buffer of the CPUs and therefore make rapid and targeted error diagnostics possible for the service personnel, even for sporadically occurring errors.

Every system error can also be reacted to separately by the program by calling a special error OB.

Basics



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Process diagnostics

Process diagnostics diagnoses all other components (sensors, actuators, usw.) or the sequences of a plant or machine.

Figure 3-13

"Normal"Program processing

HMI device

PG

CPU

Error causes• Sensor/actuator faulty• Movement faulty• Interlock not fulfilled• Runtime monitoring

Report process error,root cause analysis

Explicit or implicit monitoring program created by engineering tools

CPU message function

Errors in the process normally do not only manifest themselves by standstill or faulty function of a plant or machine but also through "unusual" signal states or temporal signal sequences, which can be detected by the connected sensors.

Process diagnostics cannot (at present) be automated in the same way as system diagnostics. This has partly to do with the lack of intelligence or redundancy of most peripheral components (switches, sensors, actuators, drives, etc.). The other reason is the special structure and/or the individual dynamic and functional dependencies of the involved machine or plant components.

This is why process error detection requires an individual monitoring strategy for each machine or plant.

The main emphasis of diagnostics is clearly to be placed in process errors, given the high hardware availability of today’s PLC, since missing messages or faulty functions cause production downtime and therefore cause significant costs.

Note The whole purpose of process diagnostics is to display the triggering error quickly and reliably. Process errors have to be detected by a logic in the user program.

Basics

3.6 Session/functional sequence of process diagnostics


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3.6 Session/functional sequence of process diagnostics

The graphic below shows the sequence of a process diagnostics session in overview. The green makings show that the actions occur in the automation system, the actions shaded red in comparison, take place in the display device.

Figure 3-14

Synchronizeprocess

Synchronizeprocess

Remove errorRemove error

Control programControl program

Error detectionError detection

Inital value acquistionInital value acquistion ReportReport

ProcessProcess

Message displayMessage display

Criteria analysisCriteria analysisError displayError display

manual

man

ual

Operation

Operation

Display device

Automatisationsystem

Error detection

The process error has to be detected by a logic in the user program. This happens via the already existing links in the control program or through an individual monitoring logic.

At the time of error all involved, relevant signals (=> initial values) are saved for later analysis.

Reporting error

The appearance and disappearance of an error is displayed on the connected HMI device. The messages also have to be acknowledged. The display of the process error is integrated in the “normal” message system of the display device.

Detecting cause

Further in the process chain, the aim is now to detect the cause of the error (the triggering error). Here, the operator is supported by the criteria analysis which can detect and display the faulty operands on the basis of initial values and/or the actual values in connection with the information on the underlying connections in the networks.

Basics

3.7 Products and tools for process diagnostics


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Removing the error

The detected error from the previous step can now either be removed by manual intervention in the process or via the controller by enabling the manual mode. Process diagnostics intervenes here from the HMI system by manual traversing of movements.

Continuing the process

In the last function step the manually adjusted machine state may have to be resynchronized with the control program. This is also where the process diagnostics tools have an effect. For example, supported by specific controllability of sequences from the display unit.


Product embedding

The process diagnostics in the SIMATIC is not a product but a universal system solution which is integrated in the individual components of TIA and therefore offers an integrated interaction among STEP 7, its option packages and the HMI configuration tools.

Figure 3-15

ProAgentProAgent

WinCC flexible

System-wide interfaceSystem-wide interface

Jointdatabase

LAD/FBD/STL

S7-PDIAG

S7-GRAPH

S7-HiGraph

Export filefor external

systems *.csv

Export filefor external

systems *.csv

SIMATIC Languages HMI systems

MP PC RuntimePanel PCTP ILOP

SIMATIC S7-300/400…

WinCC

Language embedding

The two SIMATIC languages S7-Graph and S7-HiGraph have process diagnostics capability by default.

S7-Graph offers the option to configure respective interlock and monitoring conditions for each process step and therefore have an influence on actions and switching conditions. The message mechanism is carried out automatically.

S7-HiGraph offers the option to monitor each state and each transition.

Basics



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If the user program is created in LAD/FBD/STL then the STEP7 development environment has to be integrated in the S7-PDIAG option package. With its help, you configure the signals to be monitored or the monitoring logic itself next to the appropriate message texts. From this, S7-PDIAG independently generates the necessary monitoring blocks which then only have to be integrated in the OB1 by the user. Principally, however, the monitoring functions do not change the control program.

The principle is the same for all three language variants:

a configuration of process diagnostics can already take place during the implementation of the control software.

the message concept is adjusted to all HMI systems (on which process diagnostics are principally possible).

Joint data base

The languages listed above store their configuration data in a joint database on the configuration computer. This source orientation permits a one-level configuration of process diagnostics. I.e. all configuration tools involved independently access the database and retrieve the data relevant for them or they store the data necessary for other packages.

Note For this purpose all the development tools have to be installed on a machine.

Integration in display device

The visualization software tools for WinCC (upper performance range) and WinCC flexible (intermediate to lower performance range) are enabled by the option package ProAgent for the seamless integration of process diagnostics in the HMI system. It already contains standard default screens which support the complete function process for process diagnostics with minimum configuration effort.

The ProAgent option package can be integrated on the following devices:

Table 3-5

OP TP MP PC

OP270 TP270 MP270B MP370 WinCC flexible Runtime

OP277 TP277 MP277 MP377

MP270B Touch MP370 Touch

MP277 Touch MP377 Touch

Open interface

S7-PDIAG furthermore offers the possibility of an open interface for non-SIMATIC HMI devices. In the case of an error detection by the operands monitored by S7-PDIAG an “empty” function block is called on whose formal operands all information on the error is pending. In this function block the user then has to program the error telegrams and a communication routine to his target device himself.

From the STEP7 database the relevant process diagnostics data (message numbers, messages texts, etc.) is exported to a CSV-ASCII file (Comma Separated Value) which can be read via a respective routine from the target HMI configuration tool.

Functional Mechanisms of this Application

4.1 Monitoring with S7-PDIAG (procedures for generation time)


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Functional Mechanisms of this Application 4


Introduction

As already mentioned, the S7-PDIAG option package expands the function scope of STEP 7 by the possibility of process diagnostics for the LAD/FBD/STL language. This makes it possible to detect information on error type, error location and error cause.

Some detailed configuration instructions can be found in chapter 5 in this documentation.

Error definition

The user has to define his error monitoring in so called error definitions.

Error definitions can…

be assigned units (FBs with instance DB).

be configured on global operands in FCs or OBs.

Monitoring types

S7-PDIAG offers different monitoring types. In the table below they are listed with their application.

Table 4-6

Monitoring type Application Prerequisite

Operand monitoring

as level monitoring

An operand is to be monitored for a target level of 0 or 1. (Can be combined with monitoring time.)

No intervention in the user program necessary.

Operand monitoring

as edge monitoring

An operand is monitored for a change of edge (falling or rising). (Can be combined with monitoring time.)


General monitoring Several operands are to be monitored and linked via a freely programmable monitoring logic. (Can be combined with monitoring time.)


Motion monitoring

Startup monitoring

Does a motion start within a preset startup time? (Is the present position left?)

UDT “Motion” and LAD monitoring networks have to be integrated in the user program.

Motion monitoring

Action monitoring

Is the motion finished within a preset time? (Is the target end position reached on time?)





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Monitoring type Application Prerequisite

Motion monitoring

Response monitoring

Does the target end position remain stable?


Motion monitoring

Interlock monitoring

Do the interlock conditions, necessary for the motion still apply?


Notes Criteria analysis can trace the causes which lead to the faulty operand via networks and beyond block boundaries and can replace possible intermediate results (flags) automatically.

S7-PDIAG can only detect one error per cycle! If several errors occur at the same time, they are reported in the sequence of their appearance.

S7-PDIAG always permanently monitors all units simultaneously.


4.2 Monitoring with S7-GRAPH (procedures for generation time)


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4.2 Monitoring with S7-GRAPH (procedures for generation time)

Introduction

In the S7-Graph language which simplifies programming of sequential procedures decisively, process diagnostics is already an integral part of the engineering tool. As opposed to LAD/FBD/STL no additional package has to be installed.

Some detailed configuration sessions can be found in chapter Configuration of sequence monitoring

in this documentation.

Error definition

Possible error definitions are implicitly integrated in the sequence from the S7-Graph editor and the data is stored in the assigned sequence instance DB.

Monitoring types

S7-Graph recognizes two types of errors, interlock (step interlocking) and supervision (step monitoring).

Table 4-7

Monitoring Application

Interlock The interlock is a programmable condition which influences the execution of individual actions within the respective step. If the interlock condition is fulfilled (=good case), all actions additionally linked with the interlock are executed. If the interlock condition is not fulfilled (= failure), then…

an interlocking error is reported.

all of the actions linked with the interlock in this step are not executed. the sequence as a whole remains active!

Supervision

The supervision allows the programmer to influence the switching conditions into the next step. If the supervision condition is fulfilled (= failure), then…

a supervision error is reported.

the sequence chain is locked, irrespective of possibly fulfilled transition conditions. The currently (locked) step remains active!

Note For S7-Graph it is always only the monitoring functions in the current step which are active. If several errors are detected in a cycle then all of them are reported (as opposed to S7-PDIAG).


4.3 Principles and structures of process diagnostics


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4.3.1 Diagnostics capability unit

Process diagnostics sees the process more from a technological view. Units are objects of process diagnostics here which are monitored with the help of error definitions. The term unit, in the sense of process technology, reflects a plant/machine part.

Units are logical order criteria and structure the process view. They can save the data which is common in all hierarchically subordinate objects (e.g. operating modes and group error bits).

A PLC program which uses the possibility of process diagnostics to its optimum effect should already have a “unit oriented” structure, i.e. each plant or function unit should be realized as a FB.

ProAgent displays each unit capable of diagnostics separately in the overview screen. Therefore it can be quickly diagnosed which unit (plant/machine part) caused the failure.

In the table blow, you can see how units are defined in the different languages.

Table 4-8

Language Definition

S7-Graph Each sequence (one FB with instance DB) which is designed for process diagnostics is automatically a unit.

S7-HiGraph Each graph group (one FC with respective DB) is a unit, each graph therein a subunit.

LAD/FBD/STL For LAD/FBD/STL principally every block can be displayed as a unit that has the S7_pdiag = true system attribute. For the configuration of process diagnostics from the editor, this attribute is set automatically. These blocks are marked in color for LAD/FBD/STL in the SIMATIC manager.




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4.3.2 Hierarchical units

Structuring

Units capable of diagnostics in turn can contain subunits, which, from a technological point of view, therefore structure the plant/machine hierarchically.

This leads to an increase of clarity particularly in the case of diagnostics.

Example

Figure 4-16

Drilling machine

General functions

Bohrmotor

Aggregates

Feed Clamp

consisting of

ReleaseOperating

modes

consisting of

consisting of

Realization in LAD/FBD/STL

Such a structure can be realized by using the multi-instance technique for function blocks. The figure below shows an implementation by the program of the above hierarchy, similarly realized as in the example.

Figure 4-17

Function_Block Drill unit....VarMode : UDT1Aggregate: FB2Gen.funct: FB3End_Var..CALL #Aggragate.CALL #Gen. funct..

Function_Block Aggregate....VarMode : UDT1Drill motor: FB5Clamp : FB3Drive : FB4End_Var..CALL #Drill motor.CALL #Clamp.CALL #Feed.

Function_Block Gen. funct....VarMode : UDT1Release : FB7Mode: FB8End_Var..CALL #Release.CALL #Operating modes.

Function_Block Drill motor....VarMode : UDT1End_Var.

Function_Block Clamp....VarMode : UDT1End_Var.

Function_Block Feed.VarMode : UDT1End_Var.

Function_Block Release....VarMode : UDT1End_Var.

Function_Block Op. modes.VarMode : UDT1End_Var.


4.4 Data structures


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4.4 Data structures

Data structures in process diagnostics are defined by UDTs (User Defined Types).

Included in the delivery of S7-PDIAG there are the following UDTs

Unit (unit with independent mode)

Unit_s (unit without independent mode)

Motion (unit with a motion)

Use of the UDTs

The UDTs mainly help the user in…

standardizing and structuring his units,

providing templates/interfaces which permit an automatic integration in HMI objects,

automatically generating group error bits for hierarchical units.

When using LAD/FBD/STL the UDTs have to be integrated as instance variable in the process diagnostics capability block.

S7-HiGraph implicitly uses the UDTs.

S7-Graph uses no UDTs. Motion monitoring functions have to be, e.g. explicitly realized with S7-PDIAG in LAD/FBD/STL.

Note Process diagnostics is also possible without the use of these UDTs. The user then does without the application of normed and easily to implement structural elements (especially for motion).

4.4.1 “Unit” UDT

The “unit” UDT represents a process diagnostics capability unit which determines the operating mode and the group error detection for itself and all subordinate subunits.

Use of “Unit” UDT

The unit UDT presents an interface to the process diagnostic screens of ProAgent. I.e. certain display controls know the addresses in the instance of these UDTs during runtime and can then control and display the content of these variables without a configured interconnection.

Set-up/structure

The grahic below shows the structural set-up of the unit UDT which is included in delivery with the S7-PDIAG and its embedding in a FB.


4.4 Data structures


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Figure 4-18

UDT “Unit“

Selection mode(s)

Display mode(s)

Group error display

Error acknowledgement

Modeselection

Mode display

HMI process diagnostics display

FB (unit) with independent mode

PDIAG monitoringblocks

Process diagnosticsmonitoreduser program

Sets group bits

monitors

Independent display /acknowledgementfunctions

Automatic

Manual

User program

User logic tomodes

• Evaluation• Generation• Substates

1

2

3

4

The UDT can contain up to 16 different operating modes. (The first two modes are automatic and manual by default). In the sample model the default modes are used and displayed on the interface.

Procedure for mode selection

Table 4-9

Step Instruction

1. In the process diagnostics screen (ZP_UNIT) a new mode can be selected via mode control.

2. An individual user logic now evaluates this selection and will set the respective bits in the UDT based on its results.

3. These display bits are then automatically visualized in the respective controls on the display screen.

4. The user logic also has to ensure that the selected operating mode is also passed on to the subordinate units (multi-instances).

Control of group error bit

S7-PDIAG monitors all error definitions in a unit hierarchy. As soon as an error is detected, S7-PDIAG will set the group error bit (Group_Error) there.

However, at the same time S7-PDIAG will also automatically set all error bits successively in the superior units of this hierarchy. These bits can be evaluated for an independent error logic or visualization.


4.4 Data structures


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4.4.2 “Unit_s” UDT

The Unit_s UDT is a subset of the UDT unit and only contains the group error and acknowledgement information of the unit in which it is instanced.

4.4.3 Motion unit

Motions form a basic element of a machine in manufacturing engineering. This is why this element was defined as data structure for the control program. This forms the basis for a uniform motion monitoring and the respectively normed screens for the display device are derived from it.

Note A motion does not necessarily relate only to a geometrical change of machine parts. In the broader sense it also possible to display the filling level of a container on the UDT motion.

Use of the UDTs

The “Motion” UDT provides a normed interface between the S7-PDIAG motion monitoring functions and the display devices which integrate Pro-Agent.

The benefit for the user is in…

the visualization of a movement without additional configuration effort.

the option to also make this movement in manual mode.

there being no additional need for hand panels.

Structure

The graphic below shows the structural set-up of the motion UDT which is included in delivery with the S7-PDIAG and its embedding in a FB and ProAgent screen.

Figure 4-19

UDT “Motion“

User logic tosupply and disposalof "Motion" UDT bits

FB (unit) with motion

Direction text Motion name (Instance name) Direction text

Position 1

End position1 End position 2

Position 2

A 0.1A 0.0

Direct button/soft key



Moving Status

Final Positions [0..15]

Interlocks

Manual_Operations

Control

Group_Error

Executability

ProAgent - Screen

!!


4.5 Process diagnostics and reusability


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Through instancing of the normed UDT in a FB, which represents a movement, the controls of the motion screen of ProAgent are automatically linked with the respective motion bit. The user now only has to provide a supply of these bits to the process.

Included in the delivery of S7-PDIAG is an already finished function block (FB100) which is optimized for the “Motion” UDT and for complete motion monitoring. It can be adjusted for the respective requirements.

In this application several motion monitoring functions are executed with the standard FB.

4.5 Process diagnostics and reusability

The possibility to reuse once developed standardized blocks again and again in several projects quickly pays off in the configuration of follow-up projects. In this respect, process diagnostics in connection with multi-instance technique offers many advantages.

As multi-instance, a unit can be called as often as desired in different places of the program. The monitoring of the block is configured once with S7-PDIAG (i.e. the signals which are relevant for the application are monitored). All instances therefore automatically have process diagnostics capability and have the ability to send instance-specific error messages (if configured) to the visualization device.

In the example the feed motion, the clamp motion and the drill motor are realized as instance of the same motion block.

4.6 Runtime connections

This section shows the Runtime connections as an example for the message case and the analysis case.

The graphic below shows an overview of several involved runtime components which can contain process messages of a CPU.

Figure 4-20

STEP7 programWinCC fexibleconfiguration

Tools genereratedcalls ofSFC 17/18/19

Message acknowledgement memory(Part of S7)

MPI/PR

OFIB

US

Ethern

et

Virtualpoint-to-pointconnection

WinCCconfiguration




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4.6.1 Reporting

The graphic below shows the path of a process message through the involved structural elements in the SIMATIC up to a display device in detail.

Overview

The path highlighted in color is the one for the LAD/FBD/STL language and S7-PDIAG.

Figure 4-21

S7 – Communication system"Messages and telegram generation"

User program S7-PDIAG

Monitoringblocks

LAD/FBD/STLprogram

logic

LAD/FBD/STLprogram

logic FB errordetectionFB error

detection

FB initial valueacquisitioncriteria analysis

FB initial valueacquisitioncriteria analysis

S7-Graphblock(s)S7-Graph

block(s)

S7-Higraphblock(s)S7-Higraph

block(s)

S7 acknowledgementmemory

Alarm_S(Q)(SFC 17,18)

Calls


Calls

List of registeredHMI devices

• Target address 1 (OP27)• Target address 2 (MP270)• ......

S7-BESY

MPI, Profibus, Ethernetswich on

MPI, Profibus, Ethernetswitch on

S7 communicationsystem

HMI device 1with WinCC flexible

ProAgentdiagnostic

handler

Bus

S7-CPU

Target: HMI device1, source: S7-CPU 1, message no.: 5, status: arrived, time stamp, associated values

localdatabase

Message textsSymbolic,--

5 : End position @@ not reached

Telegram

End position E3.0no contact !

1

2

3

4

5

6

7




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Message sequence

The description follows the path marked in red in the graphic for the LAD/FBD/STL programs monitored by S7-PDIAG.

Table 4-10

Step Description

1. In the process, e.g. a motion occurs in direction “1”. Input E3.0 signals the “Movement in lower end position” state. In a LAD/FBD/STL block this input is linked with the respective interlock conditions.

2. With a motion monitoring function, this input is permanently monitored by the generated error detection FB.

3. As soon as an error is detected by monitoring, the “error environment” is saved by the error blocks. A second error block will save all status and RLOs of the involved operands in an initial value acquisition if this was activated in the configuration.

4. The monitoring blocks will enter the error in the CPU internal S7 acknowledgment memory by implicit calls of the system function blocks SFC 17 or 18 (ALARM_S or ALARM_SQ).

5. The S7 communication system in the operating system of the CPU detects the changes in the S7 acknowledgement memory and generates a message telegram. The communication system takes the target addresse(s) from a list in which all HMI devices enter themselves that want to receive the telegram (specified during configuration). According to the message number procedure the only information transferred is the message number, the status of the message, a time stamp and possibly associated values.

6. The telegram is received by the communication systems of the target devices via the respective hardware interface connection and the bus system.

7. The diagnostics handler in the visualization device generates the final process error message, generated from the telegram data and from its internal database which contains the messages texts, which is then displayed by the message system.

Acknowledgement

If an error message was configured with acknowledgement then the acknowledment mechanism is carried out in reverse.

Table 4-11

Step Description

1. The acknowledgement of a message usually takes place on a display device.

2. The acknowledgement telegram is sent to the target CPU.

3. The S7 communication system marks the status change in the S7 acknowledgement memory. The repeated status change (acknowledged) is sent again as telegram to all registered display devices.

4. All display units are now again in a consistent display state.

5. The repeated status change (acknowledged) is sent again as telegram to all registered display devices.




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4.6.2 Error analysis

Since the error message was now correctly displayed, the cause of the error can be detected in the next step.

Overview

The numbered path highlighted in color shows the sequence of the criteria analysis for the LAD/FBD/STL language.

Figure 4-22

S7 communication system

"Messages andTelegram generation"

Userprogram

"Generated"PDIAG

monitoringblocks

KOP/FUP/AWLprogram

logic

KOP/FUP/AWLprogram

logic FB errordetection

FB errordetection

S7-Graphblock(s)

S7-Graphblock(s)

S7-Higraphblock(s)

S7-Higraphblock(s)

S7 messageacknowledgement

memory


Calls


Calls

List of registeredHMI devices

• Target address 1 (OP27)• Target address 2 (MP270)• ......

S7-BESY



S7 communicationsystem

HMI device 1with ProAgent

ProAgentdiagnostics

handler

Bus

S7-CPU

localdatabase

Message textsSymbolic,--

5 : End position @@not reached

Status bar, networksTelegram

Requirement criteria analysis 1

2

3

Instance DBInstance DB

E3.0

FB initial valueacquisitoncriteria analysis

FB initial valueacquisitoncriteria analysis

4

Criteria analysis

Table 4-12

Step Description

1. The display device requests the data for a criteria analysis at the CPU causing the error.

2. The S7 communication system of the target CPU retrieves the following from the instance DB…

the network data which is saved there in a normal form.

the initial values of the status and RLOs, which the operands of the involved networks maintained at the time of the error.

3. A telegram with the above content is sent back to the display unit.

4. The display can be shown as signal list, as LAD or STL detail network.

Configuration

5.1 Configuration of an operand monitoring functions (S7-PDIAG)


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Configuration 5Introduction

In the following chapter, 3 configuration sequences are explained step by step.

An operand monitoring function as linked signal in a FB

A motion monitoring function

A sequence monitoring function

You can carry this out yourself, point by point, which will lead you to exactly the result you have in mind for the developed point in the finished demo example.

Each partial error can also be configured and tested individually.


In the example the first and the second simulated error state is monitored on the WinCC flexible interface with an operand monitoring function. The first monitoring presents the monitoring of the general release signals or of an explicit individual signal.

Control program

The graphic below represents the partial program structure of the control program which supplies the release signals.

Figure 5-23

DB2

FB23

* Strom-VersorungFB22

* HydraulikFB21

* Pneumatik

* Initialisierung * SimulationFreigaben

* SimulationAggregate

* Fehler-Simulation

# Kühlung

FB2

* CALL Releases

* CALL

FB20

* FreigabeDB3

FB3

* Ablauf-Schrittkette

Funktionen

The power supply, hydraulic and the pneumatic units are called via individual function blocks (FB21-FB23), which again link different individual signals internally. In the FB20 function block the function blocks of the individual units are called and the release signals of the individual units are summarized in a system release signal. The FB20-FB23 blocks are called as multi-instance blocks in FB2.

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Figure 5-24

Monitored signals

Each of these function blocks (FB21-FB23) is called in the FB20 release block as instance and supplies its partial release via formal parameters. All these partial releases are now linked to a central release process. The picture shows an example of the code of the instance FB for the pneumatic supply.

Monitoring task

The following is to be monitored and displayed…

an individual power supply signal with the voltage value present at the time of failure,

the central release process which the FB20 supplies back to the calling block as output parameter.

As soon as the release signal disappears, which represents an error for the controller of the drilling process, the user is supposed to be lead to the cause as precisely as possible.

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5.1.1 Monitoring of individual signal

The monitoring of an individual signal can be directly configured in the symbol table of the project. To do this, proceed as follows.

Table 5-13

Step Instruction

1. Open the symbol table (project name > control name > program name > “symbols”)

2. Right click the individual signal (in the example “Voltage_1_OK”) and click the “Special object properties” > “Monitoring” menu command.

3. The monitoring dialog with the diagnostic entry operand (DEO) "#Voltage_1_OK” opens up. In the “Templates” list mark the entry “Operand monitoring” and click the “New…” button.

3

3

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Step Instruction

4. Fill in the operand monitoring as follows: 1. Monitoring is to react to a falling edge. 2. Switch off the initial value acquisition. 3. Enter the message text with associated value format string. 4. Enable the associated value and enter the symbolic name of the value.

4.2

4.1

4.2

4.3

4.4

Note: The description of the formal operands can be found in chapter “Further Notes, Tips and Tricks etc.”

5. Confirm the two dialogs by clicking “OK”. Save and close the symbol table afterwards.

6. Right click the block folder of the controller in the SIMATIC manager and click the “Check block consistency” menu command.

7. In the open dialog click “Program” > “Compile all” and close the dialog afterwards. All blocks and S7-PDIAG were compiled.

8. Click “PLC” >“Download” in the menu bar of the SIMATIC manager and confirm the following dialog with “OK” to load the program in the controller.

Summary

Only one individual signal is monitored. This means that when leaving the target status of this signal, S7-PDIAG sends a message with an associated value to WinCC flexible.

An initial acquisition is not performed; therefore a criteria analysis is not possible since there is only an input signal and no link which leads to the signal.

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5.1.2 Monitoring of central release process (criteria analysis)

For this monitoring function the central release process (in FB20) for a setpoint is monitored. In case of an error, the signal causing the error can be detected in the calling blocks (FB21-FB23), using the criteria analysis.

Table 5-14

Step Instruction

1. Open the function block (in the example FB20), in which the signal to be monitored (NW 4) is located.

2. Right click the signal to be monitored (“Sys_Release”) and click the “Special object properties” > “Monitoring” menu command.

3. The monitoring dialog with the initial diagnostic address “#Sys_Release” opens up. In the “Templates” list mark the entry “Operand monitoring” and click the “New…” button.

3

3

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Step Instruction

4. Fill in the operand monitoring as follows: 1. Monitoring is to react to a falling edge. 2. The message is to react with 1 second delay (i. e. the signal has to have the value “0” for

at least 1 second.) 3. Enable the initial acquisition for criteria analysis. 4. Enter the message text with parameters. 5. The message is to be acknowledgeable.

4.14.14.2

4.3

4.4

4.5

Note: The description of the formal operands can be found in chapter #.

5. Confirm the two dialogs by clicking OK. The signal is now marked in color in the STL/FBD/LAD editor (prerequisite “Display” >“Display with …“ > “Operand labeling” is enabled).

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Step Instruction

6. Save the block and close the STL/FBD/LAD editor and go to the block folder of the SIMATIC manager.

Note: In the block overview of the SIMATIC manager you will now see the diagnostics capability FB20 block. To be able to trace the error beyond the block boundaries all involved blocks also have to have diagnostics capability. For this purpose the “S7_pdiag” attribute has to be set to “true” in the object properties of the block. The FB2 (PrgDrillUnit) block calls the FB 20 (Releases) block, which in turn calls the FB21-FB23 blocks, therefore the blocks FB2 FB20, FB21, FB22 and FB23 have to have diagnostics capability.

7. Right click on the FB21 block and select the “Object properties” menu command.

8. Click the “Attribute” tab and enter the “S7_pdiag” attribute and “true” as value. Afterwards confirm the dialog box with “OK”.

9. Repeat the steps 7 and 8 for the blocks FB22, FB23 and FB2.

10. Since the supplementation of the diagnostics also makes changes on the data block, all involved blocks (starting from the lowest level) have to be updated. Right click the block folder and click the “Check block consistency” menu command. Note: If you have not compiled S7-PDIAG beforehand, you will receive warnings for S7-PDIAG. You can ignore these warnings.

11. In the menu bar click “Program” > “Compile all” and afterwards close the dialog. Notes:

The control program is now completely compiled.

S7-PDIAG will also be compiled. The blocks FB44, DB44, FB45 and DB45 are used or created for the process diagnosis. If you want to use other block numbers, proceed as follows: – In the SIMATIC manager click the block folder of the controller and click “Options” >

“Configure process diagnostics” in the menu bar. – In the menu bar click “Process diagnostics” > “Generate instances”. – Change the block numbers. Confirm the settings with “OK” and repeat this step 11.


Configuration

5.2 Configuration of an operand monitoring with S7-PDIAG


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The third to the sixth simulated error state on the WinCC flexible interface creates error states which react to the configured motion monitoring accordingly. The third monitoring “Feed limit switch defective or mechanism sluggish” is the standardized action monitoring for the feed motion of the drilling model.

Control program

The graphic below represents the partial program structure of the control program which is responsible for the aggregate control.

Figure 5-25

FB33

#ExtractorFB32

#Clamp#Drill motor# Coolant pump

FB30

* Aggregate / hand level

FB31

#Feed

The FB30 instances all motion blocks (FB31-FB33). The automatic control signals for individual aggregates contain the blocks from the S7-Graph sequence. The FB30-FB33 blocks are called as multi-instance blocks in FB2.

The motion blocks are all derived from the standard FB (FB100 “Motion_to_Limit_Switch”) for motion monitoring, which is included in delivery of the S7-PDIAG. This block already contains all monitoring networks which are necessary for a standardized monitoring. For the documentation, please refer to S7-PDIAG Manual.

http://support.automation.siemens.com/WW/view/de/16531809�


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Figure 5-26

UDT motion

FB31 „MotionSV_22“

Each motion control block…

is called in the FB30 aggregate block as instance and is responsible for a specific motion.

has declared the UDT motion its variable declaration. It ensures the possibility of an automatic interconnection with the motion screen of the display unit.

Monitoring task

The feed motion is to be monitored and displayed in the direction of the lower end position (“Lower”). As soon the monitoring reacts (i.e. the motion takes longer than projected), the user is to be lead as precisely as possible to the cause and he should be given the possibility to traverse the movement also in manual mode with standard operator screens in WinCC flexible.

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5.2.1 Configuration of action monitoring

Table 5-15

Step Instruction

1. Open the FB31 (“MotionSV_22”) block in the LAD/FDB/STL editor and select the LAD view (menu: “View” > “LAD”).

2. Network 3 contains the starting point for the action monitoring. The Operand #Motion.Final_Position[0] is the Diagnostics Entry Operand (DEO) and has to be monitored for the target state. Right click the operand and click the “Special object properties” > “Monitoring” menu command.

3. The monitoring dialog with the diagnostic entry operand (DEO) "#Motion.Final_Position[0]” opens up. In the “Templates” list mark the entry “Action Monitoring” and click the “New…” button.

3

3

Note: The description of the formal operands can be found in chapter Further Notes, Tips and Tricks, etc.

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Step Instruction

4. Fill in the action monitoring as follows: 1. The message should react with 10 seconds delay (i. e. if the feed motion in the direction

“Lower” is carried out for more than 10 seconds, the message is triggered.) 2. For a criteria analysis the initial value acquisition has to be enabled. 3. Enter the message text with the parameters. 4. The message is to be acknowledgeable.

4.1

4.2

4.3

4.4


5. Confirm the two dialogs by clicking OK. The signal is now marked in color in the STL/FBD/LAD editor (prerequisite “Display” >“Display with …” > “Operand labeling” is enabled).

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Step Instruction

6. Save the block and close the STL/FBD/LAD editor. Afterwards go to the block folder of the SIMATIC manager.

Note In the block overview of the SIMATIC manager you will now see the diagnostics capability FB31 block. To be able to trace the error beyond the block boundaries all involved blocks also have to have diagnostics capability. For this purpose the “S7_pdiag” attribute has to be set to “true” in the object properties of the block. The FB2 (PrgDrillUnit) block calls the FB 30 (Units) block, which in turn calls the FB31-FB33 blocks, therefore the blocks FB2 FB30 and FB31 have to have diagnostics capability.

7. Right click on the FB30 block and select the “Object properties” menu command.

8. Click the “Attribute” tab and enter the “S7_pdiag” attribute and “true” as value. Afterwards confirm the dialog box with “OK”.

9. Repeat the steps 7 and 8 for the FB2 block.

10. Since the supplementation of the diagnostics also makes changes on the data block, all involved blocks (starting from the lowest level) have to be updated. Right click the block folder and click the “Check block consistency” menu command. Note: If you have not compiled S7-PDIAG beforehand, you will receive warnings for S7-PDIAG. You can ignore these warnings.

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Step Instruction

11. In the menu bar click “Program” > “Compile all” and afterwards close the dialog. Notes:

The control program is now being completely compiled.

If you are using formal operands in the message texts, you will receive warnings that these operands are not substituted. You can ignore these warnings.

S7-PDIAG will also be compiled. The blocks FB44, DB44, FB45 and DB45 are used or created for the process diagnosis. If you want to use other block numbers, proceed as follows: – in the SIMATIC manager click the block folder of the controller and click “Options” >

“Configure process diagnostics” in the menu bar. – in the menu bar click “Process diagnostics” > “Generate instances”. – change the block numbers. Confirm the settings with “OK” and repeat this step 11.

5.2.2 Configuration of motion screens

Table 5-16

Step Instruction

1. In the SIMATIC manager click the block folder of the controller and click “Options” > “Configure process diagnostics” in the menu bar.

2. In the tree view of the S7-PDIAG editor open the path “S7-Program(1)” > “Instances (DBs,FBs, OBs”) > “Standard Group” > “DrillUnit” > “DrillUnit.Units” > “DrillUnit.Units.Feed”.

Right click the “DrillUnit.Units.Feed.Motion” motion and click the “Motion screen” menu command.

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Step Instruction

3. Enter the following data in the dialog. 1. Name of direction (“Lower” and “Raise”). 2. Operand for the directional movement as absolute address (“E2.0” and “E2.1”, are

replaced by the symbol) or as (“T_Drill_Lower” and “T_Drill_Raise”) symbol. 3. Name of end position (automatically copied in the example or marked green when

reaching the motion screen).

4.14.1

4.14.2

4.3

The configured motion in the ProAgent motion screen is displayed as shown below.

4. Click the “’Accept” button to maintain the final representation of the motion screen and confirm

the settings with “OK” afterwards.

5. In the menu bar click “Process diagnostics” > “Compile all”. Note: Previously appearing warnings for S7-PDIAG and for the formal operand have now been removed.

6. Close the S7-PIDAG editor.


Configuration

5.3 Configuration of sequence monitoring


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The seventh to eight simulated error state on the WinCC flexible interface creates error states to which the configured sequence monitoring functions interlock and supervision react in certain steps.

Definition

An Interlock is a programmable condition for step interlocking which has an influence on the execution of individual actions. Actions which have the characters “[C]” as supplement are not executed in the case of an interlock error. The step itself remains active.

Supervision is a programmable condition for step monitoring which has an influence on the advancing from one to the next step. If a supervision error occurs then advancing in the next step is blocked. The step itself remains active.

Control program

The FB3 (“Prg_Seq_DrillUnit”) function block contains the S7-Graph sequence and is called by the FB2 (“Prg_DrillUnit”) block. The following instructions shows the configuration of the supervision and of the interlock conditions of step 7 (“Cooling”) of the sequence as an example.

Monitoring task

In step 7 the coolant pump and the extractor pump is switched on. The step is left again when the setpoint pressure of the coolant has been reached.

The following is to be monitored and displayed:

Interlock condition (= step interlocking) in step 7 (“Cooling”) The actions in this step are to be carried out when the safety screen is closed or the system is traversed in manual mode. In addition, the general release process still has to be present. If the conditions are not fulfilled, the interlock error message is automatically triggered.

Supervision (=step monitoring) in step 7 (“Cooling”) If the target pressure is not reached within 5 seconds, a coolant pump error is assumed. As soon as the supervision condition reacts, the error message is triggered and advancing to the next step is blocked. The error has to be explicitly released via the display device again.

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5.3.1 Configuration of the interlock condition

Table 5-17

Step Instruction

1. Open the S7-Graph block (FB3) which contains the sequence. Doubleclick the step (step 7) in which the interlock condition is to be inserted.

2. Mark the wildcard for the interlock and click the icon for an AND link on the left icon bar.

2

2

1

Note: Only the usable functions are displayed in the icon bar. The following logic links are available for the interlock:

AND link

OR link

Comparator

3. Enter the “Rel_General” signal as operand and mark the AND link.

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Step Instruction

4. Click the “Bin. Input” icon and afterwards click the “OR link” icon.

23

4

4

Note: A configured interlock condition is displayed as “C” next to the step icon.

5. Enter the “Guard_Close” signal in the upper operand and enter the “M_Manual” signal at the lower operand. Note: the sequence of the signals entered also specifies the sequence of the signals which you can use as signals causing the error in the messages.

6. Save S7-Graph and continue with chapter Configuration of the interlock and supervision messages

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5.3.2 Configuration of the supervision condition

Table 5-18

Step Instruction

1. Open the S7-Graph block (FB3) which contains the sequence. Doubleclick the step (step 7) in which the interlock condition is to be inserted.

2. Mark the wildcard for the supervision and click the icon for “Supervision time T” on the left icon bar.

2

2

Note: A configured supervision condition is displayed as “V” next to the step icon. Only the usable functions are displayed in the icon bar. For the interlock the following logic links are available:

AND link

OR link

Comparator

Supervision time T (active time of step, without the time of an enabled interlock)

Supervision time U (active time of step, with the time of an enabled interlock)

3. Change the time “T#100MS” to the value “T#5S” and save the S7-Graph.

5.3.3 Configuration of the interlock and supervision messages

The interlock and supervision messages cannot be configured for certain steps but apply for the entire sequence. However, with the formal operands further information can be displayed in the message text which makes a specific identification of the error possible.

The compilation of the formal operands can be found in chapter Further Notes, Tips and Tricks, etc.

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Table 5-19

Step Instruction

1. Open the S7-Graph block (FB3) which contains the sequence. In the menu bar click “Options” > “Block settings…”.

2. Click the “Compile / Save” tab and enable the “Criteria analysis data in DB” radio button in the “Sequencer Properties” group.

3. Click the “Messages” tab and afterwards click the “Edit” button.

4. Click “GRAPH7_INTERLOCK-ERROR” in the tree view and click “General Data”.

5. Enter the message text for the interlock error with the parameters and the information text (not used in the example) belonging to the message in the “Text” column.

4 4

5

Note: The description of the formal operands can be found in chapter #.

6. Click “GRAPH7_SUPERVISION_FAULT” in the tree view and click “General Data”.

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Step Instruction

7. Enter the message text for the interlock error with the parameters and the information text (not used in the example) belonging to the message in the “Text” column.

6 6

7


8. Confirm the dialog box with “OK”. In the “Block settings” dialog click the “Process Diagnostics” tab.

9. In this tab the sequence can be assigned a function block (with DB). For this reason the sequence is not displayed as a separate unit in ProAgent. In this application the sequence was assigned to simulation (FB10, no diagnostics capability) so that the sequence remains intact as a separate unit. Enter the block numbers which contains the functions with which the sequence is controlled in the input fields and confirm the dialog with “OK”.

10. Save and close the S7-Graph block.

Configuration

5.4 Configuration of ProAgent


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5.4.1 Integrating standard ProAgent screens in WinCC flexible

Standard ProAgent screens offer already default pictures with all available diagnostics options and can be adjusted if need be. An extensive description of the screens can be found in the WinCC flexible ProAgent Manual.

The standard proAgent screens have to be copied from the ProAgent sample project to your own WinCC flexible project.

If you have already integrated the standard ProAgent screens in WinCC, you can skip the instruction in the table below.

Table 5-20

Step Instruction

1. Right click “SIMATIC HMI Station (1)” > “WinCC flexible RT” in the tree view of the SIMATIC Manager and click the “Open object” menu command. The WinCC flexible project is opened.

2. Go to the SIMATIC Manager, click “File” > “Open” in the menu bar and click the “Sample projects” tab.

3. Mark the ProAgent sample project “WinCC_fl” and confirm with “OK”.

4. Right click “MP377_12” > “WinCC flexible RT” and click the “Open object” menu command. The WinCC flexible project of the ProAgent sample project is opened, thus two projects are open now.

5. Open the “Screens” file in the project window and drag all screens starting with “ZP_” via “Drag&Drop” consecutively to the “Screens” file in the project window of your project. The screens are now copied in your project.

Drag&Drop

6. Afterwards close the ProAgent sample project.


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5.4.2 Generating and compiling ProAgent

Table 5-21

Step Instruction

1. Right click the “Diagnostics” file in the project window of WinCC flexible and click the “Generate” menu command.

2. In the “Diagnostics” folder doubleclick the “ProAgent” entry. The ProAgent settings window is opened in the active window.

3. Disable and enable the field before the name of the controller (“Steuerung_1”).

3

All S7-PDIAG settings have been updated.

Note As soon as any changes are made in the STEP7 project, the ProAgent settings have to be regenerated and compiled again.

The states of the projects in the controller and of WinCC flexible have to be identical; otherwise the diagnostic data is not displayed properly.


6.1 Preparation


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Startup of the Application 66.1 Preparation

Table 6-22

Step Instruction

1. Copy the “WinCCflex_Diag_Drill.zip” file in a separate folder.

2. Open the SIMATIC Manager and close all opened projects.

3. Click “File” in the menu bar and click the “Dearchive” menu command.

4. Navigate to the filing location of the “WinCCflex_Diag_Drill.zip” file in the open dialog, mark this file and click “Open”.

5. Navigate to the target directory of the application in the open dialog and click “OK”. The project is unzipped in the target directory. Note: The standard project file of STEP 7 is already preselected as target directory.

6. Confirm the “Data stored in project directory…” information with “OK”.

7. Click “Yes” in the following dialog to open the application.

6.2 Commissioning

Compiling and loading control program

Table 6-23

Step Instruction

1. Open the project structure in the tree view of the SIMATIC Manager.

2. Right click the block folder of the controller and click the “Check block consistency” menu command.

3. In the open dialog click “Program” > “Compile all” and close the dialog afterwards.

4. Mark the block folder of the controller and click “Options” > “Configure process diagnostics” in the menu bar of the SIMATIC manager.

5. Click “Process Diagnostics” > “Create Instances” in the open dialog and afterwards click “Process Diagnostics” > “Compile All”. After the compilation close the dialog.

6. In the menu bar click “Options” >”Simulate module”, to open PLCSIM. Note: When you insert a hardware CPU, proceed as follows:

Load the program in the controller (described in step 10) and start the controller.

Proceed with step 11.

7. Enable the “Select CPU node” option in the dialog of PLCSIM and confirm with “OK”.

8. Then mark the connection “MPI/DP” > “MPI(1) adr:2” and confirm with “OK”.

9. Go to the SIMATIC manager and mark the “SIMATIC 300(1)” control project.

10. Click “PLC” >”Download” in the menu bar of the SIMATIC manager and confirm the following dialog with “Yes”.

11. Go to PLCSIM and click “Execute” > “Key switch position” > “Run” in the menu bar to start the controller.


6.2 Commissioning


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Compiling WinCC flexible and starting Runtime

Table 6-24 Step Instruction

1. Open WinCC flexible: Right click “SIMATIC HMI Station(1)” > “WinCC flexible RT” in the tree view of the SIMATIC Manager and click the “Open object” menu command. The WinCC flexible project is opened.

2. Check Connection Open the connectons via menu tree “Communication > Connections”. Check if the panel is connectet wirth the station. Is the connection dispöayed as “not connected” follow the next steps.

Commissioning Connection - Right click in the tree view of SIMATIC Manager on “SIMATIC HMI Station(1)” and click on

menu entry “open object”. The SIMATIC HMI Configuration will open.

- Open the properties of the interface “IF1B MPI/DP” via double click. Select the interface (in this case “MPI” and open the properties of interface by clicking the button “Properties…”.)

- Select the corresponding network (MPI) and finalize by clicking the OK button. - Close the window “Properties – IF1B MPI/DP” by clicking OK. - Use the function “”save and compile” of the menu bar.

(Station > Save and compile) Close the contiguration. - Change to WinCC flexible engineering window.


6.2 Commissioning


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Step Instruction

3. Delete temporary files In the menu bar of WinCC flexible click “Options” > “Delete temporary files”.

4. ProAgent Diagnostics In the “Diagnostics” folder doubleclick the “ProAgent” entry. The ProAgent window is opened in the active window.

5. Compile project new Disable and enable the field before the name of the controller (“Steuerung_1”).

The files will be updated.

6. Start Runtime Subsequently click the “Start Runtime” icon in the icon bar.


7.1 Overview


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Operating the Application 77.1 Overview

The sample application is operated from the WinCC flexible interface and the model state is displayed. Furthermore, error states are also triggered by the WinCC flexible interface.

Figure 7-27

The interface consists of three areas:

Visualization part (left screen area). Here, the individual aggregates and the process sequence are displayed dynamically.

Error simulation part (right screen area): Here, different error scenarios can be triggered in different plant states via the simulation program in the STEP7 program. The error scenarios are dealt with in the following chapters.

Operating device (lower screen area): This is where:

– the operating mode of the system can be set,

– the plant can be brought in an initial state with “Init Demo”,

– a process cycle can be started via “Insert/remove part”, “Close/open safety screen” and “Start”,

– the process diagnostic standard screens can be called,

– the display language can be changed (German and English) and

– the application can be exited.


7.2 Description of fault-free process


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7.2 Description of fault-free process

If all components of the demo example are installed and started, a drilling process can now be “executed”. To do this, proceed as follows.

Table 7-25

No Instruction

1. Click the “Reset Demo” button to bring the systems in a defined initial status (all errors disabled, coolant off, automatic mode).

2. Click “Insert part” to insert a part.

2 1

3. Click “Close safety screen”. The “Remove part” button is disabled.

4. Alternatively click the “on/off” button to switch on the cooling of the part during the drilling process.

5. Click “Start” to start the drilling process

3 5

(4)

The process is starting.

Clamping pressure is building up.

The drill motor is reaching target speed.

The coolant pressure is building up when the coolant was switched on.

The feed is activating the drilling process.

The clamp is releasing the part again.

6. When the drill is back in the upper position, click “Open safety screen” and subsequently “Remove part” to finish the drilling process.

7. Repeat the steps 2-6 for another drilling process.


7.3 Simulation of operand errors (criteria analysis)


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Definition

An operand monitoring function is created on a signal or on an assignment to a network of the control program.

Error description

Error states in the system occur in the central pneumatic, hydraulic and power supply. Due to the simulation each one of the signals is “forced” to leave the target state.

Monitoring

With S7-PDIAG the following is monitored:

the central release process for the plant (Sys_Release, FB20 NW4) and

an individual important voltage value which is displayed as associated value in the message.

It is the job of diagnostics to quickly find the cause of the failure.

Simulation process of operand errors (criteria analysis)

This error can be triggered at any time in the process sequence of the drilling unit.




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Table 7-26

No Instruction

1. Trigger the error “pneumatic, hydraulic, voltage failure”.

2. Triggering the error is displayed by a red background on the buttons. The message system reacts with an acknowledgeable message in a pop-up window. In the plain message display the signals triggering the error are already named in the sequence of their appearance. Acknowledge the two messages and go to the process diagnostics screen by clicking the “Process diagnostics” buttons.

2

2

3. Click the “F14” button to open the message screen.

3




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No Instruction

4. You will see all pending messages in plain text with status and time stamp in the message screen. The “*” at message 5, tells you that the message has “diagnostics capability”, i.e. further criteria analysis is possible. Click the “F11” button to open the overview screen

4

5. In the overview screen the unit in which the error occurred is marked (here the “Releases”

unit). Click the unit causing the error and click the “F12” button to open the detailed screen.

5




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No Instruction

6. The detailed view provides the following in the first view…

information on the faulty unit (DB/FB) and

a list with information of possible signals causing the error. Click the “F8” button to open the criteria analysis and afterwards click the “F7” button to additionally display the signals not causing the errors.

6

6

On the basis of the criteria analysis you can quickly and easily find out that the releases “Voltage_1_OK”, “Hydraulic_2_Ok” and “Pneumatic_1_Ok” are faulty. Subsequently you can introduce measures to remove the faults.

7. Click the “F19” button to exit process diagnostics and click the buttons marked red under “Operand monitoring” to remove the error.

Summary

This is the information you received from the process diagnostics in this case:

the error is located in the “Releases” unit, which belongs to the superior unit “DrillUnit”.

The faulty signals are:

– E8.0 -> voltage subunit 1

– E8.6 -> hydraulic subunit 2

– E8.3 -> pneumatic subunit 1


7.4 Simulation of general monitoring


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Definition

In general monitoring the project engineer defines an independent monitoring logic which links any signals from the PLC according to defined rules.

Error description

The extraction of superfluous coolant is monitored. Possible pollutions could block the drain which could lead to an increase of the level in the drip pan, despite running extractor pump during coolant selection in automatic mode which will eventually trigger the maximum sensor.

Monitoring

An individual connection logic monitors the automatic mode, the maximum sensor and the feedback of the extractor pump.

The general monitoring is configured on the “Drilling_Run” (FB2, NW5) signal.




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Simulation process

Table 7-27

No Instruction

1. Trigger the “Extraction system blocked” error and start the system as described in the display language can be changed (German and English) and .

2. Triggering the error is displayed by a red background on the buttons. As soon as the plant switches on the coolant supply, the drip pan will fill up slowly until the monitoring conditions are fulfilled.

Acknowledge the message.

Alleviate the error if the drill motor is no longer running by clicking on the “Extraction system blocked” button again.

1, 2

2

3. Click the “Manual” button to change to manual mode and subsequently click the “Process

diagnostics” button. Note: Since the error was removed again there is no error detectable in the subsequent process diagnostics. Normally you would now have to perform a diagnosis of the error and afterwards alleviate the error. These steps are skipped at this point.

4. Click the “F11” button in the ProAgent splash screen and click the “IDB_DrillUnit” unit which has caused the error.




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No Instruction

5. The extractor unit is implemented as motion in the configuration. This is why there is automatically a manual operator screen. Go from the diagnostics start page to the motion screen with the “F13” button.

4

4

5

6. Mark the motion of the “IDB_DrillUnit.Units.ExtractionUnit.Motion” extractor unit and hold the

left button of this line pressed until the pan is emptied (Oilpan_Min marked green). This is how you pumped the oil pan empty in manual mode.

6

7. Click the “F19” button to get back to the process screen.

The process is now in step 6 of the sequence. Proceed as follows to get back to the initial state.

Go to automatic mode.

Open the safety screen.

Remove the part.

Summary

This is the information you received from the process diagnostics in this case:

the error is located in the “Units” unit.

with the motion screens, the container on the drip pan can be pumped empty in manual mode after the removal of the causes.


7.5 Simulation of motion errors (sequence synchronization)


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There also are also four simulation cases to the four motion monitoring types. Below, you will find a detailed explanation of the action monitoring with subsequent manual traversing and sequence synchronization. Additionally, there will be a brief description of the remaining cases.

Definitions

If a motion does not reach its end position after a fixed period of time despite correct control and approach then there is an action error.

If a motion does not start from your start position (but all requirements are fulfilled), then there is a startup error.

If the end position is left despite pending control in this direction then there is a response error.

If the necessary interlocks are no longer fulfilled for the motion direction then there is an interlock error.

7.5.1 Action monitoring

Error description

The drill feed is blocked. For example, through a mechanical fault in its motion phase or the limit switch supplies incorrect signals.

Monitoring

The “Final_Position[0]” (FB31, NW3) signal of the UDT2 (Motion) is monitored. The action error is triggered if the end position is not reached within 10 seconds after starting to lower the drill motor.




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Simulation process of action monitoring - diagnostics

Table 7-28

Step Instruction

1. Trigger the “Feed limit switch defective or mechanism sluggish” error and start the drill process as described below under the display language can be changed (German and English) and . The error is detected and triggered at the end of the feed motion of the drill motor.

2. Ten seconds after starting the feed in the direction “lower”, motion monitoring will report the location and the cause of the fault in plain text. Acknowledge the message and click the “Process diagnostics” button.

1

2

2




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Step Instruction

3. In the ProAgent splash screen click the “F11” button to detect the unit causing the error and mark this unit.

3

3

4. Click the F12 button to detect the signal causing the error and click the “F8” button twice to

select the LAD display.

33

5. Click the “F19” button to get back to the operator screen.




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Simulation process of action monitoring – manual traversing and sequence synchronization

Table 7-29

Step Instruction

1. Click the “Manual” button to go to the “Manual mode”.

2. - Alleviate the error by clicking the “Feed limit switch defective or mechanism sluggish” button and click the “Process diagnostics” button.

1

2

2

3. Click the “F11” button in the ProAgent splash screen and mark the “IDB_DrillUnit” unit to

operate the system in manual mode.

3

33

Note: When the unit is not listed, click (possibly several times) the “F2” button to get to the top level.




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Step Instruction

4. Click the “F13” button and hold down the right button of the “DrillUnits.Units.Motion” motion until the “D_Up” operand is marked green (approx. 7 seconds). The feed is now again in the upper position.

3

4

4

Note: During the “DrillUnit.Units.Clamp. Motion” motion the “CLMP_Open” operand is marked green, i.e. the clamp has opened through the “manual” operating mode.

5. Click the “F11” button and mark the “Seq_DrillUnit” unit to synchronize the changed plant state with the sequence.

5

5




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Step Instruction

6. Click the “F15” button and mark the active step 4 (S4) in the table view.

6

6

7. Click the “F7” button to disable step 4 (S4). Step 4 is no longer suitable for the continuation of

the automatic function since the clamp is open.

8. Mark step 2 (S2) and click the “F8” button to enable step 2. In this step the clamp is closed again.

8

87

Note: The sequence is in manual mode this is why step 2 is not yet performed.

9. Click the “F19” button to go to the operator screen and click the “Automatic” button to continue the drilling process.




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Summary of action error

You have…

localized the feed error (limit switch),

moved the aggregate back to a defined position after alleviating the error (in manual mode),

synchronized the sequence again with the process.

7.5.2 Startup monitoring

Error description

The feed of the drill motor is blocked in the upper position or the upper limit switch is defective and continues to supply the signal “Upper end position reached” after having left the end position.

Monitoring

The “Final_Position[1]” (FB31, NW4) signal of the UDT2 (Motion) is monitored. The startup error is triggered if the end position is not left within 1.5 seconds after starting to lower the drill motor.

The simulated process supplies the startup error and as subsequent error the action error.

Simulation process

The error is enabled with the “Feed jams in upper position” button.

After starting the drilling process (described under the display language can be changed (German and English) and

) the error is triggered as soon as the feed is enabled in the “Lower” direction.

Afterwards a criteria analysis [described under Simulation of operand errors (criteria analysis)

] is performed to detect the error.

With the alleviation of the error, the drilling process is continued.

7.5.3 Response monitoring

Error description

Once the clamp has reached the target pressure during the clamping of the part, the target pressure will fall again by a certain value. This can, for example, be caused by the breakage of a part or a defect of the clamp.

Monitoring

The “Final_Position[0]” (FB32, NW2) signal of the UDT2 (Motion) is monitored. If the end position 1 is left 1.5 seconds after reaching the target pressure, the response error is triggered.

The simulated process supplies the response error and as subsequent error the interlock error of the sequence.

Simulation process

The error is enabled with the “Clamping device can’t hold end pressure” button.

After starting the drilling process (as described under the display language can be changed (German and English) and




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) the error is triggered as soon as the clamp has reached the target pressure and starts falling again.




7.5.4 Interlock monitoring

Error description

The motor circuit breaker of the drilling motor is tripped due to a fault on the drill motor.

Monitoring

The “Motion.Executability1” (FB32, NW6) signal of the UDT2 (Motion) is monitored. If the interlock signal for the motion is pending for more than 2 seconds, the error is triggered.

Simulation process

The error is enabled with the “Drill motor interlock Overheating” button. After starting the drilling process (as described under the display language can be changed (German and English) and

) the error is triggered as soon as the drill motor started.



7.6 Simulation of sequence errors


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As described in chapter “Monitoring with S7-GRAPH (procedures for generation time)

”, S7-Graph has implicit possibilities for monitoring the sequence. These are only configured in the S7-Graph editor itself and supply an automatic error text generation.

7.6.1 Interlock error

Definition

An interlock is a programmable condition for step interlocking which has an influence on the execution of individual actions. Actions which have the characters “[C]” as supplement are not executed in the case of an interlock error. The step itself remains active.

Error description of interlock error

The safety screen is opened during a running drilling process.

Monitoring

The “Guard_Close” signal is used as interlock condition in the following steps:

S2 (Clamp)

S3 (Drilling motor)

S7 (Cooling)

S4 (Lower)

S9 (Lower_Stop)

S5 (Raise)

Simulation process

This error is not triggered by an independent button. During the entire drilling process the safety guard can be opened with a click on the “Open safety guard” button.

As soon as the safety guard is opened during the running drilling process, an error is triggered and displayed on the right side. Depending on the plant state, follow-up messages can still be triggered.



With the removal of the interlock error, the drilling process is continued but follow-up messages can stop the continuation of the drilling process.




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7.6.2 Supervision error

Definition

A supervision is a programmable condition for step monitoring which has an influence on the advancing from one step to the next. If a supervision error occurs, advancing (from this step to the next step) is blocked. The step itself remains active.

Error description

Due to a leakage in the coolant supply, the cooling pump cannot reach the target pressure.

Monitoring

The execution time of step S7 (Cooling) of the sequence is monitored as supervision condition. If the step is enabled for more than five seconds, the error is triggered.

The “CLT_P Ok” signal (cooling pressure reached) was furthermore used as interlock error in step S4 (Lower) of the sequence.

Simulation process




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Table 7-30

Step Instruction

1. Click the “Cooler pump pressure not reached” button and start the drilling process with cooling. (As described under the display language can be changed (German and English) and .)

2. Five seconds after the coolant pump was switched on automatically, the supervision message is triggered. The cooling pressure only reached the value 380; the value of the target pressure is 400. The supervision message reports the location and cause of the fault in plain text. Acknowledge the message and click the “Process diagnostics” button.

1

2

2




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Step Instruction

3. In the ProAgent splash screen click the “F11” button and mark the “Seq_DrillUnit” unit causing the error.

3

2

4. Click the “F15” button to open the sequence screen.

In this screen you see the following information: 1. left, upper table: active step causing the error (No. 7 “Cooling”). 2. right side: graphic display of the sequence.

The step and the “V” icon (supervision) left, next to the step was marked (red) as causing the error.

3. left, lower table: signal causing the error (with operand, icon, comment and status at the time of error).

4.2.

4

4.1.

4.3.




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Step Instruction

5. Click the “F19” button to get back to the process screen. Remove the fault. Note: The sequence is not automatically continued.

6. Click the “Process diagnostics” button and click the “F15” button in the ProAgent splash screen to open the sequence screen once again.

7. Click the “F10” button to continue the sequence with step 4 (Lower).

7

8. Click the “F19” button to get back to the process screen.

Further Notes, Tips and Tricks, etc.


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Further Notes, Tips and Tricks, etc. 8Formal operands which are replaced during the generation of S7-PDIAG

The table below represents only a selection of formal operands. A complete list and description can be found in the S7-PDIAG manual

Table 8-31

Operand Description

$$CpuName$$ Name of the configured CPU. If no CPU was configured, the formal operand continues to exist and will not be substituted during the generation process.

$$ur$$ Name of the top unit within a tree structure.

$$u$$ or $$u1$$ to $$u9$$

Name of the superior unit and/or the respectively superior unit. Example: in the S7-PDIAG tree structure with subordinate units, the name of the second level is displayed from the fifth level by $$u3$$.

$$m$$ Name of the motion

$$o$$ Diagnostics Entry Operand (DEO) of the instance error definition (icon display, if there is no symbol in absolute display).

$$s$$ Diagnostics entry operand in symbol display.

$$a$$ Diagnostics entry operand in absolute display.

$$c$$ Symbol comment on diagnostics entry operand Note: In the message text, you can display the formal operand as symbol comment from the symbol table.

$$d1$$ to $$d16$$ Name of motion direction

Further Notes, Tips and Tricks, etc.


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Formal operands which are displayed when the message is displayed

You can specify the position and display format of the associated value. Compile a description block for the associated value with the following structure:

Figure 8-28

Table 8-32

Component Description

@ Beginning and end of the formal operand

a Number of the associated value (1-9)

b Data type of the associated value X = BOOL, BYTE, WORD, DWORD, INT, DINT C = Char R REAL

% Start of formatting.

d.e Number of characters (optional) dd = Total number of characters (incl. decimal points) ee = Number of fractional digits

f Display format of the associated value d = Decimal signed u = Decimal unsigned x = Hexadecimal b Binary f = Fixed point number s = Character

Example: @1R4.2f@

The first associated value (REAL) of a message is displayed with 4 characters. Out of the 4 characters 2 characters are fractional digits. The associated value is displayed as fixed point number. The value 5.4 is displayed as 5.40.

Wild cards in messages text

Table 8-33

Operand Description

@ErrOpAll@: Absolute operands, icons and comments of all faulty operands.

@ErrOpAbs1@ Absolute address of 1st faulty operand.

@ErrOpSym1@ Icon of 1st faulty operand.

@ErrOpCom1@ Comment of 1st faulty operand.

@ErrOpSta1@ For the status of the faulty unit (0 or 1).

@ErrOpDes1@ For the status of the faulty unit (system message: “Signal does not have to be” or "Signal has to be").

Literature


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Literature 99.1 Bibliography

This list is by no means complete and only presents a selection of suitable literature.

Table 9-34 Bibliographic references

Subject Title

/1/ STEP7 Automating with STEP7 in STL and SCL Hans Berger Wiley-VCH ISBN 3-89578-341-2

9.2 Internet Link Specifications

This list is by no means complete and only presents a selection of suitable information.

Table 9-35 Internet links

Topic Title

\1\ Reference to the entry


\2\ Siemens I IA/DT Customer Support

http://support.automation.siemens.com

\3\ Manual S7 PDIAG


\4\ Manual WinCC fexible ProAgent


\5\ Manual S7 GRAPH



http://support.automation.siemens.com/�




History


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History 10Table 10-36 History

Version Date Modification

V1.0 20.01.2003 First issue

V2.0 14.12.2009 Changes:

Change of visualization from ProTool to WinCC flexible

Changes to simulation blocks

Changes on cause of drilling process

Changes on message trigger

Documents

Applications & Tools...Further Notes, Tips and Tricks, etc. 8 Literature 9 History 10. Warranty and Liability 4 ... - WinCC flexible 2008 - WinCC flexible ProAgent - (optional: WnCi