Diagnostics in User Program with S7-1500 STEP 7 (TIA Portal), S7-1500

Application Description 09/2014

Diagnostics in User Program with S7-1500

STEP 7 (TIA Portal), S7-1500

http://support.automation.siemens.com/WW/view/en/98210758

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Diagnostics in User Program with S7-1500

Entry ID: 98210758, V1.0, 09/2014 2

Table of Contents

Table of Contents

8

9

3

4

Warranty and Liability ................................................................................................. 2

1 Task ..................................................................................................................... 4

2

1.1

1.2

Overview............................................................................................... 4

Requirements / Scenarios .................................................................... 5

Solution............................................................................................................... 6

5

2.1

2.2

2.2.1

2.2.2

Solution overview ................................................................................. 6

Hardware and software components ................................................... 8

Validity .................................................................................................. 8

Components used ................................................................................ 8

Basics ............................................................................................................... 11

Function Mechanisms ..................................................................................... 12

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

General overview ............................................................................... 12

Global data block DiagDataDB [DB6] ................................................ 14

Function block DiagStartupFB [FB100] .............................................. 18

Function block DiagMainFB [FB1] ...................................................... 20

Function block DiagDevicesFB [FB2] ................................................. 22

Function block DiagSignalFB [FB4] ................................................... 25

Function block DiagUsrMsgFB [FB5] ................................................. 27

Function block DiagPNIOFB [FB3] ..................................................... 29

Configuring the HMI Screens ......................................................................... 31

6

7

5.1

5.2

Configuring a device in the plant overview......................................... 31

Configuring a device in the detail view ............................................... 34

Installation and Commissioning .................................................................... 36

6.1

6.2

6.3

6.4

6.5

6.6

6.6.1

6.6.2

6.6.3

Installing the hardware ....................................................................... 36

IP addresses and device names ........................................................ 36

Installing the software (download) ...................................................... 37

Assigning PROFINET device names ................................................. 38

Loading the project ............................................................................. 39

Integrating the application into an existing project ............................. 40

Configuring the diagnostic settings .................................................... 40

Integration of the PLC elements ......................................................... 40

Integration of the HMI elements ......................................................... 43

Operating the Application ............................................................................... 44

7.1

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.3

7.3.1

7.3.2

Overview............................................................................................. 44

Diagnostics on the operator panel ..................................................... 45

Diagnostics “Value status on AI8” ...................................................... 45

Diagnostics “Wire break on the DI module of the ET 200SP” ............ 46

Diagnostics “Supply voltage missing on the DI module of the

ET 200MP” ......................................................................................... 47

Diagnostics “Overtemperature on G120 drive” .................................. 48

Diagnostics in the TIA Portal .............................................................. 49

Diagnostics “Value status on AI8” ...................................................... 49

Diagnostics “Wire break on the DI module of the ET 200SP” ............ 50

Related Literature ............................................................................................ 52

History............................................................................................................... 52


Entry ID: 98210758, V1.0, 09/2014 3

1 Task

1.1 Overview

1 Task

1.1

Overview

Introduction

The diagnostics of devices, modules and networks play an ever-increasing role in automation technology. By diagnosing with a user program, faulty modules can be detected. This enables you to also program responses to diagnostic messages, such as, for example, that your plant is stopped in the event of certain diagnostic messages.

Note When diagnostic information is displayed on different visualization devices and not used in the user program, it is generally recommended to use the integrated system diagnostics of the S7-1500 controllers (see System Diagnostics with S7-

1500 and TIA Portal ).

Please note that the integrated system diagnostics also work in the “STOP” mode of the S7-1500 controller. This is not possible with the manual diagnostics in the user program.

Overview of the automation task

The figure below provides an overview of the automation task.

Figure 1-1

Controller

Diagnostic information

HMI

Fault Fault Fault Fault

PROFINET IE

IO-Device 1 IO-Device 2 IO-Device 3 IO-Device n

Description of the automation task

The automation tasks consists of monitoring a PROFINET IO distributed system with different network components. It is to guarantee the possibility of individual diagnostics of the devices and components. The user program takes on the system diagnostics of the plant with the help of the integrated diagnostic instructions. The diagnostic information detected is displayed on an operator panel.


Entry ID: 98210758, V1.0, 09/2014 4

1 Task

1.2 Requirements / Scenarios

1.2

Requirements / Scenarios

Requirements of the automation task

With the application, the programmer is to get an introduction to system diagnostics via the user program.

Apart from the integrated system diagnostics, a series of instructions for system diagnostics is provided in the user program with the TIA Portal. Based on an example, this application is to help you to describe the functions and the use of the diagnostic instructions to the plant programmers.

Scenarios

The example for the use of the diagnostic instructions is divided into different scenarios.

User-defined alarm, based on the evaluation of the value status (quality information) on the AI module of the CPU S7-1516

Wire break on the DI module of the ET 200SP

Missing supply voltage on the DI module of the ET 200MP

Overtemperature on the SINAMICS G120 drive


Entry ID: 98210758, V1.0, 09/2014 5

2 Solution

2.1 Solution overview

2 Solution

2.1

Solution overview

Schematic layout

The following figure displays the most important components of the solution:

Figure 2-1

Fault

STEP 7 S7-1500

Diagnostic information

HMI

Fault Fault Fault

PROFINET

Industrial Ethernet

ET 200SP ET 200MP G120

Setup

The different distributed I/O devices are connected with a S7-1500 controller via

PROFINET. The devices detect the faults on their modules and send the diagnostic data to the respective controller. The controller evaluates this diagnostic information with the help of the diagnostic instructions in the user program. The operator panel displays evaluated information graphically in a plant overview or in the respective device view.

Note The diagnostics described here in the user program can also be used for

PROFIBUS systems.


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2 Solution

2.1 Solution overview

Delimitation

This application does not include a description of the integrated system diagnostic.

This application does not contain a complete discussion of all diagnostic possibilities with the user program. The extension of the present code by the user is therefore possible and necessary.

This application does not include a detailed description of the diagnostic instructions.

Note A more detailed description on the diagnostic instructions is available in the TIA

Portal V13 online help or in the System Manual STEP 7 Professional V13.0

.

This application does not include a description of the diagnostic instructions of

S7-1200 controllers.

Basic knowledge of these topics is assumed.

Required knowledge

Basic knowledge of the following issues is assumed:

STEP 7 V13

WinCC V13

STEP 7 block architecture and programming

PROFINET-IO


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2 Solution

2.2 Hardware and software components

2.2

2.2.1

2.2.2

Hardware and software components

Validity

This application was tested with

STEP 7 V13 Update 5

S7-1500 V1.6

Components used

The application was generated with the following components:

It is recommended to perform the hardware configuration with the TIA Selection

Tool: http://www.siemens.com/tia-selection-tool

Note The hardware and software products used can also be found in the file in the

“98210758_User_defined_diagnostics_PRODUCTS_v10.zip” archive folder. Use the TIA Selection Tool for this purpose.

Since not all products were yet available in the TIA Selection Tool at the time of creation, all articles which are not yet available in the TIA Selection Tool are marked “gray” in the following list.

Hardware components

Table 2-1

Component

CPU 1516-3 PN/DP

Memory card,

12 Mbytes

Digital input,

DI 32x24VDC HF

Front connector, screw terminal, 40-pin

Digital output,

DQ 32x24VDC/0.5A ST

Analog input,

AI 8xU/I/RTD/TC ST

Front connector, push-in technology, 40-pin

2

1

1

1

1

1

No.

1

Article number Note different CPU

S7-1500 can be used.

6ES7954-8LE02-0AA0

6ES7521-1BL00-0AB0 Diagnostics can be configured

6ES7592-1AM00-0XB0


6ES7531-7KF00-0AB0 Diagnostics can be configured

6ES7592-1BM00-0XB0


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2 Solution


Component

IM 155-5 PN ST

Digital input,

DI 32x24VDC HF

Front connector, screw terminal, 40-pin

Digital output,

DQ 32x24VDC/0.5A ST

Analog input,

AI 8xU/I/RTD/TC ST

Front connector, push-in technology, 40-pin

IM 155-6 PN ST with server module, with bus adapter 2xRJ45

DI 16x24VDC ST

No.

1

1

2

1

1

1

1

Article number Note


6ES7592-1AM00-0XB0


6ES7531-7KF00-0AB0 Diagnostics can be configured

6ES7592-1BM00-0XB0

1 6ES7131-6BH00-0BA0 Diagnostics can be configured

6ES7193-6BP00-0DA0 BU type A0, 16 push-in,

2 infeed term. separate

(digital/analog, max.

24VDC/10A)

DQ 16x24VDC/0.5A ST

1

1

1

1

1

1

6ES7132-6BH00-0BA0 Diagnostics can be configured

6ES7193-6BP00-0BA0 BU type A0, 16 push-in,

2 infeed term. jumpered

(digital/analog,

24VDC/10A)

AQ 4xU/I ST

CU240E-2 PN-F

PM340

IOP

TP1200 Comfort

SIMATIC Field PG M4

2

1

1

6ES7135-6HD00-0BA1 Diagnostics can be configured

6SL3244-0BB13-1FA0 SINAMICS G120 with

FW 4.6

6SL3110-1SB11-0AA0

6SL3255-0AA00-4JA0

6AV2124-0MC01-0AX0

(optional)

6ES7716-.....-0...

Article not in the TIA Selection Tool at the time of creating the application.


Entry ID: 98210758, V1.0, 09/2014 9

2 Solution


Standard software components

Table 2-2

Component

STEP 7

Professional V13

Update 5

WinCC Advanced

V13 Update 5

SINAMICS

Startdrive V13

Update1

1

1

1

No.

Article number

6ES7822-1..03-..

6AV210.-....3-0

6SL3072-4DA02-0XG0

Note can be downloaded for free see

\3\

Sample files and projects

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

Table 2-3

Component Note

98210758_User_defined_diagnostics_DOKU_v10_en.pdf

This document.

98210758_User_defined_diagnostics_CODE_v10.zip

This zip file includes the

STEP 7 project.

98210758_User_defined_diagnostics_PRODUCTS_v10.zip The zip file contains:

TIA Selection Tool file with hardware and software products.


Entry ID: 98210758, V1.0, 09/2014 10

3 Basics

3 Basics

Basics on system diagnostics

In the SIMATIC environment the diagnostics of devices and modules are summarized by the term “system diagnostics”. The monitoring functions are automatically derived from the hardware configuration.

All the SIMATIC products refer to integrated diagnostic functions with which you can detect and repair faults. The components automatically report a possible operational fault and supply additional detailed information. Plant-wide diagnostics can minimize downtimes.

Diagnostic instructions

There is a cross-vendor structure for data records with diagnostic information. For the determination of the system diagnostics of a device in the user program, the following instructions are available in STEP 7.

Table 3-1

Instruction

RD_SINFO

RT_INFO

LED

Get_IM_Data

GET_NAME

GetStationInfo

DeviceStates

ModuleStates

GEN_DIAG

GET_DIAG

Description

Read out start information of the current OB

Read out runtime statistics (not part of this application)

Read LED status

Read identification and maintenance data

Read out name of a module

Read out information of a IO device

Read module state information in an IO system

Read module status information of a module

Generate diagnostic information (not part of this application)

Read diagnostic information (not part of this application)

Reporting instructions

The following instructions are available in STEP 7 for creating messages in the user program.

Table 3-2

Instruction Description

Program_Alarm

Get_AlarmState

Gen_UsrMsg

Create program message with associated values

Output message state

Create user diagnostic messages

Note For more detailed information about the instructions, please refer to the TIA

Portal V13 Online Help.


Entry ID: 98210758, V1.0, 09/2014 11

4 Function Mechanisms

4.1 General overview

4 Function Mechanisms

4.1

General overview

Program overview

The following figure shows the program structure of the whole STEP 7 project.

Figure 4-1

Startup DiagStartupFB GEO2LOG Get_Name

DiagMainOB DiagMainFB LED

DeviceStates

RD_LOC_T

ModuleStates DiagDevicesFB

DiagDataDB

DiagSignalFB Program_Alarm

Diagnostic error interrupt

Pull or plug of modules

Rack or station failure

DiagUsrMsgFB

DiagPNIOFB

Gen_UsrMsg

RD_SINFO

Data block User-defined program System blocks

In the following table, all blocks of the user program are described.


Entry ID: 98210758, V1.0, 09/2014 12


4.1 General overview

The user program consists of the following elements:

Table 4-1

Symbolic name

DiagDataDB

Description

The global data block includes the data structures:

Controller

Devices with their modules

Startup

[OB100]

DiagStartupFB

[FB100]

DiagMainOB

[OB123]

DiagMainFB

[FB1]

DiagDevicesFB

[FB2]

DiagSignalFB

[FB4]

DiagUsrMsgFB

[FB5]

Diagnostic error interrupt

[OB82]

Pull or plug of modules

[OB83]

Rack or station failure

[OB86]

DiagPNIOFB

[FB3]

The startup OB calls the “DiagStartupFB” function block and transfers the structures of the global “DiagDataDB” block to the block.

The function block determines the hardware ID of the modules and the individual modules from the slot with the “GEO2LOG” instruction. The “Get_Name” instruction reads out the device name.

The cycle OB calls the “DiagMainFB” function block and transfers the structures of the global “DiagDataDB” block to the block.

In order to evaluate a digital signal, the block calls the

“DiagSignalFB” function block.

The function block evaluates the status of the error LED of the controller with the “LED” instruction. In the event of a fault, it calls the “DiagDevicesFB” function block.

The function block reads the status of the PROFINET IO devices with the “DeviceStates” instruction and therefore detects the faulty IO devices.

The “ModuleStates” instruction reads out the module status of the faulty IO devices and of the local modules of the controller.

In the block, a program message is created with

“Program_Alarm”.

The block calls the “DiagUsrMsgFB” function block.

The function block writes a user diagnostic message into the diagnostic buffer of the controller with the “Gen_UsrMsg” instruction.

The diagnostic interrupt OB calls the “RD_SINFO” instruction.

The OB is called by the operating system when a diagnosticcapable module detects a change of its diagnostic state.

The pull/plug OB calls the “RD_SINFO” instruction. The OB is called by the operating system when a configured module or submodule of the distributed IO is pulled or plugged in.

Der module rack failure OB calls the “RD_SINFO” instruction and the “DiagPNIOFB” function block. “RD_SINFO” reads the start information of the OB and transfers it to the

“DiagPNIOFB” function block.

The function block checks whether there is an error in the

PROFINET IO system.


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4.2 Global data block DiagDataDB [DB6]

4.2

Global data block DiagDataDB [DB6]

Overview

The following figure shows the structure of the global “DiagDataDB” data block.

Figure 4-2

The data block is used as interface of the application for the outside. The DB

“DiagDataDB” saves the hardware ID and the error status of the following components:

PROFINET IO system

Controller

Devices

Modules

In addition it saves the last ten errors in a buffer.

The individual tags of the components were summarized in the following structure for a better overview.

IOSystem [IOSystemStruct]

This structure includes the tags of the IO system.

Table 4-2

Tag name Data type Default value

Laddr HW_IOSYSTEM -

Meaning

ErrorState Bool -

Hardware ID of the IO system (system data type)

Error status of the IO system


Entry ID: 98210758, V1.0, 09/2014 14



PLC [PLCStruct]

This structure includes the tags of the controller and of the local modules.

Table 4-3


Meaning

ModuleNumHigh Int

DeviceIdPLC

ErrorState

SlotLaddr

SlotErrorState

HW_DEVICE

Bool

Array[0..4] of HW_IO

Array[0..4] of Bool

-

-

-

4

32

Highest Slot number of local modules

Hardware ID of the controller for module status (system data type)

Error status of the controller

Hardware ID of the local module (system data type)

The array index corresponds to the slot number.

Error status of the local modules


Note If you change the default value of „ModuleNumHigh“, you also have to adjust the two arrays.

Devices [DeviceStruct]

This structure includes the tags of the devices.

Table 4-4


DeviceNumHigh Int

ModuleNumHigh Int

3

4

ErrorLED

ErrorLEDFlash

ProblemMode

Device

UInt

Int

UInt

Array[0..3] of

DeviceSingleStruct

-

2

4

5

Meaning

Highest device number

Highest Slot number of modules

Identification number of the

ERROR LED

LED status color 1 flashes

Selection of status information to be read

See DeviceSingleStruct

The array index corresponds to the device number.

Note If you change the default value of „DeviceNumHigh“, you also have to adjust the array.


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Note If you change the default value of „ModuleNumHigh“, you also have to adjust the two arrays in “ModulStruct”.

Devices.Device[x] [DeviceSingleStruct]

This structure includes the tags of the individual devices.

Table 4-5


Laddr HW_Device -

Name

ErrorState

Module

String

Bool

ModulStruct -

-

-

Meaning

Hardware ID of the device

(system data type)

Device name

Error status of the device

See ModulStruct

Devices.Device[x].Modul [ModulStruct]

This structure includes the module tags of a device.

Table 4-6


SlotLaddr Array[0..4] of HW_IO -

Meaning

SlotErrorState Array[0..4] of Bool -

Hardware ID of the modules

(system data type)


Error status of the modules


ErrorList [ErrorListStruct]

This structure includes the tags of the error list.

Table 4-7

Tag name Data type

Index Int 0

Default value

MaxError

Error

Int

Array[0..10] of

ErrorSingleStruct

-

10

Meaning

Index indicates the last error entry

Max. Number of error entries

See ErrorSingleStruct

Note You can specify the maximum number of error entries with MaxError. If you change the value you also have to adjust the array.


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ErrorList.Error [ErrorSingleStruct]

This structure includes the tags of an error entry of the error list.

Table 4-8


ErrorState

Laddr

DeviceNr

DeviceName

SlotNr

Timestamp

Bool

HW_ANY

String

String

Int

DTL

-

-

-

-

-

-

Meaning

Error status

( 0 = outgoing, 1 = incoming)

Hardware ID of the faulty components (system data type)

Device number of the faulty device

Name of the faulty device

Slot number of the faulty module

Time stamp of the fault


Entry ID: 98210758, V1.0, 09/2014 17


4.3 Function block DiagStartupFB [FB100]

4.3

Function block DiagStartupFB [FB100]

The function block detects the hardware IDs of the components of the plant already when the controller starts up in order not to stress the running process further.

Interfaces

Figure 4-3 Call in “Startup [OB100]”

Table 4-9

Type Parameter

InOut IO_System

PLC

Devices

Data type Description

IOSystemStruct Diagnostic data of the IO system

PLCStruct Diagnostic data of the controller and their local modules

DeviceStruct Diagnostic data of the devices and modules

Call of instruction „GEO2LOG“

Abbildung 4-4 Call „GEO2LOG“

Call of instruction „Get_Name“

Abbildung 4-5 Call „Get_Name“


Entry ID: 98210758, V1.0, 09/2014 18


4.3 Function block DiagStartupFB [FB100]

Function description

The hardware IDs are required to determine the diagnostic information in the user program of the diagnostic instructions.

The block is used for detecting the hardware ID of the components automatically with the “GEO2LOG” instruction based on the slot information. The slot information is rewritten before each call of the instruction with a tag of the “GEOADDR” system data type.

The “GET_NAME” instruction additionally reads out the names of the

PROFINET IO devices.

The hardware IDs and the names are saved in the respective structure in the global “DiagDataDB” data block.

The function block detects the hardware IDs of the following components:

Local modules of the controller

PROFINET IO system

PROFINET IO devices

Modules of the PROFINET IO devices

The following figure shows the principle flow of the function block.

Figure 4-6

Start/Stop

Slot information set local module x

GEO2LOG hardware ID read local module last module

Yes

Slot information set IO system

No

GEO2LOG hardware ID read IO system

Slot information set IO device y

GEO2LOG hardware ID read IO device

GET_NAME read device name last

IO device

Yes

No

Slot information

IO device y set module x

GEO2LOG hardware ID read module last module

Yes last

IO device

Yes

Start/Stop

No

No


Entry ID: 98210758, V1.0, 09/2014 19


4.4 Function block DiagMainFB [FB1]

4.4

Function block DiagMainFB [FB1]

The function block monitors the diagnostic status of the plant and calls the error diagnostics only if there is a fault.

Interfaces

Figure 4-7 Call in “DiagMainOB [OB123]”

Table 4-10

Type Parameter Data type Description

InOut IO_System

PLC

Devices

Error

AlarmsDeviceStates



DeviceStruct

ErrorListStruct

Diagnostic data of the devices and modules

Error list of the last error

Word

AlarmsModuleStates Word

Trigger tag for message texts of the “DeviceStates” instruction

Trigger tag for message texts of the “ModuleStates” instruction

Call of instruction „LED“

Abbildung 4-8 Call „LED“


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4.4 Function block DiagMainFB [FB1]


The function block evaluates the status of the error LED of the controller with the

“LED” instruction. If the LED displays a fault (LED status = 4), the block calls the

“DiagDevicesFB” function block to evaluate the diagnostics. If there is no fault, it resets the error status in the data block.


Figure 4-9

Start/Stop

Read local time

LED Status read PLC Error LED

PLC Error LED on

Yes

DiagDevicesFB

No

Rest error status

Start/Stop


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4.5 Function block DiagDevicesFB [FB2]

4.5

Function block DiagDevicesFB [FB2]

The function block evaluates the status of the PROFINET IO devices and their modules.

Interfaces

Figure 4-10 Call in “DiagMainFB [FB1]”

Table 4-11

Type Parameter Data type Description

InOut IO_System

PLC

Devices

Error

Local_Time

AlarmsDeviceStates



DeviceStruct Diagnostic data of the devices and modules

ErrorListStruct

DTL

Word

AlarmsModuleStates Word

Error list of the last error

Time stamp of the fault

Trigger tag for message texts of the “DeviceStates” instruction

Trigger tag for message texts of the “ModuleStates” instruction

Call of instruction „DeviceStates“

Abbildung 4-11 Call „DeviceStates“

Call of instruction „ModuleStates“

Abbildung 4-12 Call „ModuleStates“


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The function block reads the status of the PROFINET IO devices with the

“DeviceStates” instruction. If the instruction reports an error, the block interrupts the processing with a message on the operator panel. If the instruction is executed without errors, the block evaluates the status of the individual devices and saves the data in the global “DiagDataDB” data block.

If the devices are faulty, the “ModuleStates” instruction reads out the status of the modules. The block evaluates the status and saves the data in the global

“DiagDataDB” data block.

In addition, the “ModuleStates” instruction reads out the local module status of the controller which is also evaluated and saved.

The block saves the incoming and outgoing error events in an error list.


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Figure 4-13

Start/Stop

Device States

(read status of the devices)

Instruction error free

Yes

Evaluate and save status of the devices

No

No

Device n faulty

Yes

Module states

(read status of the module)

Instruction error free

Yes

Evaluate and save the individual modules

No

Next device

No

Last device

Yes

Module states

(read status of the local modules)

Evaluate and save the individual modules

Start/Stop

Output message text to HMI

RETURN

Output message text to HMI


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4.6 Function block DiagSignalFB [FB4]

4.6

Function block DiagSignalFB [FB4]

The function block monitors a binary signal and creates program and diagnostic messages.

Interfaces

Figure 4-14 Call in “DiagMainOB [OB123]”

Table 4-12

Type Parameter

Input Signal

UserMsg

Data type

Bool

UserMsgStruct

Description

The signal to be monitored.

Data for user diagnostic message

Call of instruction „Program_Alarm“

Abbildung 4-15 Call „Program_Alarm“


The “Program_Alarm” instruction monitors the binary input signal and generates an incoming or outgoing program message if there is change of signal.

The block calls the “DiagUsrMsgFB” function block and in the process transfers the

“UserMsg” input data for a user diagnostic message.

Note If required, you can read out and evaluate the message status of the program message with the “Get_AlarmState” instruction. In the process, you can e.g.

check whether a message was acknowledged in order to then continue the sequence in the program.


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4.6 Function block DiagSignalFB [FB4]


Figure 4-16

Start/Stop

Reading local time

Program_Alarm

(program message incoming / outgoing)

DiagUsrMsgFB

(FB Diagnostic message)

Start/Stop


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4.7 Function block DiagUsrMsgFB [FB5]

4.7

Function block DiagUsrMsgFB [FB5]

The function block generates a user diagnostic message in the diagnostic buffer of the controller for a binary input signal. The block is required since the

“Gen_UsrMsg” instruction otherwise writes the user diagnostic message cyclically into the diagnostic buffer.

Interfaces

Figure 4-17 Call in “DiagSignalFB [FB4]”

Table 4-13

Type Parameter

Input UserMsg

Data type

UserMsgStruct

Description

Data for a user diagnostic message

Call of instruction „Gen_UsrMsg“

Abbildung 4-18 Aufruf „Gen_UsrMsg“

UserMsgStruct

This structure includes the tags for a user diagnostic message.

Table 4-14

Start value Tag name

Sig

TextID

TextListID

Value1 to

Value8

Bool

UInt

Data type

UInt

Int

Meaning

The signal to be monitored.

ID of the text list entry, which is to be used for the message text

ID of the text list that includes the text list entry

Associated values 1 to 8 of the message


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4.7 Function block DiagUsrMsgFB [FB5]


The function block checks the signal state of the input signal. If the signal status is

TRUE, the status of the message (“mode”) is set to incoming message or if it is

FALSE to outgoing message.

The “Gen_UsrMsg” instruction writes a user diagnostic message into the diagnostic buffer of the controller based on the input parameter of the function block. A query prevents that the message is written cyclically into the diagnostic buffer.


Figure 4-19

Start/Stop

Signal state binary signal

FALSE

TRUE

Set “mode” parameter

(status of the message) to “1”

(incoming message)

Set “mode” parameter

(status of the message) to “2”

(outgoing message)

Has message already been created?

No

Gen_UsrMsg

(create user diagnostic message)

Yes

Start/Stop


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4.8 Function block DiagPNIOFB [FB3]

4.8

Function block DiagPNIOFB [FB3]

The function block evaluates the status of the PROFINET IO systems based on the start information of the OB.

Interfaces

Figure 4-20 Call in “Rack or station failure [OB86]”

Table 4-15

Type Parameter

Input TOP_SI

InOut IO_System

Error

Data type Description

SI_classic Start information of the OB


ErrorListStruct Error list of the last error

Note The description of the system data type (SDT) “SI_classic” can be found in the online help of SIMATIC STEP 7 V13.

Call of instruction „RD_SINFO“ in „Rack or station failure [OB86]“

Abbildung 4-21 Call „RD_SINFO“ in „Rack or station failure [OB86]“


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4.8 Function block DiagPNIOFB [FB3]


In the event of a failure of the PROFINET IO system, the operating system of the controller calls the “Rack or station failure” error OB for an incoming and also for an outgoing event. The OB therefore calls the “DiagPNIOFB” function block only once per event and in the process transfers the start information of the OB which is read out in the OB with the “RD_SINFO” instruction.

The “DiagPNIOFB” function block checks the start information of the OB based on whether an event occurred in the PROFINET IO system. If this is the case, it is polled whether an incoming or an outgoing event is pending and the respective status is saved in the global “DiagDataDB” data block.


Figure 4-22

Start/Stop

Read local time

Error

PROFINET

IO system

Yes

No

Error incoming / outgoing incoming outgoing

Status (incoming) save PROFINET IO system

Status (outgoing) save PROFINET IO system

Start/Stop


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5 Configuring the HMI Screens

5.1 Configuring a device in the plant overview

5 Configuring the HMI Screens

As an example, this chapter describes the integration of the collected diagnostic data of the controller to the screen elements of the HMI based on the “ET 200MP” device.

5.1

Configuring a device in the plant overview

The “Topic_001.0_PlantOverview” screen shows a global overview of the plant.

The integration of the “ET 200MP” device is described below.

Table 5-1

No.

Action

1. Open the “Topic_001.0_PlantOverview” screen in the TIA portal.

2. 1. Add a graphic object of the device. Alternatively, you can also use a rectangle.

2. Insert a rectangle into the screen for the status display.

3. Add an output field into the screen for the name of the STRING type.

4. Place a transparent button for the navigation in the detail view over the graphic object.

2

1

4

3


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No.

Action

3. 1. Select the rectangle for the status display.

2. Add a new animation of the “Appearance” type.

3. Assign the tag the respective control tag of the device status from the global data block. In this example, the device has device number “2” (see device property). For this reason, select “ErrorState” of the device with index “2”.

4. Specify the background colors for the ranges “0” and “1”.

1

3

2

4


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4. 1. Select the output field for the device name.

2. Assign the tag the respective control tag of the device name from the global data block. In this example, the device has device number “2” (see device property). For this reason, select “Name” of the device with index “2”.

1

2

5. 1. Select the transparent button for the navigation in the detail view.

2. Add the “Activate Screen” function in “Click”.

3. Select the screen of the “Topic_001.3_ET200MP“ detail view.

2

1

3


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5.2 Configuring a device in the detail view

5.2

Configuring a device in the detail view

The “Topic_001.3_ET200MP” screen shows the detail view of the “ET 200MP” device. The integration of the modules is described below.

Table 5-2

No.

Action

1. Open the “Topic_001.3_ET200MP” screen in the TIA Portal.

2. 1. Add the graphic objects of the modules. Alternatively, you can also use a rectangle.

2. Insert a rectangle into the screen for the status display.

2 2 2 2

1 1 1 1

3. 1. Select the rectangle for the status display of the head module.


3. Assign the tag the respective control tag of the device status from the global data block. In this example, the device has device number “2” (see device property). For this reason, select “ErrorState” of the device with index “2”.


1

3

2

4


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5.2 Configuring a device in the detail view

4. 1. Select the rectangle for the status display of the first module.


3. Assign the tag the respective control tag of the module from the global data block. In this example, the module is inserted in slot 2 (see device view). For this reason, select “SlotErrorState” with index “2”.


1

3

2

4


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6 Installation and Commissioning

6.1 Installing the hardware

6 Installation and Commissioning

6.1

Installing the hardware

The figure below shows the hardware setup of the application.

Figure 6-1

L+ M

SIMATIC

CPU 1516

L+ M

DI

32x24VDC

L+ M

DQ

32x24VDC

PN PN

Simulation

Wire break

1 19

L+ M

AI

8xU/I/RTD/TC

PROFINET IE

L+ M

SIMATIC HMI

TP1200

Comfort

PN PN

L+ M

SIMATIC

IM 155-6 PN

PN PN

L+ M

DI

16x24VDC

L+ M

DQ

16x24VDC

L+ M

AQ

4xU/I

20…200 Ohm

Simulation overtemperature

14 15

SINAMICS

CU240E-2PN-F

PN PN

L N

U2

PM340

V2 W2

Motor 3-phase ~M

L+ M

SIMATIC

IM 155-5 PN

PN PN

L+ M

DI

32x24VDC

L+ M

DQ

32x24VDC

L+ M

AI

8xU/I/RTD/TC

6.2

Note Always note the setup guidelines of the devices.

IP addresses and device names

The following device numbers, IP addresses and device names are used in the example:

Table 6-1

Component Device number IP address

SIMATIC CPU 1516

SIMATIC IM 155-6 PN

SIMATIC IM 155-5 PN

SINAMICS CU240E

SIMATIC HMI TP1200

0

3

-

1

2

192.168.0.1

192.168.0.2

192.168.0.3

192.168.0.10

192.168.0.4

Device name

(PROFINET name)

PLC_1

ET200SP

ET200MP

Drive_1

HMI_1


Entry ID: 98210758, V1.0, 09/2014 36


6.3 Installing the software (download)

6.3

Installing the software (download)

Note At this point, it is assumed that the necessary software has been installed on your computer and that you are familiar with the software.


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6.4 Assigning PROFINET device names

6.4

Assigning PROFINET device names

In order for all PROFINET devices to be able to communicate with each other, a

PROFINET device name must be assigned. The configured IP addresses of the devices are automatically transferred when downloading the project.

Table 6-2: Instruction –PROFINET in the TIA Portal

No.

Action

1.

Start the TIA Portal and open the example project.

-

2.

Open “Devices & Network“ and enable the “Network view”.

Right click on the PROFINET connection and select “Assign

device name”.

Remark

3. In this window, assign the

PROFINET device names to all of the devices.

1. Select the “PROFINET

device name”.

2. Assign the correct devices to the PROFINET device names.

3. Click "Assign name".

4. Repeat step 3 until all devices have a PROFINET device name.

1

2

3


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6.5 Loading the project

6.5

Loading the project

The software example is available on the HTML page from which you downloaded this document.

Table 6-3

No.

Action

1. Unzip the compressed code folder

98210758_CODE_V10.zip into a directory of your choice.

2. Open the “DiagnoseAWP_V10.ap13” project with the TIA Portal V13 Update 5.

3. Select the “PLC_1” folder of the controller in the project navigation and click the “Download to device” button in the toolbar.

Remark

4. Select the “HMI_1” folder in the project navigation of the operator panel and click the

“Download to device” button in the toolbar.

5. Select the “Drive_1” folder in the project navigation of the operator panel and click the

“Download to device” button in the toolbar.

Notice

All motor data is always downloaded. This may possibly result in a faulty configuration.

If you do not want to do this, only change the parameter p601 = [2] KTY.


Entry ID: 98210758, V1.0, 09/2014 39


6.6 Integrating the application into an existing project

6.6

6.6.1

Integrating the application into an existing project

You can completely integrate the application described here into your project. The required steps are described below.

Configuring the diagnostic settings

You can release the module-specific diagnostic settings for every module of your project separately.

The following diagnostic settings are e.g. possible:

Missing supply voltage L+

Wire break

Short circuit to ground

Value status

Channel diagnostics for drives

etc.

Note For information of how to configure the diagnostic settings, please refer to

System diagnostics with S7-1500 and TIA Portal in chapter 5.

6.6.2

Integration of the PLC elements

Table 6-4

No.

Action

1. Copy the “Diagnostic” folder in your project in “PLC_1 > PLC data types”.

2. Copy the “Diagnostic” folder in your project in “PLC_1 > Program blocks”.

3. If your project already includes error OBs, copy the networks of the error OBs of the application to their respective error OBs. Note that the position of the inserted code may have an effect on the program sequence.

Then delete the error OBs of the application.

4. Open the data type „PLCStruct“ and adapt the default value of the tag

„ModuleNumHigh“ as well as the size of the arrays „SlotLaddr“ and

„SlotErrorState“ to the highest slot number occupied by the local modules.


Entry ID: 98210758, V1.0, 09/2014 40



No.

Action

5. Open the data types „DeviceStruct“ and „ModulStruct“.

Adapt the default value of the tag „DeviceNumHigh“ as well as the size of the array „ Device“ to the highest device number.

Adapt the default value of the tag „ModuleNumHigh“ as well as the size of the arrays „SlotLaddr“ and „SlotErrorState“ to the highest slot number occupied by the modules.

6. Open the FB “DiagMainFB” and the “Default tag table“. Replace the HW ID

“PLC_1[Common]” with the HW ID of your controller. To do this, drag the respective tag from the tag table via drag & drop to “PLC_1[Common]” in the FB.

7. Open the OB “DiagMainOB” and assign a new signal of your plant to the

“AlarmSignal” tag. Replace “ValueStatus_AI8”.%X0.

If required, duplicate the program part for further signals or delete the program part if you do not wish to evaluate signals.


Entry ID: 98210758, V1.0, 09/2014 41



No.

Action

8. Open the FB “DiagSignalFB” and adjust the texts to the new signal for the

“Program_Alarm” instance “#Program_Alarm_Instance”.

9. Copy the “Textlist_AI8” text list into your project in “PLC_1 > Text lists”.

10. Open the text lists in “PLC_1 > Text lists”. Adjust the texts to the new signal and, if required, add new text lists for further signals.


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6.6.3

Integration of the HMI elements

This chapter describes the integration of the complete HMI application.

Table 6-5

No.

Action

1. Copy the “Diagnostic” folder to your HMI project in “HMI_1 > HMI tags”.

The HMI messages are automatically copied in the process.

2. Open the “HMI tags” “Tagtable_Diagnostic” and set the HMI connection of your

HMI in the “Connection” column.

3. Copy the folders “000_General”, “001_Application” and “002_Support” in your HMI project in “HMI_1 >Screens”.

The “Templates” are automatically copied in the process.

4. Link the screens with the already existing screens.

Note You can also only copy the tags and screens relevant for you. You have to adjust the elements in order for the HMI application to be compiled without errors.


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7 Operating the Application

7.1 Overview

7 Operating the Application

7.1

Overview

The screen below shows the user interface of the operator panel.

Figure 7-1

System

Back

From all subordinate screens

Example project Online Support

Language

The “Plant overview” screen displays the configured PROFINET IO devices. The detail view of the device opens by clicking on a device. By clicking on the “Plant overview” button you go back to the “Plant overview” screen.


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7.2 Diagnostics on the operator panel

7.2

7.2.1

Diagnostics on the operator panel

Diagnostics “Value status on AI8”

The value status (quality information) is enabled on the analog input module AI8 of the CPU S7-1516. This example evaluates the value status and creates a program message with the “Program_Alarm” instruction as well as a diagnostic message with the instruction “Gen_UsrMsg” which is entered in the diagnostic buffer. In order to diagnose the fault, please proceed as follows.

Table 7-1

No.

Action

1. Pull, for example, the front plug of the analog input module AI8 in order to set the value status to FALSE.

2. Open the “Plant Overview” screen on the operator panel.

The program message can be seen in the bottom part.

Remark


Entry ID: 98210758, V1.0, 09/2014 45



7.2.2

Diagnostics “Wire break on the DI module of the ET 200SP”

The diagnostics “Wire break” are enabled on the digital input module DI16 of the

ET 200SP. In order to diagnose the fault, please proceed as follows.

Table 7-2

No.

Action

1. Simulate a wire break with a switch on channel 0.

2. Open the “Plant overview” screen on the operator panel.

The screen displays the fault on the ET 200SP and on the controller.

The error message created by the TIA Portal can be seen in the bottom part.

For more detailed information of the fault, click the symbol of the ET

200SP or the “ET 200SP” button.

Remark

3. You can see the modules of the ET 200SP in the

“ET 200SP” screen.

The head module and the faulty module show an error.


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7.2.3

Diagnostics “Supply voltage missing on the DI module of the

ET 200MP”

The diagnostics “Supply voltage L+ missing” are enabled on the digital input module DI32 of the ET 200MP. In order to diagnose the fault, please proceed as follows.

Table 7-3

No.

Action

1. Pull the front plug of the input module DI32.


The screen displays the fault on the ET 200MP and on the controller.

The error messages created by the TIA Portal can be seen in the bottom part.

For more detailed information of the fault, click the symbol of the ET

200SP or the “ET 200SP” button.

Remark

3. You can see the modules of the ET 200MP in the

“ET 200MP” screen.

The head module and the faulty module show an error.


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7.2.4

Diagnostics “Overtemperature on G120 drive”

The channel diagnostics are enabled on the “Drive_1” drive. In order to diagnose the fault, please proceed as follows.

Table 7-4

No.

Action the overtemperature with the potentiometer on the drive.

See

Figure 6-1


The screen displays the fault on the drive and the controller.

The error messages created by the TIA Portal can be seen in the bottom part.

For more detailed information of the fault, click the symbol of the drive or the “SINAMICS

G120” button.

Remark

3. You can see the drive in the “Device view

SINAMICS G120” screen.

The drive shows an error.


Entry ID: 98210758, V1.0, 09/2014 48


7.3 Diagnostics in the TIA Portal

7.3

7.3.1

Diagnostics in the TIA Portal

Diagnostics “Value status on AI8”

The value status (quality information) is enabled on the analog input module AI8 of the CPU S7-1516. This example evaluates the value status and creates a program message with the “Program_Alarm” instruction as well as a diagnostic message with the instruction “Gen_UsrMsg” which is entered in the diagnostic buffer. In order to diagnose the fault, please proceed as follows.

Table 7-5

No.

Action

1. Pull, for example, the front plug of the analog input module AI8 in order to set the value status to FALSE.

2. To display the diagnostic message, proceed as follows:

1. Select the “PLC_1” folder and click

“Go online”

2. Open the online and diagnostic window by double clicking "Online

& diagnostics"

3. Click “Diagnostic buffer”

4. In the “Events” area, you will find the diagnostic message.

2

3

4

1

Remark


Entry ID: 98210758, V1.0, 09/2014 49



7.3.2

Diagnostics “Wire break on the DI module of the ET 200SP”

The diagnostics “Wire break” are enabled on the digital input module DI16 of the

ET 200SP. In order to diagnose the fault, please proceed as follows.

Table 7-6

No.

Action

1. Briefly simulate a wire break on channel 0 with a switch.

2. The fault is saved in the global data block

“DiagDataDB” in an

“ErrorList”. The error list is to be interpreted as follows:

1. Open the global data block “DiagDataDB” in the TIA Portal.

2. Click the “Watch all” button.

3. Open the “ErrorList” folder in the global

“DiagDataDB” data block.

4. The “Index” tag indicates the index of the last error entry.

5. The entry with index 1 displays the “incoming” fault on device 1 and slot 1.

6. The entry with index 2

(last entry) displays the

“outgoing” fault.

3

2

Remark

4

5

6

1


Entry ID: 98210758, V1.0, 09/2014 50



No.

Action

3. The pending fault is saved in “DiagDataDB” in a

“Devices” device list. The list is to be interpreted as follows:

1. Open the “Device >

Device[1]” folder.

2. This is where the error status and the device name is displayed.

3. Open the “Module >

SlotErrorState” folder.

4. Here, an error on slot 1 is displayed.

1

3

Remark

2

4

Note For the scenarios “Missing supply voltage” and “Overtemperature on the drive” you can proceed as described above.


Entry ID: 98210758, V1.0, 09/2014 51

8 Related Literature

8 Related Literature

Table 8-1

Topic Title / Link http://support.automation.siemens.com

Online Support

\2\ Download page of this entry

\3\ SINAMICS

Startdrive

\4\ http://support.automation.siemens.com/WW/view/en/98210758

Commissioning tool for SINAMICS drives as option package for SIMATIC STEP 7 V13 http://support.automation.siemens.com/WW/view/en/68034568 http://support.automation.siemens.com/WW/view/en/68011497

\5\

\6\

System

Diagnostics with

S7-1500 and TIA

Portal

STEP 7

Professional V13

System Manual

S7-1500 System

Manual http://support.automation.siemens.com/WW/view/en/89515142 http://support.automation.siemens.com/WW/view/en/59191792

9 History

Table 9-1

Version

V1.0

Date

09/2014 First version

Modifications


Entry ID: 98210758, V1.0, 09/2014 52

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