User Manual 00 MW E1 AB ...clear view into PLC! 30,055 25,753 PLC-ANALYZER pro 5 www.autem.de The logic analyzer for programmable logic controls User Manual PLC-ANALYZER pro 5 Copyright 1995 - 2011 AUTEM GmbH. All rights reserved. No part of this user manual, including excerpts, may be reproduced, photocopied or electronically stored without the expressive written permission of AUTEM. The software described in this manual is subject of a software license agreement and may only be used according to the terms of this agreement. AUTEM GmbH Dithmarscher Straße 29 D-26723 Emden Germany Telephone Telefax Email Web +49 (0)4921 9610-0 +49 (0)4921 9610-96 [email protected] www.autem.de AUTEM does not give any warranty for this manual as well as no express or tacit warranties on commercial quality and suitability for a particular use. AUTEM does not take over adhesion for errors contained in it or for damages that may occur as a result of using or applying this material. The soft and hardware designations mentioned in this book are in most cases also registered trade marks and are subject to the legal regulations as such. For references, suggestions and improvement suggestions we are always grateful. Please send these to AUTEM. 1st Edition 2011 SIMATIC, SINUMERIK, SIMOTION, S5, S7, C7, M7, Siemens LOGO!, STEP5, STEP7, S7-200, S7-300, S7-400, and S7-PLCSIM are registered trademarks of Siemens AG Table of contents iii Table of Contents 1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 2 Overview Fields of application PLC-ANALYZER pro Technical features Typical operation Help Technical Support INSTALLATION 2.1 2.2 2.3 2.4 2.5 3 Hardware and software requirements Installation Installation of additional licenses, upgrades Uninstallation Starting the program CONFIGURATION 3.1 3.2 PLC driver Options 3.2.1 Signals 3.2.2 Directories 3.2.3 Language 3.2.4 Toolbars 3.3 Tools 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.4 5.5 1-1 1-1 1-2 1-3 1-4 1-4 1-4 2-1 2-1 2-1 2-2 2-3 2-4 3-1 3-1 3-2 3-3 3-4 3-5 3-5 3-7 DATA ACQUISITION 4-1 Address selection 4.1.1 Use of PLC symbol files 4.1.2 Pseudo signals 4.1.3 Address sets 4.1.4 Assign given addresses to other drivers Online signal selection 4.2.1 Define online window 4.2.2 Choose addresses for online display Trigger 4.3.1 AND / OR combination of trigger signals 4.3.2 Trigger on bit signals 4.3.3 Trigger on analog signals 4.3.4 Trigger action 126.96.36.199 Activate and deactivate address sets and trigger (cascading) 188.8.131.52 Send an E-Mail 184.108.40.206 Send an SMS 220.127.116.11 Acoustic signaling Scaling of register values Modes of data acquisition 4.5.1 Cycle-precise acquisition Starting data acquisition 4-1 4-3 4-3 4-4 4-4 4-4 4-5 4-5 4-6 4-7 4-7 4-8 4-11 4-11 4-12 4-12 4-12 4-13 4-14 4-15 4-15 SIGNAL DISPLAY AND ANALYSIS 5-1 Opening a signal file Signal selection Signal Scaling of register values Signal cursor Time information 5-1 5-2 5-3 5-3 5-4 Table of contents 5.5.1 Absolute and relative time display 5.5.2 Setting the time base 5.5.3 Time measurement 18.104.22.168 Time difference measurement 22.214.171.124 Bit measurement 5.6 Search functions 5.6.1 Find trigger 5.6.2 Find time 5.6.3 Find bit pattern 5.6.4 Find analog value 5.6.5 Find edge 5.6.6 Find note 5.7 Adapting signal display 5.7.1 Moving of signals 5.7.2 Change signal color 5.7.3 Insert notes 5.7.4 Changing symbol addresses and symbol comments 5.7.5 Mark area 5.8 Signal file comparison 5.9 Signal statistics 5.10 Project info 5.11 Saving a signal file 5.11.1 Saving an extract 5.12 Printing a signal file 5.13 Exporting of signal files 5.13.1 Export as a graphic (bitmap) 5.13.2 Export as a HTML-Site 5.13.3 Exporting signal files as a text 5.13.4 Graphical evaluation of signal data in Microsoft® Excel® 5.14 Import of signal files 6 PLC-PROCESS DATA RECORDING AND REMOTE SERVICE 6.1 6.2 6.3 7 BLACKBOX 2 for PLC-ANALYZER BLACKBOX - fields of application Remote service with the BLACKBOX iv 5-4 5-4 5-4 5-5 5-5 5-6 5-6 5-6 5-7 5-7 5-8 5-8 5-9 5-9 5-9 5-9 5-9 5-10 5-10 5-11 5-13 5-13 5-13 5-13 5-15 5-15 5-15 5-16 5-16 5-18 6-1 6-1 6-2 6-2 DRIVER ADDENDUM SIEMENS SIMATIC S7 7-1 Installation 7.1.1 Installing additional hardware 7.1.2 Installing additional software 7.2 Configuring the PLC driver 7.3 Data acquisition 7.3.1 Supported PLC models and CPUs 7.3.2 Recordable PLC addresses 7.3.3 Number of recordable addresses 7.3.4 Time behavior and particularities 7.4 Cycle-precise acquisition 7.4.1 Installation of additional software 7.4.2 Installation of additional Hardware 7.4.3 Configuration of PLC-driver for cycle-precise acquisition 7.4.4 Input of addresses 7.4.5 Start acquisition 7.4.6 Particularities in signal display and analysis 7-1 7-1 7-1 7-2 7-3 7-3 7-3 7-4 7-4 7-5 7-5 7-5 7-5 7-7 7-7 7-9 DRIVER ADDENDUM SIEMENS SIMATIC S5 8-1 7.1 8 8.1 Installation 8.1.1 Installing additional hardware 8-1 8-1 Table of contents v 8.1.2 Installing additional software Configuring the PLC driver Data acquisition 8.3.1 Supported PLC models and CPUs 8.3.2 Recordable PLC addresses 8.3.3 Number of recordable addresses 8.3.4 Time behavior and particularities 8.4 Cycle-precise acquisition 8.4.1 Address entry 8.4.2 Trigger condition entry 8.4.3 Start acquisition 8.4.4 Particularities of signal display and analysis 8.2 8.3 8-1 8-2 8-3 8-3 8-4 8-5 8-5 8-6 8-6 8-6 8-6 8-9 9 APPENDIX A - FREQUENTLY ASKED QUESTIONS (FAQ) 10 DRIVER APPENDIX SIMOTION, PILZ, FESTO, BOSCH, CoDeSys, PHOENIX, JETTER, B&R, MITSUBISHI, ALLEN-BRADLEY, GE Fanuc, HITACHI, OMRON, SCHNEIDER, BECKHOFF, AUTEM AD_USB-Box® ... please refer to special reference book 9-1 Table of contents vi Table of Figures Fig. 1-1 PLC-ANALYZER pro 5 Fig. 2-1 License-Key management Fig. 2-2 The initial screen Fig. 3-1 Options-menu Fig. 3-2 Configuration of the PLC driver Fig. 3-3 Selecting the PLC driver Fig. 3-4 Setting signal options Fig. 3-5 Selecting the standard directories Fig. 3-6 Language selection Fig. 3-7 Configuring toolbars Fig. 3-8 Tools menu Fig. 4-1 Definition of a new project Fig. 4-2 Entering signals to acquire Fig. 4-3 Generate pseudo signals Fig. 4-4 Selecting signals for online display Fig. 4-5 Entering trigger conditions Fig. 4-6 Entering the trigger value of a bit signal Fig. 4-7 Entering trigger value of an analog signal Fig. 4-8 Principles of analogue triggering ( < , > , = , <> ) Fig. 4-9 Setting trigger properties Fig. 4-10 Register scaling for online display Fig. 4-11 Setting the acquisition mode Fig. 4-12 Signal acquisition with graphics and text online window Fig. 5-1 Opening a signal file Fig. 5-2 Signal file display Fig. 5-3 Time information Fig. 5-4 Activated time difference measurement Fig. 5-5 Find trigger Fig. 5-6 Find time Fig. 5-7 Find bit pattern Fig. 5-8 Searching for an analog value Fig. 5-9 Find edge Fig. 5-10 Find note Fig. 5-11 Signalinfo Fig. 5-12 Signal file comparison Fig. 5-13 Signal statistics Fig. 5-14 Signal statistics - register values Fig. 5-15 Printer selection window Fig. 5-16 Printout of a signal file (not to scale) Fig. 5-17 Export in ASCII format Fig. 5-18 Example of an exported signal file (extract) Fig. 5-19 Logarithmic representation of PLC analog signals with Excel® Fig. 5-20 3D representation of PLC analog values with Excel® Fig. 5-21 Discrete signals with Excel® Fig. 5-22 Importing Data Fig. 6-1 BLACKBOX 2 Fig. 7-1 Settings PLC driver (SIMATIC S7) Fig. 7-2 Driver settings for cycle-precise driver (SIMATIC S7) Fig. 7-3 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 7-4 Message before modifications in the PLC for pre-setting "No PLC safety stop" Fig. 7-5 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 7-6 Message before modifications in the PLC for pre-setting "No PLC safety stop" Fig. 8-1 Driver settings (SIMATIC S5) Fig. 8-2 Message before modifications in the PLC for pre-setting "With PLC safety stop" 1-1 2-2 2-4 3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7 4-1 4-2 4-4 4-5 4-6 4-8 4-8 4-10 4-11 4-13 4-14 4-16 5-1 5-2 5-4 5-5 5-6 5-6 5-7 5-7 5-8 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-17 5-17 5-18 6-1 7-2 7-6 7-8 7-8 7-9 7-9 8-2 8-7 Table of contents vii Fig. 8-3 Fig. 8-4 Fig. 8-5 Fig. 8-6 Message before modifications in the PLC for pre-setting "No PLC safety stop" Cycle-precise acquisition status Message before modifications in the PLC for pre-setting "With PLC safety stop" Message before modifications in the PLC for pre-setting "No PLC safety stop" 8-7 8-8 8-9 8-9 List of Tables Table 3-1 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 5-1 Table 5-2 Table 5-3 Table 7-1 Table 7-2 Table 8-1 Table 8-2 Table 8-3 Toolbar icons Address syntax SIMATIC S7 Saving behaviour at trigger recording Trigger operator Modes of data acquisition Use of the keyboard Statistical evaluation of a bit address Statistical evaluation of a register address Address syntax SIMATIC S7 Time stamp settings Overview of the supported SIMATIC S5 models Address syntax SIMATIC S5 Status display cycle-precise recording S5 3-7 4-3 4-7 4-9 4-15 5-3 5-12 5-12 7-3 7-6 8-3 8-4 8-8 Introduction 1 1-1 Introduction Welcome to the new PLC-ANALYZER pro 5, the software logical analyzer, that gives you valuable help in solving automation problems. The program is very easy and intuitive to use. Nevertheless please read through the manual in order to familiarize yourself with the numerous applications of PLC-ANALYZER pro. This manual informs you about installation, operation, and application areas of this program. Fig. 1-1 PLC-ANALYZER pro 5 1.1 Overview PLC-ANALYZER pro is a software tool for logic analysis and registration of measured values on equipment operated with a PLC (Programmable Logic Controller). PLC signals of all kinds can easily be collected, displayed and evaluated. Among others, these signals include inputs and outputs, flags, timers, counters and data words. Equipped with the capability of a traditional logic analyzer, PLC-ANALYZER pro normally requires no software or hardware modification of the PLC for the capturing signal data. This is Introduction 1-2 the result of using the existing PLC protocol for data acquisition, whereby PLC-ANALYZER pro simply uses the typical hookup of programming units via serial connection or automation network. A to the PLC connected programming device (PC) can be used directly for data acquisition without further modification. With PLC-ANALYZER pro the user is also able to record all internal PLC signals, e. g. flags or timers, which are normally not accessible from outside the PLC. Additionally by using the special measurement interface AD_USB-Box®, external voltage and current signals, which are not available in the PLC, can also be recorded. In this manual the MPI/PPI/PROFIBUS driver for Siemens SIMATIC S7 was selected in order to demonstrate the program operation. The essential facts apply also to all other available PLC drivers, e.g. the ETHERNET driver for Siemens SIMATIC S7 or the AS511 driver for Siemens SIMATIC S5. You will find specific comments on the characteristics of other PLC drivers in the corresponding driver addendum. It is important that you read through the appropriate driver addendum before using a PLC driver. Please pay attention to the highlighted warnings on possible dangers associated with the use of PLC-ANALYZER pro. ! 1.2 1 WARNING Errors that may occur in the automated device endangering humans or causing large-scale material damages must be prevented by additional external precautions These precautions (e.g. independent limit monitors, mechanical interlocks) must guarantee safe operation, even in a case of dangerous errors. Fields of application PLC-ANALYZER pro Fault analysis in PLC systems Finding and localizing sporadic errors Analysis and optimization / cycle time reduction Short-term and long-term registration of measured values Documentation and support for your quality assurance system, e.g. QA, TPM/ OEE1 Installation, maintenance, development, training TPM: Total Productivity Management / OEE: Overall Equipment Effectiveness Introduction 1.3 2 3 1-3 Technical features Data acquisition via the PLC programming unit interface or automation network /fieldbus Acquisition of input, output, flags, timers, counters, peripheral, data words, data block, etc.2 Signal display in bit, byte, word or double word formats Creating of pseudo signals Adding of additional addresses or trigger conditions while recording Simultaneous acquisition on several PLC systems (e.g. SIMATIC S7 + S5 or SIMATIC S7 + Allen-Bradley ...) Software solution, no additional hardware necessary No modifications in the PLC program necessary3 Cycle-precise acquisition for SIMATIC controls Recording of the signal waveform on hard disk Trigger-controlled creation of signal files or continuous recording Time controlled signal recording Online signal display (similar to an oscilloscope) Comfortable definition of trigger per drag & drop Substantial trigger features with an and-/or linkage and cascading Pre-trigger and post-trigger time can be set by user Start- and stop-trigger Trigger on binary and register value Automatic alarm in case of trigger event (E-Mail or send SMS, acoustic announcement) Comparing signal files Search for trigger, edge, bit pattern, time and advices over several signal files Relative and absolute data time Flexible register scaling and conversion to physical units Use of symbolic address names and comments from the PLC programming software Project files for pre-configuring and automating data acquisition runs Printout and storage of project settings for documentation of measurements Printout of signal files Export of signal files as image format, text (CSV / Excel) or HTML-file Import of measured values in text format (CSV) Multilingual (German, English, French) S7-PLCSIM supporting AD_USB-Box® (optional): Recording of external voltage and current by means of external box, which will be connected to the USB-Port BLACKBOX (optional): Ultra compact Mini-PC for installation in switching cabinet, longterm recording of measured values over several years. Available PLC-Driver: Siemens SIMATIC S7 / C7 / M7, SAIA xx7, VIPA, SIMATIC S5, Siemens LOGO!, SINUMERIK, SIMOTION, BOSCH, CoDeSys, PILZ, Phoenix, Jetter, Allen-Bradley, GE Fanuc, HITACHI, OMRON, Mitsubishi, Schneider, AUTEM AD_USBBox®, Beckhoff TwinCat a.o. Varying terminology and restrictions possible according to PLC model An exception is cycle-precise acquisition. Introduction 1-4 1.4 Typical operation A typical control expiration of the PLC-ANALYZER pro looks as follows: Connect PC with the PLC programming unit interface Select signals to record Select signals to be displayed on the screen Set trigger combinations to freeze the data being recorded Start data recording End data recording Evaluate and analyze recorded signals in a graphical display Use recorded signals to calculate the time intervals 1.5 Help You have access to a convenient online help for PLC-ANALYZER pro. To activate help just select the menu item Help topics in the help menu. A help window appears with important information and comments on program operation. If you need detailed help on a specific window, simply press the F1 key when the window is active. Direct help on individual dialog elements can be obtained by positioning the mouse over the element and clicking the right mouse key. 1.6 Technical Support If you have problems while using PLC-ANALYZER, first try the online help or have a look at the specific pages of this manual. There is a FAQ list at our Web site http://www.autem.de containing answers to frequently asked questions. Please contact our technical department for support, if you cannot solve the problem. Technical support AUTEM: Tel. (+49) (0)4921-9610-0 Fax (+49) (0)4921-9610-96 Email [email protected] Introduction 1-5 In case you need assistance from our technical department the following information needs to be at hand: Exact error description Version- and serial number of PLC-ANALYZER pro Model and exact type description of the PC or programming unit, release number Amount of memory (RAM) and free space on the hard disk Exact version of operating system (e.g. Windows XP - ServicePack2) PLC model and CPU type (e.g. SIMATIC S7-300 / CPU 314) and release number NOTE Don’t forget to register the software with the enclosed recording form. As a registered user you are eligible to receive new information and updates about your product. Installation 2-1 2 Installation 2.1 Hardware and software requirements To operate PLC-ANALYZER pro the following system configuration is necessary: PC with 1 GHz Microsoft® Windows 98SE/2000/XP/Vista/7 256 MB RAM ca. 100 MB of available hard-disk space Depending on the PLC driver, additional requirements may have to be met by the computer such as the installation of a network card and supplementary device drivers. In this case please read through the chapter Installation in the corresponding driver addendum. 2.2 Installation Install the PLC-ANALYZER pro on your PC: Insert the CD of PLC-ANALYZER pro in your CD-drive Click on the Windows Start button on the task bar Select the menu item Run Search for SETUP.EXE on CD and start the installation program with OK After the installation program starts, several dialog windows appear in which you are asked to make settings. Simply follow the instructions of the installation program. After successful installation, the licenses has to be activated. Insert the USB License-Key Dongle into a free USB port of your PC and click the button “Activate licenses now”. The License Management will start immediately. NOTE It is possible to activate the licenses after the installation. Therefore start the License Management of PLC-ANALYZER pro 5. Installation 2-2 Fig. 2-1 License-Key management Select those licenses from the list Licenses on this License-Key Dongle you want to install on your PC. Press and hold the button <Ctrl>, if you want to select several licenses. Then press the button > to transfer the selected licenses to your PC. The button All> transfers all licenses to your PC once. ! 2.3 Warning Formatting or re-installation of your hard disk causes a loss of activated license(s). Insure that all activated licenses are re-transferred to License-Key Dongle before deleting your hard disk. Installation of additional licenses, upgrades After purchasing additional licenses or upgrades, you will get a license file (e. g. „123456.lic“). This license file contains all necessary data required to update the licenses on your USB License-Key Dongle. Start the license management and choose Load Dongle-License file. Select the license file in the file selection window and press Open. After positive confirmation of the information window your licenses on the USB License-Key Dongle will be updated. Installation 2-3 2.4 Uninstallation If you do not need a license on your PC anymore, re-transfer it to the USB License-Key Dongle. Insert the USB License-Key Dongle into a free USB port of your PC and start the License Management of PLC-ANALYZER pro 5. Select those licenses from the list Licenses on your PC you want to uninstall. Press and hold the button <Ctrl>, if you want to select several licenses. Press button < to uninstall the licenses from your PC. The button All< uninstalls all licenses at once. In both cases the licenses will be transferred back to the USB License-Key Dongle. NOTE The licenses can only be transferred back to that License-Key Dongle, from which they were installed originally. The License-Key Dongle and the license(s) to be transferred back must have the same serial number. Installation 2.5 2-4 Starting the program NOTE Please make sure that time and date in your PC are set correctly. Correct the values if necessary. Start PLC-ANALYZER pro simply by a double-click on the PLC-ANALYZER pro 5 icon in the program group PLC-ANALYZER pro. Fig. 2-2 The initial screen After successful activation of the licenses, the above screen should appear (figure 2-2). If not, you will see a message window with the request to install the correct licenses. After you have successfully installed PLC-ANALYZER pro, you have to make several appropriate basic settings in the program. You will find a detailed description on the settings in the next chapter. Configuration 3-1 3 Configuration Before you can start to acquire and analyze data, you must configure PLC-ANALYZER pro. The general settings are performed in the menu item Extras. Choose an adequate PLC driver and configure the program under Options according to your guideline. During installation the program was already pre-configured according to your specifications. The options set are saved when exiting PLCANALYZER pro. The saved options are automatically set when starting the program again. Fig. 3-1 Options-menu 3.1 NOTE All options are also saved in the project files. PLC driver Fig. 3-2 Configuration of the PLC driver In the window Extras - PLC driver all PLC drivers that have already been loaded are listed. You can select further PLC drivers with Add and define the necessary attributes for communication. Configuration 3-2 In Fig. 3-3 the selection window for loading a PLC driver is shown with all available drivers listed. In case the desired driver is not on the list, the driver license has to be installed via the License-key management (see also chapter 2-2 Installation). Select a driver and click on the Add button, in order to load it. Fig. 3-3 Selecting the PLC driver After loading the desired drivers set all important parameters of the selected PLC driver with Properties you will find a description of these parameters in the corresponding driver addendum under Configuring the PLC driver. Already loaded PLC drivers can be removed from the list of the loaded drivers with Delete. Note PLC-ANALYZER pro can load the same or different PLC-drivers more than once. E. g. to acquire signal data from two different SIMATIC S7 controls via Ethernet, simply load PLC-driver for S7 - TCP/IP twice and parameterize both accordingly (TCP/IP address etc.). To acquire signal data from a SIMATIC S7 and a SIMATIC S5 simultaneously, just load the PLC-driver SIMATIC S7 and the PLC-driver SIMATIC S5. 3.2 Options Under Options PLC-ANALYZER pro can be configured according to your conception. Your configuration settings are stored and will be used when the program is restarted. 3-3 Configuration 3.2.1 Signals Under Signals you set the signal display and the scope of signal-information. Fig. 3-4 Setting signal options Select under Address display the display for the address indication. Here you have the choice to select besides the absolute display also symbolic or comment. In order to do so it is necessary, that a symbol file has been loaded (see also Driver-Addendum). The desired font and font size can also be set. Under Standard Signal Colour the signal display can be set. By choosing the option colored each address type (input, output, flag, etc.) will be displayed in a different colour. By choosing the option black all signals to be displayed are shown in black. The signal colour can be changed at any time. The Standard height of binary signals, the Standard height of analogue signals as well as the Signal line width can also be set. With Signal file you can choose if the last stored cursor position and time base shall be set automatically. By selecting the control field Adjust signal height, the height of the PLC signals will be chosen automatically so that all signals can be printed on one page. Configuration 3-4 3.2.2 Directories Now the standard directory path for project files and signal files have to be set. The PLCANALYZER pro works with this directory in case you don’t explicitly indicate something else. Fig. 3-5 Selecting the standard directories You can change the directory paths by clicking on the buttons right of the text fields. 3-5 Configuration 3.2.3 Language This window is used to set the menu language of PLC-ANALYZER pro. Choose a language, and then click the OK button to switch to the desired language while using PLC-ANALYZER pro. Fig. 3-6 Language selection 3.2.4 Toolbars PLC-ANALYZER pro offers several toolbars enabling the user to directly select important functions through the corresponding icons4. You can configure the toolbars according to your needs on the Toolbars tab page. 4 Icon = small symbolic graphic. Configuration 3-6 Fig. 3-7 Configuring toolbars The available toolbars are listed under Toolbars. Activate the control box next to the specific corresponding name in order to visualize the toolbar. Individual icons can be moved from the selected toolbar to another toolbar simply by dragging the desired symbol with the mouse onto the corresponding toolbar in the PLC-ANAYLZER pro main window. Use Reset to re-establish the original state of the selected toolbar. The following table describes the toolbar icons: Button Meaning Creates a new project. Any open project will be closed Loads a project. Any open project will be closed Stores the current project Loads a signal file Stores the active signal file under its current name Exports the current signal file as a graphic, a text or a HTML-page Compares two signal files with each other Activates a time difference measurement Activates bit measurement Inserts a note into the online window Configuration 3-7 Button Meaning Stores a selected range of the active signal file Prints the signal file of the active online window Starts the signal recording in the current project Stops the signal recording in the current project Opens the Project settings window Opens the Bit pattern search window Opens the Signal-edge search window Opens the Analog value search window Opens the Trigger search window Opens the Time search window Displays all open online windows as overlapping All opened online windows are arrange next to each other Switches the grid on/off in the active online window Switching between relative and absolute time display Graphical display of the signals Signal display in text mode Loads a PLC driver and the corresponding settings Opens the help window of PLC-ANALYZER pro and indicates a list of the help themes Starts context-sensitive help. Click this button and select a menu item or a toolbar button in order to display a corresponding help text. Table 3-1 Toolbar icons 3.3 Tools Fig. 3-8 Tools menu The Tools menu can be used to start external programs via PLC-ANALYZER pro. The programs are free selectable and can by modified at any time by using Customize. Clicking on an existing menu item causes the corresponding program to be started from PLC-ANALYZER pro. Data acquisition 4 4-1 Data acquisition This chapter describes how to acquire data from a PLC. With PLC-ANALYZER pro every data acquisition is navigated by a so-called project. In a project all settings will be stored. Start a project with Assistant 'New project' in the File menu. The project assistant leads you step-by-step through the new project. In the first dialog window of the assistant you give the project an appropriate name and if necessary some descriptive comments. With Continue you can move to the next item. Enter the data appropriate to your new project on each page. The menu item New project... in the File menu offers another possibility of defining a project. In the Create new project window you give the project an appropriate name with descriptive comments. Go to project settings with clicking on Continue. Fig. 4-1 Definition of a new project 4.1 Address selection In the Addresses window you specify which signals you want to record. First, select the PLC driver under Driver for the desired addresses. Then enter the desired addresses sequentially into the text field Absolute according to the syntax of the PLC driver. Clicking on the Accept button or pressing <ENTER> causes the entered address to be included in the Addresses in set list. If several addresses shall be recorded in sequence, e.g. EB0, EB1, EB2, click on the Next address button. Already inserted addresses can be changed with Replace. With Remove the signal addresses that should not continue to be recorded will be deleted. Data acquisition 4-2 Fig. 4-2 Entering signals to acquire NOTE The simultaneous acquisition of signals from different PLC controllers with several drivers is possible. Simply load all necessary drivers and make sure that the correct driver for each address has been selected. The following table shows for instance the address syntax for the Siemens SIMATIC S7 family. Syntax Address type Example Qx.z QBx QWx QDx Ix.z IBx IWx IDx Fx.z FBx FWx Output byte x, bit z Output byte x Output word x Output double word x Input byte x, bit z Input byte x Input word x Input double word x Flag byte x, bit z Flag byte x Flag word x Q32.4 QB9 QW14 QD98 I17.0 IB127 IW12 ID124 F3.7 FB250 FW24 Data acquisition 4-3 Syntax Address type Example FDx FGx Tx Cx DByDBXx.z DByDBBx DByDBWx DByDBDx PIBx PIWx PIDx Flag double word x Flag x (floating-point representation) Timer x Counter x Data byte x, bit z from data block y Data byte x from data block y Data word x from data block y Data double word x from data block y Periphery input byte x Periphery input word x Periphery input double word x FD134 FG104 T2 C5 DB23DBX2.5 DB2DBB5 DB12DBW5 DB27DBD0 PIB 123 PIW 124 PED 126 Table 4-1 Address syntax SIMATIC S7 Please have a look at the appropriate driver addendum for the address syntax of other PLC systems. 4.1.1 Use of PLC symbol files With PLC-ANALYZER pro you can use the PLC symbol files produced by the programming software. For this purpose load from PLC driver setting the desired symbol file. You will find the exact procedure in the corresponding driver addendum under Configuration of PLC-Driver. If a symbol file is loaded all symbolic identifiers and comments of the symbol file will be indexed in the Symbol address list. Now you can also insert symbolic addresses in the text field Symbol or address comments in the text field Comment. Alternatively you choose a symbol address while making a double click on it or drag the symbol address with the mouse from the list Symbol addresses to the list Addresses in set. NOTE Some programmable controllers (e.g. SIMATIC S7) only allow byte-wise data acquisition. In such a case PLC-ANALYZER pro converts a given bit-address automatically into a byte-address. All bits are available for display. 4.1.2 Pseudo signals With PLC-ANALYZER you have the possibility to generate pseudo signals from chosen addresses. Pseudo signals are artificial signals, which calculate themselves by means of any mathematical formula by existing signals. According to the formula P = U x I (performance = voltage x current) for example, the performance of a machine can permanently be calculated and indicated in pseudo signals, if voltage and current are present as measuring signals. Choose Pseudo signal and click on Add in order to generate a pseudo signal. Now create a formula for this signal through selection of the appropriate buttons. Now this pseudo signal will continuously be calculated and indicated during the registration. Data acquisition 4-4 Fig. 4-3 Generate pseudo signals 4.1.3 Address sets With the PLC-ANALYZER pro you are able to define several sets of addresses, so-called address sets. You can assign specific signals to each address set. By selecting the New, a new address set can be generated. Give the address set a name and choose the online window, in which the address is supposed to be displayed. With the control field Generate address set you decide, if the signals of the address set shall be generated. With Remove the selected address set can be deleted. 4.1.4 Assign given addresses to other drivers If you want to assign given addresses to another driver, mark these addresses in the list Set of addresses and choose the new PLC-driver under Driver. If the desired driver is not in the list, you must load the driver first (s. 3.1 PLC-driver). 4.2 Online signal selection A particular feature of PLC-ANALYZER pro is the online display of recorded values in a continuous line recorder and/or an oscilloscope. In the Online window the current signals to be displayed can be chosen. Data acquisition 4-5 Fig. 4-4 Selecting signals for online display 4.2.1 Define online window You can define several online windows and even indicate them simultaneously in need. Clicking on the New button causes a new online window. Give the online window a name and under Display, select the type of display in the online window. The Time base displays the time per screen pixel. This value also can be changed at any time during acquisition. Choose under Display online window, if the online window shall be displayed during the acquisition. When the control field Grid is activated, a raster grid appears in the display area of the online window. Indicate whether discrete signals (binary signals) are to be displayed as Bar display or as lines. Under Display sample points you can activate the display of sample points, which are then displayed as small points on the signal curve. The sample interval can be set in the window Properties of the PLC driver. More information on this item can be found in the driver addendum for the corresponding PLC driver. The selected window can be deleted with Remove. 4.2.2 Choose addresses for online display All signals, which are registered with the actual project, are indexed under Addresses. Drag all addresses, which are displayed in the online window with the mouse into the list Addresses in online window. Alternatively the buttons All > and > can also be used. Position the addresses in the list Addresses in online window with the mouse in the order in which they shall appear in the online window. Adjust, if necessary apart from the Position also the Height and the Color of the signals. Data acquisition 4-6 Under Reset all signals, Position, Height and Color are reset to default values (see chapter 3.2.1. Options - Signals). If previously selected addresses are no longer displayed in the online window, please drag them with the mouse out of the list Addresses in online window or use the button < all and <. Under Change address symbol you can change the symbolic designator and the comment of an absolute address. Select the desired Absolute address and register the Symbol as well as the Comment of the address. With Accept the changes will be stored. 4.3 Trigger The PLC-ANALYZER pro offers the possibility to trigger on certain events, e.g. sporadic arising errors. With this feature you can create signal files containing a specific event with the signal history leading up to and following the event. You can trigger on binary and analog signals. For binary signals you can trigger on either logical "0" or "1". For analog signals you can trigger on the relations greater than (>), less than (<), equal (=), and not equal (< >). Trigger conditions can be combined with the logical operators AND and OR, enabling you to specify complex trigger conditions. Fig. 4-5 Entering trigger conditions A new trigger is generated by activating the button Add. Give the trigger a name and assign it a Description. You can define several triggers. By using the control field Trigger active you can activate or deactivate the selected trigger. With a deactivated trigger no trigger will be activated, even if the trigger conditions are performed. Data acquisition 4-7 The Trigger time of a trigger indicates how many times the trigger conditions must be performed in order to activate a trigger. The activation of the control field Save leads, by the controlled trigger record (see chapter 4.5 Modes of data acquisition) to the fact that PLC signals are saved in a signal file only if all the trigger conditions are performed. You can also define, how many times before and after the trigger occurrence information will be saved. The save reaction depends on the activating of the control field start trigger and stop trigger. Activated control fields Save reaction Start trigger The saving starts when the trigger condition is performed. It ends when a stop trigger occurs or if the storage is ended manually. Stop trigger If a start trigger was activated before, the stop trigger will end the storage of signals. Otherwise the stop trigger has no influence on the data storage. Start trigger and Stop trigger At first appearance of a trigger condition the storage will be started and at a second time it will be ended. Neither start trigger nor stop Data around trigger event will be saved. Adjust, how long trigger before the trigger and how long after the trigger signals have to be saved. Table 4-2 Saving behaviour at trigger recording By activating the control field Create new signal file, if trigger occurs a new signal file will be created on each trigger. Otherwise all files will be saved in one signal file. NOTE In the record menu Manual (see chapter 4.5 Modes of data acquisition) the trigger options, which are set under Save are annulled. Under Action a dialogue window, in which settings for events at trigger release can be made, appears (see chapter 4.3.4 Trigger actions). In the window Addresses all addresses are listed, which are available for formatting of trigger conditions. 4.3.1 AND / OR combination of trigger signals In order to specify complex trigger conditions PLC-ANALYZER pro allows you to combine individual conditions with logical AND and OR operations. The AND blocks are combined with logical OR. The individual conditions within each block are combined with logical AND. 4.3.2 Trigger on bit signals Drag with the mouse a bit signal address on the desired position in the Trigger list. As soon as you let go of the address the window Trigger value will open. Now choose 1 = TRUE or 0 = 4-8 Data acquisition FALSE. Confirm your selection with OK. Now the address appears with its trigger value in the trigger list. By a double click on the address the trigger value can also be changed later. With <Del> the selected address will be removed from the trigger list. Fig. 4-6 Entering the trigger value of a bit signal 4.3.3 Trigger on analog signals Drag with the mouse an analog value address to the desired position in the Trigger list. As soon as you let go of the address the window Trigger value will open. Select one of the four comparison operators under Operator, than enter the corresponding number value under Trigger value. The Hysteresis can be set in order to prevent trigger-bouncing resulting from small signal fluctuations. The program determines the Upper cut-off and Lower cut-off automatically according to the entered hysteresis value. When triggering on equal „=“or unequal „< >“ the entered hysteresis is used as the fuzzy value. Fig. 4-7 Entering trigger value of an analog signal Data acquisition 4-9 The following table explains the function of the various trigger operators: Trigger operator Description < Triggering occurs, if the trigger value is exceeded. Triggering can occur again, only if the signal falls below the lower cut-off value. Triggering occurs, if the signal falls below the trigger value. Triggering can occur again, only if the signal exceeds the upper cut-off value. Triggering occurs, if the measured value lies in the range between the lower and upper cut-off values. Triggering can occur again, only if the signal goes outside the range. Triggering occurs, if the measured value leaves the range between the lower and upper cut-off values. Triggering can occur again, only if the signal enters the range. > = <> Table 4-3 Trigger operator 4-10 Data acquisition Fig. 4-8 Principles of analogue triggering ( < , > , = , <> ) Data acquisition 4-11 Confirm your selection with OK. Now the address appears with your trigger value in the trigger list. With a double click on the address you can also change the trigger condition later. With <Del> the selected address will be removed from the trigger list. 4.3.4 Trigger action With Action in the window Trigger you can open the action window of the selected trigger. Here all actions can be set, which should be carried out during the trigger action. Fig. 4-9 Setting trigger properties 126.96.36.199 Activate and deactivate address sets and trigger (cascading) A fired trigger can activate or deactivate trigger addresses as well as triggers. The list Address set activate/deactivate displays the address sets that were defined before in the Address selection window. Selecting the control field in front of an address set causes the corresponding set to be selected. If a trigger fires during signal acquisition, the selected address sets in the lists are activated (or deactivated). After the trigger has fired the addresses of the activated address sets are thus seized, whereas the collection the deactivated sets stops. Under Trigger activate and Trigger deactivate triggers can be activated and deactivated in the same way. Data acquisition 4-12 188.8.131.52 Send an E-Mail Activate the control field Sending E-Mail in order to send an E-Mail during a trigger event. Under Configure you set the options to send an E-Mail from your computer. The E-Mail will be send either over the fitted Standard Mail program (e. g. Outlook) or over a SMTP server. Enter one or more E-Mail addresses. Under Subject the PLC-ANALYZER pro enters a subject line automatically, which can be changed if necessary. Now enter under Text an E-Mail text. Through activating Attach signal file to E-Mail the signal file, which has been produced by the trigger event will automatically added be to the E-Mail. With Test you can test in advance, if all settings are correct and if the E-Mail has been sent duly. 184.108.40.206 Send an SMS Activate the control field Send SMS in order to send an SMS during a trigger event. Under Configure you set the options for sending an SMS. First choose how a connection to the SMS exchange has to be established. Depending on the equipment of your computer the PLCANALYZER pro can produce a connection over DUN (Dial-Up Networking) adapter (analog modem or ISDN-CAPI). Choose an SMS Center. Enter, if necessary, your MSN number and activate the control field Modem at an extension line, as long as your DUN adapter is connected to an extension. Confirm the input with OK. NOTE Other settings for DUN adapter have to be made, if necessary, in the control system of Windows. Now enter the telephone number of the receiver as well as the text of the SMS. With Test you can test in advance, if all settings are correct and if the SMS has been sent duly. 220.127.116.11 Acoustic signaling Activate the control field Acoustic signaling in order to announce a trigger event acoustically via a sound file (WAV-file) or alternative via audio response. First choose a path to the WAVfile or enter the text the computer should pronounce. With Test you can test in advance if all settings are correct and if the acoustic signaling has been sent duly. Note The installation of Microsoft Text-to-Speech-Engine is required for a text announcement as well as a soundcard with online speakers. Free download of Microsoft Text-to-Speech-Engine under: http://www.microsoft.com Data acquisition 4.4 4-13 Scaling of register values With the help of online scaling you can influence the display of analog values in respect to their number value and the graphical representation. For example, you can convert signal values to physical units (m, kg, hPa ...) and display them correspondingly on the screen. You can specify unit, factor, and offset of an analog value. The analog signal is converted according to the following formula: Display value = Factor Measured value + Offset Fig. 4-10 Register scaling for online display Select the signal to be scaled and change, if necessary, the default values in the corresponding text boxes. First change the Format of the selected address. Depending on the selected address different number representations can be chosen. Enter the number of Decimal places. With choice of Display as floating point the numerical value of the address will be indicated as a floating point number. If you are interested in seeing the bit pattern for a particular measured value, switch under Signal display to Bitpattern. In order to reduce the amount of recorded data for lightly fluctuating analog values, choose Low order bits ignore. Variation of measured values in these bits will not be considered. The vertical scale of an analogue signal can be adapted automatically with Auto scaling. The signal is scaled in such a way that the maximum value lies at the upper end of the scale and the minimum value at the lower end. Automatic scaling is preset as default. Data acquisition 4-14 If you desire fixed scaling of the displayed values, you can choose the Automatic scaling. Now you can manually enter the scaling limits for the display under Min and Max. Entry takes place according to the format set under format. Fixed scaling is useful, for example, if you would like to “zoom” small changes of a measured value in a particular value range. Please note, that changing the sign interpretation may cause the minimum and maximum values to be reversed. 4.5 Modes of data acquisition Three different types of acquisition are available. You can specify the type of data acquisition under Acquisition mode. Fig. 4-11 Setting the acquisition mode Data acquisition 4-15 The signal data acquired by the PLC are saved in a signal file according to the acquisition mode. The following table shows the differences: Acquisition mode Description Manual The selected PLC signals are recorded from manual start to end without breaks. Under Signalfile size you can limit the size of the signal file. If the limit is reached, the current signal file is saved and a new signal file will automatically be created. With the control field Ringbuffer you can activate the ring memory function. The signals are saved in signal files, under Signal file size with adjustable, fixed size. When the ring memory is full the oldest signal file will be deleted. The standby of recording will be started and ended manually. According to the trigger conditions set, (see also chapter 4.3 Trigger) the measuring data will be saved around one trigger or between a start trigger and a stop trigger in a signal file, if a trigger occurs. When acquisition starts, you are requested to specify the Start time and Stop time for the recording. The selected PLC signals are recorded between these points in time. Recording stops when the stop time is reached. Trigger Time controlled Table 4-4 Modes of data acquisition 4.5.1 Cycle-precise acquisition In addition to the acquisition modes already explained, some PLC drivers (e.g. SIMATIC S7 and S5) allow cycle-precise data acquisition. Selected signals within the PLC are pre-acquired cycle-precise. More detailed information can be found in the corresponding driver addendum. 4.6 Starting data acquisition Make sure that the data acquisition attributes have been set correctly. Exit the Project options window only by clicking on the OK button. The online windows you have defined appear on the screen. Save your project with Save project in the File menu, so it can be used again later. If you want to modify your project again, select the menu item Project options... in the Project menu or confirm . Start acquisition with Start acquisition in the Project menu or by the symbol in the icon toolbar. PLC-ANALYZER pro tests the communication with the automation device first, in order to test the connection and to determine any particularities of the connected PLC driver or its CPU. Data acquisition 4-16 NOTE If the communication test fails, you are notified with the message "Error during connection attempt". In this case, check the settings of the PLC driver under Extras - PLC driver and hardware connection to the PLC (see driver addendum). After successful connection PLC-ANALYZER pro records the selected PLC signal data and creates - depending on the acquisition mode - one or more signal files. If you have selected online signals, these are displayed on the screen either in an oscilloscopelike manner or in text form. Otherwise the signal display area of the screen remains empty. For online display the left column shows the address identifier in absolute or symbolical form as well as the y-axis of the signals. In the right column the currently measured values are displayed. Occurring triggers are displayed immediately as vertical dashed lines on the screen. The time base can be changed during acquisition. Signals and their scaling can be changed when data acquisition is running. To do this, select the menu item Project - Project settings . Data acquisition is not interrupted, however. The settings are stored in the signal file. Fig. 4-12 Signal acquisition with graphics and text online window Data acquisition 4-17 NOTE An analog signal is displayed in grey, if the signal falls outside the range of the scaling limits. With automatic scaling the scale is corrected after every pass of the signal over the screen. Communications trouble also causes the signal color to change to grey. In this case the current values are not displayed. The name of a signal file is dependent on the time of the first recorded PLC signal entry. The name is made up of day, month, year, hour, minute, and second, plus extension ".SPS ", e.g. 45 2005-04-21 12.45.00.SPS (created on 21 April 2005 at 12. ). Acquisition is terminated by selecting the menu item Project - Stop acquisition or by the symbol in the icon toolbar. After ending acquisition the last signal file created will automatically be opened. The time base is automatically chosen, so that the entire recorded signal is visible in the online window. Signal display and analysis 5-1 5 Signal display and analysis The evaluation of recorded signal data is described in this chapter. Various tools are available from PLC-ANALYZER pro for detailed analysis, e.g. time measurement, various search functions and signal statistics. 5.1 Opening a signal file After data acquisition PLC-ANALYZER pro automatically loads the last signal file created. You can also open a signal file in the File menu either with the History list (contains the four most recently loaded signal files) or with Open signal file... Fig. 5-1 Opening a signal file The signal files are listed chronologically in the file selection window. Comments with notes on the contents of a signal file are displayed under Comment. To open a signal file, select it and then simply click on the Open button. Signal display and analysis 5-2 Fig. 5-2 Signal file display The name of the opened signal file is displayed in the title bar of the signal window. You can have several signal files open simultaneously, so that a direct comparison is possible. A signal window is opened with the signal selection and scaling contained in the signal file. In a signal window the left side displays the address identifiers of the displayed signals in absolute or symbolic form. The right side shows the signal values at the current cursor position. The time base for the display is always chosen, so that the contents of the entire file fit in the signal window. For a detailed analysis it is useful to set an appropriate time base (s. chapter 5.5.2 Setting the time base). 5.2 Signal selection When a signal file is opened the PLC signals are displayed according to the online selection in the signal file. If you wish to change the signal selection then click on the menu item Selection in menu Signal file. Alternatively, you can click the right mouse button in the display area of the signal window and choose the Selection menu item in the context menu Signal file. Now make the adequate settings (see chapter 5.2 Signal selection) and press the button OK. Now the signal process is displayed in the signal window. Signal display and analysis 5-3 5.3 Signal Scaling of register values While opening a signal file the PLC signals will be displayed as set by the stored online selection. If you like to change the signal selection choose under Signal file the menu item Signal selection. You also can use the right mouse button in the current signal display and select Signal selection. Now make the adequate settings (see chapter 4.4. Scaling of register values) and press the button OK. The signal course will now be displayed in the signal window. 5.4 Signal cursor The vertical green line (blinking) is the signal cursor. All values displayed in the display fields, such as current level and time, are always in respect to the current cursor position. You simply move the cursor to the signal position you wish to investigate and than read the corresponding measurement values. The signal cursor can easily be moved either with the mouse or the keyboard. You can move the cursor to a desired position e.g. by moving the mouse. If you move the cursor through the left or right border of the signal display window, the signal file view will scroll slowly forward or backward. The same effect can be achieved by clicking in the address display or on the current values. Key Function cursor steps forward cursor steps backward scroll forward by 10 pixels (cursor does not move) scroll backward by 10 pixels (cursor does not move) page up page down cursor to beginning of screen on left cursor to end of screen on right cursor to beginning of signal file cursor to end of signal file Ctrl+ Ctrl+ Page Page Home End Ctrl+Home Ctrl+End Table 5-1 Use of the keyboard Signal display and analysis 5.5 5-4 Time information On the bottom of the graphics signal window important information and options in respect to time display are shown. Fig. 5-3 Time information 5.5.1 Absolute and relative time display In the Cursor time text field the current time at the signal cursor position is displayed continuously. Two different displays can be selected: 1. Relative: Time display relative to the beginning of the signal file. 2. Absolute: System time (computer time) from the moment of incoming data. You can change the time display under menu item Relative time display in menu View or via the symbol in the toolbar. The general format for time display is: hh:mm:ss,xxx (hh = hour, mm = minute, ss = second, xxx = millisecond). 5.5.2 Setting the time base The time base shows the time per screen pixel. The setting has to be made under Time base. Activate the left spin field with the mouse in order to modify the time base. Alternatively, you can enter the new time base directly into the text field. Confirm your entry with <ENTER>. The time-base unit is automatically adapted to the number value entered. When the number value moves outside certain limits, the unit is automatically changed to the next lower or higher unit. If the signal file is long enough, you can also manually change the unit by using the right spin field. In cycle precise signal files the time base „ZP“ (cycle per pixel) resp. „mZP“ (milicycle per pixel) is used too. Refer to 7.4.6 Particularities in signal display and analysis for detailed information. 5.5.3 Time measurement For making a time measurement of signals via PLC-ANALYZER pro it is possible to accomplish a time difference measurement and a bit measurement. Signal display and analysis 5-5 Fig. 5-4 Activated time difference measurement 18.104.22.168 Time difference measurement The time difference measurement allows you to measure the time difference between two arbitrary positions. First, position the signal cursor on a reference point. Now activate the time difference measurement and choose under Signalfile the menu item Time measurement / timedifference or click on the symbol in the toolbar. The reference point is marked by a fixed reference cursor. Click with the mouse on the second measuring point. The time difference will now be shown. If you like to change the measuring points later, drag with the left mouse button to the new measuring point. If you like to change the measuring points with the keyboard, navigate the cursor to a measuring point and press the button <Ctr>. Hold the button <Ctr> and change the position of the measuring point with the arrow keys ( and ). Mark a time difference measurement with the mouse to remove it and press <Del>. 22.214.171.124 Bit measurement With the bit measurement bit signals can be measured easily. The time between two edges of a bit signal will be measured. Activate the bit measurement and choose under Signalfile the menu item Time measurement / time-difference or click on the symbol in the toolbar. Click with the signal cursor on a bit signal. The corresponding bit signal will be measured automatically. Finish the measurement via the menu item Time measurement / time-difference or click on the symbol in the toolbar Mark a bit measurement with the mouse to remove it and press <Del>. Signal display and analysis 5.6 5-6 Search functions PLC-ANALYZER pro supports the search for certain bit patterns, signal slopes, triggers, specific points in time or notes within a signal file. Activate the search function with the menu Find by clicking the right mouse button in the display area of the signal window (keyboard: Ctrl + ) or by choosing the adequate symbol in the toolbar. 5.6.1 Find trigger The triggers set within a signal file are displayed as vertical dashed lines. Select the menu item Find – Find trigger , in order to activate the Find trigger window. Fig. 5-5 Find trigger Enter the name of the trigger in the Trigger text field. With the option "All triggers", all arising triggers will be searched for. Specify the search direction with forward and backward. If you like to scan all signal files in the directory of the current signal file, choose the menu item Search in all signal files in this directory. Click on Find to start the trigger search. The program now searches for the next trigger in the given search direction and positions the signal cursor on it. 5.6.2 Find time Select the menu item Find - Find time to find a specific point in time in a signal file. Fig. 5-6 Find time Enter the desired time. It is also possible to use the spin controls to find a specific point in time. The time search will be done according to the setting in the signal window (absolute or relative time). The time search will be started with Find. The program searches for the corresponding time stamp and positions the signal cursor on it. 5-7 Signal display and analysis 5.6.3 Find bit pattern In order to search for a particular binary signal pattern, select the menu item Find - Find bit pattern . All bit addresses displayed in the active signal window are listed under Addresses. Now enter the desired search pattern in the text fields right of the addresses. Permitted signal conditions are "1", "0", and "X" (1 = TRUE, 0 = FALSE, X = don’t care). Alternatively, you can change the search values by using of the spin controls on the appropriate spin field. If you like to scan all signal files in the directory of the current signal file, choose the menu item Search in all signal files in this directory. Specify the search direction with forward and backward. Click on Find to start the trigger search. The program now searches for the next bit pattern in the given search direction and positions the signal cursor on it. Fig. 5-7 Find bit pattern 5.6.4 Find analog value To find a specific analog value in a signal file, use the analogvalue search. Select the menu item Search - analog value . Fig. 5-8 Searching for an analog value First, select under Address the signal to be examined, and then enter the Operand and the Value you wish to find. If you like to scan all signal files in the directory of the current signal file, choose the menu item Search in all signal files in this directory. Specify the search direction with forward or backward. Start the search with Search. The program now searches for the next analog value in the given search direction and positions the cursor on it. Signal display and analysis 5-8 5.6.5 Find edge In order to search for a particular signal edge, select the menu item Find - Find edge . All bit addresses displayed in the active signal window are listed under Addresses. Now enter the desired edge form in the text fields to the right of the addresses. Permitted entries are "+", "", "B", and "X" (+ = positive edge, = negative edge, B = any edge, X = don’t care). Alternatively, you can change the search values by using of the spin controls on the appropriate spin field. If you like to scan all signal files in the directory of the current signal file, choose the menu item Search in all signal files in this directory. Specify the search direction with forward and backward. Click on Find to start the search. The program now searches for the next edge pattern in the given search direction and positions the signal cursor on it. Fig. 5-9 Find edge 5.6.6 Find note To find already inserted notes you have to choose the menu item Find - Note (see also chapter 5.7.3 Insert Note). Fig. 5-10 Find note First choose the note you are looking for. If you select „All Notices“, all notices will be searched for. Set the search direction via forward und backward. Set Find to start the search. The program will search for the next note in the search direction and positions the signal cursor on it. Signal display and analysis 5-9 5.7 Adapting signal display PLC-ANALYZER pro allows you to make an individual configuration of the signal display. The signal colour, shift signals and title signals can be changed. 5.7.1 Moving of signals Choose from the left column of the online window the identifier of the PLC-address with the mouse, then drag the signal with the left mouse button to the desired position. It is also possible to change the height of analogue signals. Drag the upper or lower gage of the signal scale with the left mouse button upward or downwards. The signals can also be moved directly in the online window (see chapter 5.2 Signal selection). 5.7.2 Change signal color Choose from left column of the online window the identifier of the PLC-address, which colour you want to change. Press the right mouse button and select the menu item Change signal color. Choose the desired colour. It is also possible to change the colour of the signals directly in the online window (see chapter 5.2 Signal selection). 5.7.3 Insert notes Choose the menu item Notice / New in the signal file menu and click on a point in window where the signals are shown and where you want the note to be shown. A text field will appear. Fill in your desired text. By pressing <ENTER> you can jump to the next line. With the mouse you can click in this text field or press <ESC> to accept the note. Already existing notes can also be moved. Drag the note with the left mouse button to the desired position. The position of the arrowhead can also be moved in the manner. The text of a note can be changed by a double click on the note. If you like to remove an existing note, move the mouse on the not, press the right mouse button and choose menu item Delete. 5.7.4 Changing symbol addresses and symbol comments Position the mouse cursor on the PLC address whose symbol or comments you wish to modify. Right-click the mouse and select the menu item Signal info. Fig. 5-11 Signalinfo Via the window Signalinfo it is possible to change the symbol and the comments. Signal display and analysis 5-10 5.7.5 Mark area For specific features of PLC-ANALYZER pro it is necessary to mark an area of a signal file, e. g, if you like to store, export, print, zoom an area or make a statistic analysis. Position the signal cursor on the beginning of the part, which you like to be marked. Choose Area / Mark in the menu Signal file and drag the cursor to the desired end of the marking. The marked area will be displayed in blue. Make a left-click to end the marking, or choose the menu item Area / Mark via right-click. It is also possible to press and hold the shift button (Shift ) and move the signal cursor with the mouse or through the keyboard. Press right mouse key in the marked area to choose more options under the menu item Area. 5.8 Signal file comparison PLC-ANALYZER pro also gives you the opportunity to compare two signal files. By doing so it is for instance easy to find out creeping wear and tear of machines. Open the signal files, which you like to compare, one after another. Now choose Compare in the signal file menu. The signals of both signal files will be shown superimposed in one online window. Fig. 5-12 Signal file comparison The signals of the non-active signal file are displayed in grey. The signals of the active signal file appear in the previously set color. Under Active signal file the active signal file can be changed if needed. Signal display and analysis 5-11 All signal-file functions, e.g. cursor time, time difference, search functions, refer to the active signal file. With Offset you can shift the signals of the active signal file horizontally. This enables you to specify a common reference point. 5.9 Signal statistics With PLC-ANALYZER pro you can create a statistical overview of the signals over a period of time. Select the menu item Signal statistics in the signal-file menu in order to obtain various statistics on a given signal. Fig. 5-13 Signal statistics Select under Absolute the address over which statistical information is to be obtained. Symbol name and comments of the selected address are adapted automatically. Select under Range the desired range of the signal file to which the analysis is to refer. If you have marked the desired range of the signal file already (see chapter 5.7.5 Mark area), only the marked range will be valuated statistically. Signal display and analysis 5-12 The following table explains the statistical evaluation for a discrete signal (bit address): Field Explanation Signal high Shows the period of time during which the signal in the selected range was HIGH (TRUE, logical 1) Shows the period of time during which the signal in the selected range was LOW (FALSE, logical 0) Number of signal-edge changes in the selected range Shows the longest period of time during which the signal in the selected range was HIGH (TRUE, logical 1) Shows the shortest period of time during which the signal in the selected range was HIGH (TRUE, logical 1) Shows the longest time during which the signal in the selected range was LOW (FALSE, logical 0) Shows the shortest time during which the signal in the selected range was LOW (FALSE, logical 0) Signal low State change Longest high phase Shortest high phase Longest low phase Shortest low phase Table 5-2 Statistical evaluation of a bit address Under Cycle time cycle times of single bit signals will be shown. First adjust the type of cycle. Choose either Signal at High (from rising edge to next rising edge) or Signal at Low (from trailing edge to next trailing edge). The longest high phase, the shortest high phase, the longest low phase and the longest low phase will be displayed. For register values (byte, word, or double word) the following information is displayed: Field Explanation Maximum value Maximum value of the signal in the selected range. Minimum value Minimum value of the signal in the selected range. Average Average value of the signal in the selected range. Table 5-3 Statistical evaluation of a register address Fig. 5-14 Signal statistics - register values When selecting a register value you can also calculate how often a particular signal value has occurred. Enter an operand and a signal value. Click on Calculate and the result will be displayed. 5-13 Signal display and analysis 5.10 Project info With PLC-ANALYZER pro it is also possible for the documentation of a project to create a general view of all project settings. Select the menu item Project info in the project menu. All project data will be shown by Project info. If you select Save all project settings will be stored in a text file. Use Print to print all project data. 5.11 Saving a signal file To save changes in a signal file select in the menu File the menu item Save signal file or Save signal file as. 5.11.1 Saving an extract PLC-ANALYZER pro enables you to also save extracts of a signal file. Simply select the desired area with the help of the time difference measurement (see chapter 5.7.5 Mark area) and select the option Area / Save under the menu Signalfile. Specify a name for the extract and click Save. 5.12 Printing a signal file You can either print the entire signal files or extracts of the signal files. Via the menu item Print… in the File menu the printer selection window will be opened. Select under Printer the desired printer. Enter the desired range to be printed from the signal file. Click on the option Current page, if you would like to print the displayed area in the active signal window. Select All in order to print the entire signal file with the time base set in the current online window. Fig. 5-15 Printer selection window If you like to print a very specific range, please mark the range first (see chapter Mark area), then choose Current page in the printer menu to print this area. The option field Copies indicates how many copies of the signal file shall be printed. Start printing with OK. An information window appears during printing. In figure 5-16 you can see an example of a printout: Signal display and analysis Fig. 5-16 Printout of a signal file (not to scale) 5-14 5-15 Signal display and analysis 5.13 Exporting of signal files Signal data can be exported as a text (CSV - comma separated values), as a graphic or as a WebSite (HTML). In text form the measuring data can e.g. be processed in a spread-sheet analysis. HTML exports are very useful for showing the signal files to third parties, via Web-Browser (e.g. Internet-Explorer). Via the menu item Export… in the menu File the export selection window will be opened. Fig. 5-17 Export in ASCII format 5.13.1 Export as a graphic (bitmap) Enter the name of the export file under File / Export and activate the control-field Graphic. Under Properties you are able to specify the graphic format. By using Export the signal file will be exported as a graphic in the specified format. 5.13.2 Export as a HTML-Site Activate the control button Web-Site and select under Export folder the path of the HTML-site and the attached JPEG-pictures (Signal file sector). By clicking on Properties the properties window will be opened. Here you can create a Description and the Size of thumbnails and you can define the Number of pictures, in which the signal file shall be separated. Clicking the button Export generates a Web-Site and exports the signal file areas as a JPEGpicture. The Web-Site can be opened with each Web-Browser (e. g. Internet-Explorer). With the WebSite you get an overview and it shows the signal file - divided in sectors - as little thumbnails. Click on the thumbnails to display the pictures in original size. Signal display and analysis 5-16 5.13.3 Exporting signal files as a text Specify under Export file the name of the export file and activate the control field Text (CSV). Under Range you can choose the desired area of the signal file, which shall be exported. You only can activate Mark, if you have marked an area in the signal window before (see chapter Mark area). Click on the Properties button to open the properties window. Determine the Separating characters between each measured value. If you activate Data definition in the first line the data column will be captioned with headlines. With Interval you set the time lag between the signals you like to export. Choose Export when signal changes only, if you like to export signal changes. The export file will be much smaller then. By choosing Every scan point data will be exported, if a scan point appears. Clicking on Export exports the signal file. Relative time, absolute time, signal values, trigger as well as occurred errors during the data recording will be exported. The export file is formatted in such a way, that a processing for instance with Microsoft® Excel® is possible. Relative time ... Absolute time Q 3.1 Q 3.2 Q 3.5 Q 3.7 FW3 T 1 Z 1 10 DW 1 Trigger Errors 0 12:50:40.000 0 1 0 0 8677 95 55 29745 0 0 50 12:50:40.050 1 1 0 0 8677 95 56 32301 0 0 100 12:50:40.100 1 1 0 0 8816 87 57 32301 0 0 150 12:50:40.150 0 0 0 0 8957 80 58 30679 0 0 200 12:50:40.200 1 0 0 0 8957 72 59 28123 0 0 250 12:50:40.250 1 0 0 0 9097 72 60 28123 1 0 300 12:50:40.300 0 1 0 0 9238 65 61 25567 0 0 350 12:50:40.350 1 1 0 0 9238 58 62 23011 0 0 400 12:50:40.400 1 1 0 0 9377 58 63 23011 0 0 450 12:50:40.450 0 0 0 0 9517 50 64 20473 0 0 ... ... ... ... ... ... ... ... ... ... ... Fig. 5-18 Example of an exported signal file (extract) 5.13.4 Graphical evaluation of signal data in Microsoft® Excel® The following examples illustrate the graphical evaluation of signal data in a spread-sheet program (Microsoft® Excel®). The examples shown are designed to give you ideas. Interesting results can also be obtained by using other analysis programs, e.g. mathematics and statistics programs. Start Excel® and open the CSV file exported by PLC-ANALYZER pro. After you have responded to some queries regarding import (e.g. used separators), Excel® reads the data formatted into cells (see Fig. 5-18). Now you can use the built-in graphic functions of Excel® to obtain useful graphical representations for various application purposes. Signal display and analysis 5-17 Revolution turbine SLK04 100000 10000 FW 3 1 / min 1000 10 DW 123 100 10 11:48:50.800 11:48:40.800 11:48:30.800 11:48:20.800 11:48:10.800 11:48:00.800 11:47:50.800 11:47:40.800 1 time Fig. 5-19 Logarithmic representation of PLC analog signals with Excel® Furnace 6 700 600 500 FW 130 400 T 3 300 10 DW 10 Z 11 200 100 11:48:50.800 11:48:40.800 11:48:30.800 11:48:20.800 11:48:10.800 11:48:00.800 11:47:50.800 11:47:40.800 0 Fig. 5-20 3D representation of PLC analog values with Excel® Impulse plan 25 I 21.7 I 32.2 I 32.1 Q 3.1 Q 3.2 Fig. 5-21 Discrete signals with Excel® 30000 25000 20000 15000 10000 5000 0 0 Signal display and analysis 5-18 5.14 Import of signal files With PLC-ANALYZER pro it is also possible to import data in a text format. The import format has same structure as the format for the signal export (see chapter 5.13.3 Exporting signal files as a text). Fig. 5-22 Importing Data Click the Import button in the file menu to start the importing of data. Choose the data file, which shall be imported and click Open. The window Import will appear. The settings for the import can be made from here. In the bottom part of the window data preview is shown. Here you can see how the settings affect themselves. Set the Separating character, which separates the measured values in the data file. By activating Data definition in the first line the first line will be ignored when importing the data, because normally the headlines of the columns are positioned here. Under Data format of columns you can assign the appropriate format to each column. Mark in the data preview those columns, where you would like to change the format. Change to the desired format. A column can include the Relative time, the Absolute time, a Date or a Measured value. For a measured value determine the Name of the measured value as well as the Format. Choose Don’t import column, if a column shall be ignored. Click Import. PLC-ANALYZER pro will take over the data form from the text file and indicates it in an online window. The created signal file can be changed and stored at any time. Remote diagnosis 6-1 6 PLC-Process data recording and remote service Long-term recording of signals is favourable in many respects. Besides detecting of sporadic errors, the recorded data also serves as and incorruptible evidence in searching for causes and helps to eliminate faults. Based on the logic analyzer „PLC-ANALYZER pro“, AUTEM provides a BLACKBOX Mini-PC, which archives PLC-signals. This equipment records signal data of different PLCs over years and also allows remote service. Fig. 6-1 BLACKBOX 2 6.1 BLACKBOX 2 for PLC-ANALYZER The BLACKBOX from AUTEM provides an ultra-compact data acquisition computer for longterm recording of PLC signals and external electrical values (PLC process data archiving). Due to its small dimensions, the system can be integrated in a switching cabinet without any problem. The BLACKBOX can continuously record and archive processing data over a longer period of time; typically in excess of 3 years. The special recording software “PLC-ANALYZER pro for BLACKBOX” is used. The BLACKBOX works autarchic and does not need any additional periphery. Simply power supply (24 V DC or 100-240 V AC) and a connection to the PLC are necessary. An integrated “Watchdog” ensures that the BLACKBOX is automatically rebooted in case of a recording fault. The operating status of the BLACKBOX can also be requested at any time from an external device (floating contact). Recording is automatically resumed after rebooting. The high degree of operational reliability enables a continuous recording of signals over several years. When the capacity limit has been reached, the oldest signal file is automatically deleted to create new space for signal data. Remote diagnosis 6.2 6-2 BLACKBOX - fields of application PLC-process data recording Failure diagnosis Determine cause of downtimes Preventive maintenance Plant documentation QS, TPM, OEE Remote service This form of continuous recording is relevant for system- and machine- manufacturers and users because the data obtained is applicable for localizing faults as well as documenting operating behavior and system operation. Maintenance, construction and quality assurance receive valuable information concerning the system. The recorded data also serves as incorruptible evidence in searching for the causes and elimination of faults. It is connected to the PLC by the PLC-ANALYZER pro, via connection to the PU interface or an automation network (MPI, PROFIBUS, Industrial Ethernet TCP/IP, Modbus+ …). The optionally available AD_USB-Box even enables additional, simultaneous acquisition of external electrical measured values (Input: 8 x analog, 20 x discrete). It is possible acquire data from several, different PLCs simultaneously. The same values as from PLC-ANALYZER pro can be recorded: Input, output, flag, counter, timer, data word, data block, etc. Operating disturbances and associated losses of production cause immense costs. Therefore it is very important for the management to find out, who is responsible for damages and for instance to claim against the suppliers. Detailed recorded process data is very helpful in this matter. 6.3 Remote service with the BLACKBOX The keyboard, the mouse and the screen can be directly connected to the BLACKBOX. Very smart is the Remote-Service via network connection (LAN) from any desired PC. The software needed is part of the scope of delivery. The BLACKBOX is preset for distance control by DUN (Dial-Up Networking Modem) or Internet (VPN). The remote service of facilities is therefore much easier. At any time it is possible to transfer signal data, recorded by PLC-ANALYZER pro, via the remote network connection to any external PC, even during the recording process. The BLACKBOX will be supplied with the desired software configuration - “ready-to-run”. SIMATIC S7 7-1 7 Driver addendum Siemens SIMATIC S7 This driver addendum describes the particularities of the following PLC drivers and gives you hints on using them. Siemens SIMATIC S7 - MPI / PPI / PROFIBUS - cycle-precise1 Siemens SIMATIC S7 - Industrial Ethernet TCP/IP / PROFINET - cycle-precise The listed driver SIMATIC S7 - MPI / PPI / PROFIBUS allows acquisition of PLC signals through PROFIBUS and all usual MPI/PPI PLC circuits from Siemens. The SIMATIC S7 Industrial Ethernet driver makes a recording of data via Industrial Ethernet TCP/IP or PROFINET possible. It is important that you read through the driver addendum before using a PLC driver. Please pay attention to the WARNINGS that advise you on possible dangers when using PLCANALYZER pro. ! 7.1 WARNING Errors that may occur in the automated facility, endangering humans or causing large-scale material damage, must be prevented by additional precautions. These precautions (e.g. independent limit monitors, mechanical interlocks) must guarantee safe operation, even in case of dangerous errors. Installation The PLC driver can be installed while PLC-ANALYZER pro is operating. Select PLC driver in the menu Extras. Click Add in the PLC driver window. If the desired driver is not on the list, you have to install a new driver via the License-key management (see chapter 2-2 Installation). PLC-ANALYZER pro can load the same or different PLC-drivers more than once. E. g. to acquire signal data from two different SIMATIC S7 controls via Ethernet, simply load PLCdriver for S7 - TCP/IP twice and parameterize both accordingly (TCP/IP address etc.). To acquire signal data from a SIMATIC S7 and a SIMATIC S5 simultaneously, just load the PLC-driver SIMATIC S7 and the PLC-driver SIMATIC S5. 7.1.1 Installing additional hardware If you have already connected your programming unit (or your PC) for programming under STEP7 (or alternative programming software) with the automation device through a PROFIBUS-, Ethernet-, an MPI or a PPI interface, normally nothing else must be done. All conventional programming-interfaces are supported. 7.1.2 Installing additional software To use the S7 driver STEP 7, at least version 3.0 must be installed on your computer. You also have to install SIMATIC NET, if you want to establish a connection via Industrial Ethernet TCP/IP / PROFINET. 1 also suitable for SIMATIC C7, SAIA xx7 and VIPA SIMATIC S7 7.2 7-2 Configuring the PLC driver After installing the driver important parameters can be set under Properties. If you have loaded more than one driver, you can set the properties for each driver individually. Fig. 7-1 Settings PLC driver (SIMATIC S7) Choose a Name for the driver first. Set the Station address and the slot number of the desired CPU. Depending on the PLC driver, the Station address can be an MPI/PPI/PROFIBUS- or an ethernet address. If the CPU is only reachable via a gateway, acivate Gateway. Enter Station address of Gateway and S7 subnet ID of destination network. Refer to the hardware configuration of your STEP7 project for these settings. Note For SIMATIC S7 Ethernet-driver you can enter either the TCP/IP-address or the MAC-address of the CP. Pay attention to enter under slot the slot of the CPU and not the slot of the CP. Use Time stamp to specify whether the time stamps should be entered into the signal file continually (at every scan point) or only for signal changes. For a continuous time stamp the exact scan points are documented, even for a signal which does not change. The signal files are therefore larger. Under Scan interval enter the length of time between read-out of data from the PLC. A longer scan interval may be chosen for non-critical time signals, e.g. temperature. The signal files thus created then become smaller. Under Symbolism you can refer a symbol file for the loaded driver. This makes it possible to use symbolic identifier for the address definition (see chapter 4.1 Address selection). Besides the absolute addresses, the symbolic identifier and the comments will be shown and stored in a signal or a project file. SIMATIC S7 7-3 For recording of very brief signal changes, activate Cycle acquisition (see chapter 7.4 Cycleprecise acquisition). 7.3 Data acquisition 7.3.1 Supported PLC models and CPUs The drivers for the SIMATIC S7 family support the CPUs for the PLC S7-200, S7-300, S7-400, S7-1200, M7, C7, SINUMERIK (S7), SAIA xx7, VIPA S7 and also S7-PLCSIM. 7.3.2 Recordable PLC addresses The following table shows the recordable addresses and the corresponding address syntax: Syntax Address type Example Qx.z QBx QWx QDx Ix.z IBx IWx IDx Fx.z FBx FWx FDx Tx Cx DByDBXx.z DByDBBx DByDBWx DByDBDx PIB x PIW x PID x Output byte x, bit z Output byte x Output word x Output double word x Input byte x, bit z Input byte x Input word x Input double word x Flag byte x, bit z Flag byte x Flag word x Flag double word x Timer x Counter x Data byte x, bit z from data block y Data byte x from data block y Data word x from data block y Data double word x from data block y Peripheral input byte x Peripheral input word x Peripheral input double word x Q32.4 QB9 QW14 QD98 I17.0 IB127 IW12 ID124 F3.7 FB250 FW24 FD134 T2 C5 DB23DBX2.5 DB2DBB5 DB12DBW5 DB27DBD0 PEB 231 PEW 232 PED 304 Table 7-1 Address syntax SIMATIC S7 SIMATIC S7 7-4 NOTE The automation devices of the SIMATIC S7 family allow only byte-oriented data acquisition. PLC-ANALYZER pro automatically converts a given bit address to a byte address. All bits are available for display. 7.3.3 Number of recordable addresses Up to 1000 addresses can be recorded. Per scan 20 addresses are transferred simultaneously. If more than 20 addresses are selected, blocks of 20 addresses will be transferred. 7.3.4 Time behavior and particularities NOTE Acquiring data with PLC-ANALYZER pro results in a small increase in cycle time in the automation device to the same extent as with STEP7 in the operating mode "Watch and control variable". The intervals between scan transfers from the SIMATIC PLC to the computer are dependent on the PLC CPU, the number of acquired signals and the transmission speed of the Ethernet-, PROFIBUS- or the MPI- network. For the S7-300 the scan interval (with MPI board) for a byte is approximately 25-30 ms, i.e. for a cycle time > 30 ms there is one scan for each cycle. For each an additional acquired byte the scan interval increases by about 2 ms. With Industrial Ethernet (TCP/IP) the minimum scan interval is about 10 ms. SIMATIC S7 7-5 7.4 ! Cycle-precise acquisition1 WARNING For cycle-precise acquisition PLC-ANALYZER pro programs a small extension to the PLC program in the connected automation device. Please pay attention to the fact that an effect on the operation of the automation device or the PLC program cannot be completely ruled out. Cycle-precise signal acquisition guarantees an acquisition of selected signals of each PLC-cycle without gaps. During cycle-precise signal acquisition a limited number of signals are acquired in the memory of the PLC. The selected signals are stored in the memory during each PLC cycle and are transmitted to the PC in such way, that a continuous cycle-precise acquisition is possible. There is no visible difference in contrast to a normal acquisition. Even the online display can be used as usual. 7.4.1 Installation of additional software For using the SIMATIC S7-driver the STEP7-Software (at least version 3.0) must be installed on your computer. You also have to install SIMATIC NET, if you want to establish a connection with the SIMATIC Industrial Ethernet driver. 7.4.2 Installation of additional Hardware We strongly recommend the usage of a PROFIBUS-, Ethernet- or MPI-card for cycle-precise acquisition; otherwise you may get gaps in the acquisition. 7.4.3 Configuration of PLC-driver for cycle-precise acquisition You can set important parameters for the cycle-precise S7-driver in the menu Options – PLCdriver under Properties. The base configuration of the driver is described in chapter 7.2 Configuring the PLC driver. 1 SIMATIC S7-200 doesn’t support cycle-precise acquisition SIMATIC S7 7-6 Fig. 7-2 Driver settings for cycle-precise driver (SIMATIC S7) For recording of very brief signal changes, activate Cycle acquisition (see chapter 7.4 Cycleprecise acquisition). Generate time stamp is used to associate the time with the data during cycle-precise recording. Deactivate this option when you have so much data to record that data loss can not be prevented. In this case there will be no time information available during signal analysis. In addition you can choose, if the PLC is to be stopped before and after the transmission of the modules to the PLC, by selecting With PLC-Security Stop, you can select whether a conditional module end (BEB) should be checked with a corresponding notification. Such a command in OB1 can result in the required modules for cycle-precise acquisition not being executed. Choose in Time stamp if the data shall be stored in signal file continuously for each cycle or only if the signal changes. The following settings are recommended: Setting Description continuously Choose this setting, if the desired signals will probably change in each cycle. Choose this setting, if the desired signals will probably not change in each cycle. You enable PLC-ANALYZER pro to optimise the recording of signals and to acquire more signals continuously cycleprecise. Only if signal changes Table 7-2 Time stamp settings SIMATIC S7 7-7 NOTE If more addresses are stored to the memory than can be read from the PLC at one time, an overflow of the circular memory will occur and data will be lost. This can be avoided by reducing the number of addresses to be recorded. 7.4.4 Input of addresses Up to 200 addresses (byte-, word- or double word-values) can be acquired simultaneously in the cycle-precise acquisition mode. This restriction is the result of the restricted memory capacity of the PLC and the transmission speed of the PROFIBUS-, Ethernet- or MPI-Interface. An acquisition without gaps is not guaranteed for, if too many addresses are recorded. The number of addresses which will be recorded continuously depends on the following: Cycle time of the PLC program Setting of the time stamp-option (see chapter 7.4.3 Configuration of PLC-driver for cycleprecise acquisition) Transmission speed of the PROFIBUS or MPI-Interface Frequency of the signal change Recording with/without time stamp For a cycle time of 10 ms with a S7-300 (CPU315-2 DP) you can acquire approx. 40 bytes without gaps, if the bytes change each cycle. If the bytes change only each 10th cycle you can continuously acquire approx. 200 bytes without gaps. 7.4.5 Start acquisition Select the option Cycle-precise acquisition in the Properties windows of the PLC driver. ! WARNING It is absolutely necessary that the system is in a safe state before making any modifications. With the setting "With PLC safety stop" PLC-ANALYZER pro switches control of module transfer (or modification) into a STOP state. The operation after the end of the recording will be analog. Now select in the menu Project the menu item Start acquisition. The modules are transferred either during operation or after control stop, depending on the setting you have made in the PLC driver window Properties (see chapter 7.4.3 Configuration of PLC-driver for cycle-precise acquisition). One of the following information windows will appear: SIMATIC S7 7-8 Fig. 7-3 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 7-4 Message before modifications in the PLC for pre-setting "No PLC safety stop" Confirm with Yes only after you have stopped the process or if it is in a safe state. Make sure that damages to property and person by impairment of the function of the control is impossible! PLC-ANALYZER pro searches in the PLC for free module numbers and creates a function module and two data modules for data recording. In addition, a call to the new function module is appended to the end of OB1. The controller is now in the RUN state or is switched to the RUN state. The cycle-precise acquisition begins. The signal changes will now be displayed online. Recording is stopped with Stop acquisition. You should now stop your system (process) or bring the system into a safe condition. Removal of the modifications is now done analogously in the stop state or online. One of the following message windows will appear: 7-9 SIMATIC S7 Fig. 7-5 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 7-6 Message before modifications in the PLC for pre-setting "No PLC safety stop" Confirm the message after you have stopped your system or bring it into a safe condition. The original state in the PLC is restored now. After the end of acquisition the last signal file created is automatically opened for display. The time base is chosen in such a way, that the entire file fits on the screen. 7.4.6 Particularities in signal display and analysis Evaluation of cycle-precise acquired signal files is nearly identical to normal signal files. If no time stamp is generated during signal recording (see 7.2 Configuring the PLC driver), no exact time is assigned to the data. In this case the time will be specified in cycles. The time base is „mZP“ (milli cycle per pixel) resp. „ZP“ (cycle per pixel). Example: A time base of 100 mZP means a PLC cycle is 10 screen pixel wide. If more addresses are recorded than can be read from the PLC continuously, an overflow of ring buffer will occur. Some data will be lost. These gaps in the acquisition are displayed as grey lines. SIMATIC S5 8 8-1 Driver addendum Siemens SIMATIC S5 This driver addendum describes the particularities of the following PLC drivers and gives you hints on the usage: Siemens SIMATIC S5 - PG-Interface - cycle-precise The listed driver makes the acquisition of PLC signals through the programming interface of the PLC possible. In addition to normal operation the cycle-precise data acquisition is also possible. Chapter 8.4 Cycle-precise acquisition describes the particularities of this recording mode. It is important, that you read through the driver addendum first, before you use a PLC driver. Please pay attention to the WARNINGS that advise you on possible dangers when using PLCANALYZER pro. ! 8.1 WARNING Errors that may occur in the automated facility endangering humans or causing large-scale material damage must be prevented by additional external precautions. These precautions (e.g. independent limit monitors, mechanical interlocks) must guarantee a safe operation even in the case of dangerous errors. Installation The PLC driver can be installed while PLC-ANALYZER pro is operating. Select PLC driver in the menu Extras. In the window PLC driver click the button Add. If the desired driver is not on the list, you have to install a new driver via the License-key management (s. content 2-2 Installation). With PLC-ANALYZER pro you can load the same or different PLC drivers more than once. You can, for example, acquire simultaneously signal data from two SIMATIC S5, which are connected to two different COM ports of the PC. 8.1.1 Installing additional hardware If you have already connected your programming unit (or your PC) for programming under STEP 5 (or alternative programming software) with the automation device over a serial cable, usually nothing else must be done. Otherwise connect a free COM port (serial connection) of your programming unit (or PC) with the PG interface of the automation device. Because the serial PG interface on the automation device functions as a current interface (TTY/20mA) , you will need for the connection of you PC, an appropriate connecting cable with integrated RS232 TTY converter (AUTEM item-no. ANA1500 or Siemens item-no. 6ES5 734-1BD20). 8.1.2 Installing additional software In addition to the PLC-ANALYZER pro basic module and the PLC driver no other software is necessary. SIMATIC S5 8-2 8.2 Configuring the PLC driver After installing the driver you can change important parameters under Properties. If you have loaded several drivers, you can set the properties for each driver individually. Fig. 8-1 Driver settings (SIMATIC S5) Choose a Name for the driver first, than specify under Connection the COM-Port (serial interface) of the PC, which is connected by a cable to the PLC. For recording of very brief signal changes, activate Cycle acquisition (see chapter 7.4 Cycleprecise acquisition). This setting has priority over the choice of the acquisition mode (s. chapter 4.5). You can also specify, if for safety reasons the automation device should be stopped before and after the transfer of the acquisition modules. Additionally you can specify, if a conditional module end shall be checked. Use Time stamp to specify, if the time stamps should be entered into the signal file continually (at every scan point) or only for signal changes. For a continuous time stamp the exact scan points are documented even for a signal which does not change. The signal files are therefore larger. Under Scan interval enter the length of time between read-out of data from the PLC. A longer scan interval may be chosen for non-critical time signals, e.g. temperature. The signal files thus created become smaller. Under Symbolism you can refer a symbol file for the loaded driver. This makes the use of a symbolic identifier for the address definition possible (see chapter 4.1 Address selection). Besides the absolute addresses, the symbolic identifier and the comments will be shown and stored in a signal- or project-file. SIMATIC S5 8.3 8-3 Data acquisition 8.3.1 Supported PLC models and CPUs The following models of the SIMATIC S5 family are supported by the AS511 driver: PLC CPU 90U 95U 95F 100U 101U 115U 115F 135U 150U 155U 100, 102, 103 941, 942, 943, 944, 945 942 921, 922, 928, 928B Particularities No acquisition of PW, No cycle-precise acquisition No acquisition of PW No cycle-precise acquisition, no acquisition of PW Cycle-precise acquisition only with CPU 103 No cycle-precise acquisition No cycle-precise acquisition No cycle-precise acquisition 946, 947, 948 Table 8-1 Overview of the supported SIMATIC S5 models Other automation devices and CPUs from the S5 family are generally compatible with PLCANALYZER pro, but have not been explicitly tested. SIMATIC S5 8-4 8.3.2 Recordable PLC addresses The following table shows the recordable addresses and the corresponding address syntax: Syntax Address type Example Qx.z QBx QWx QDx Ix.z IBx IWx IDx Fx.z FBx FWx FDx FWAx PWx Sx.z SYx SWx SDx Tx Cx yDLx yDRx yDWx yDDx yDXx Output byte x, bit z Output byte x Output word x Output double word x Input byte x, bit z Input byte x Input word x Input double word x Flag byte x, bit z Flag byte x Flag word x Flag double word x Flag word analog6 x I/O word x (only input) Special flag x, bit z Special flag x Special flag word x Special flag double word x Timer x Counter x Left data byte x from DB y Right data byte x from DB y Data word x from data block y Data double word x from DB y Data word x from DX-module y Q32.4 QB9 QW14 QD98 I17.0 IB127 IW12 ID124 F3.7 FB250 FW24 FD134 FWA26 PW214 S1010.1 SY2027 SW1423 SD1028 T2 C5 20DL15 21DR53 12DW5 27DD0 22DX15 Table 8-2 Address syntax SIMATIC S5 6 NOTE The automation devices of the SIMATIC S5 family allow only byte-oriented data acquisition. PLC-ANALYZER pro automatically converts a given bit address to a byte address. All bits are available for display. The address type FWA (flag word analog) can be used to acquire analog output values, which are directly transferred in a flag word in the user program to left-justified output format and finally to the analog periphery without using a standard functional module. Backward formatting to the right-justified two-complement-form takes place. SIMATIC S5 8-5 8.3.3 Number of recordable addresses Up to 20 addresses can be recorded. The term “address” means a byte- or a word-address. The recording of a double-word-address results in transferring of 2 words, so 10 double-wordaddresses can be recorded. 8.3.4 Time behavior and particularities NOTE Acquiring data with PLC-ANALYZER pro results in a small increase in cycle time in the automation device to the same manner as it happens with STEP5 in the operating mode STAT VAR. The intervals between scan transfers from the SIMATIC PLC to the computer are depending on the PLC CPU and the number of acquired signals. For the SIMATIC S5-115U (CPU942) and the 95U the interval for a byte is approximately 30 ms, i.e. for a cycle time > 30 ms there is one scan for each cycle. For a longer PLC cycle time data transfer is synchronized with the PLC cycle. For a shorter cycle time the computer does not obtain a scan for each cycle, resulting in a partial loss of information. In the normal acquisition mode this loss can be made up by repeated measurements of the signals in question. If you request more signal addresses than one byte, the minimal transfer interval increases by about 4 ms per byte. The scan interval for the S5-155U has been fixed in the automation device by Siemens to 150 ms. The CPU 921 (S processor 135U) is the second slowest CPU with regard to the transfer rate; about 70 ms scan interval for the first byte. SIMATIC S5 8-6 8.4 Cycle-precise acquisition WARNING ! For cycle-precise acquisition PLC-ANALYZER pro programs a small extension to the PLC program in the connected automation device. Please pay attention to the fact that an effect on the operation of the automation device or the PLC program cannot be completely ruled out. NOTE In the properties window of the PLC driver (see chapter 8.2 Configuring the PLC driver) you can select, if a conditional module end should be checked with a corresponding notification. Such a command in OB1 can result in the fact, that required modules for cycle-precise acquisition cannot be executed. During cycle-precise signal acquisition a limited number of signals are acquired in a circular memory within the PLC. The selected signals are stored in the circular memory during each PLC cycle. Acquisition will only be done trigger-controlled. After triggering, the acquired signals are transferred to the PC and are saved as a signal file. The so created signal file can be displayed and evaluated at any time. Online display is not possible. 8.4.1 Address entry For cycle-precise acquisition you can acquire up to 8 addresses (byte or word values) simultaneously. This restriction is a result from the limited storage capacity of the PLC. The fewer addresses you enter, the more cycles can be acquired in one run. 8.4.2 Trigger condition entry A trigger condition must be entered for cycle-precise acquisition. In contrast to the other acquisition modes only two AND blocks are available for entering the trigger conditions. For each AND block you can insert a maximum of 8 bit values or 2 analog values in the trigger combination (one analog value corresponds to 4 bit values). 8.4.3 Start acquisition Select the option Cycle-precise acquisition in the Properties windows of the PLC driver. ! WARNING It is absolutely necessary that the system in a safe state before making any modifications. With the setting "With PLC safety stop" PLC-ANALYZER pro switches control of module transfer (or modification) into the STOP state. The operation after the end of the recording will be analogously. SIMATIC S5 8-7 Now select in the menu Project the menu item Start acquisition. The modules are transferred either during operation or after control stop, depending on the setting you have made in the PLC driver window Properties (see chapter 8.2 Configuring the PLC driver). Fig. 8-2 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 8-3 Message before modifications in the PLC for pre-setting "No PLC safety stop" Confirm with Yes only after you have stopped the process or after it is in a safe condition. Make sure, that injury or damage cannot happen by affecting control operation! PLC-ANALYZER pro searches in the PLC for a free module number and creates a function module and a data module for data recording. In addition, a call to the new function module is appended to the end of OB1. SIMATIC S5 8-8 The controller is now in RUN condition or is switched to RUN condition. Cycle-precise acquisition will start. The following display will appear: Fig. 8-4 Cycle-precise acquisition status The displayed signals serve as a status display for cycle-precise recording. Their meaning is shown in the following table: Signal Meaning Trigger Mem full Transfer Signals, if the trigger condition is fulfilled. Shows that the circular memory is full. The circular memory is transferred from the PLC to the PC and a signal file is created. The trigger combination from AND block # 1 is activated. The trigger combination from AND block # 2 is activated. T1 active T2 active Table 8-3 Status display cycle-precise recording S5 Recording is stopped with Stop acquisition. You should now stop your system (process) or put the system into a safe condition. Removal of the modifications is now done analogously in the stop state or online. One of the following message windows appears: SIMATIC S5 8-9 Fig. 8-5 Message before modifications in the PLC for pre-setting "With PLC safety stop" Fig. 8-6 Message before modifications in the PLC for pre-setting "No PLC safety stop" Confirm the message after you have stopped your system or put it into a safe state. The original state in the PLC is restored now. After the end of acquisition the last signal file created is automatically opened for display. The time base is chosen in such a way, that the entire file fits onto the screen. 8.4.4 Particularities of signal display and analysis Evaluation of cycle-precise acquired signal files is nearly identical to normal signal files. However no time stamp is generated during signal recording, so no exact time is assigned to the data. Therefore the time will be specified in cycles. The time base is „mZP“ (milli cycle per pixel) resp. „ZP“ (cycle per pixel). Example: A time base of 100 mZP means a PLC cycle is 10 screen pixel wide. Appendix A - FAQ 9-1 9 Appendix A - Frequently asked questions (FAQ) Installation and License-key-management During the installation following error message appears „File xxx cannot be opened“ The Installation-CD is defect. You can start the License-key-management, but there are no licenses visible (following message appears: „Licenses not found“) Check, if there are data files in the installation directory (Data.000, Data.001, ...). If there are no data files, install the PLC-ANALYZER pro on another PC (but do not activate) and copy the data files to the first PC afterwards. PLC-ANALYZER pro cannot be deinstalled Pay attention, that during the deinstallation the license medium is connected to the PC. There is a posibility of forced deinstallation. NOTE: All activated licenses get lost. Start License-Key Management Press button <Strg> + <Alt> + D simultaneously By confirmation of the information window all licenses will be deleted irrecoverably Following it is possible to deinstall PLC-ANALYZER pro under control panel / software-program Dongle malfunctioning Download the WIBU-KEY Runtime-Kit (Win 32) under www.wibu.de/download_user.php and install it. Start PLC-ANALYZER PLC-ANALYZER pro cannot be started. Did you activate the license of the ANALYZER? An errors appears while starting PLC-ANALYZER pro If the PLC-ANALYZER crashes during the start or other errors appear during the start, remove the following key in the registry (Start / Run / insert „regedit“/OK ): HKEY_CURRENT_USER\Software\AUTEM\PLC-ANALYZER pro 5\DRIVER Start the PLC-ANALYZER pro again. No drivers can be loaded Make sure, that you have installed a PLC-driver. In the registry (Start / Run / insert „regedit“ /OK ) the key "DriverPath" is defined under HKEY_CURRENT_USER\SOFTWARE\AUTEM\PLC-ANALYZER pro 5\Settings Check, if the PLC-driver of PLC-ANALYZER pro is present in this path. If not, change the path or copy the driver into the directory. Appendix A - FAQ 9-2 Connection establishment to PLC and data recording Error occurs during connecting to SIMATIC S7 STEP7 (min. Version 3.0) has to be installed. During the connecting via Ethernet „Softnet“ has to be installed If you are not able to make a connection to you PC by STEP7, check the hardware connection between PLC and PC. Check, if the right settings for the connection under „PG/PC-set interface“ (STEP7) have been made. Did you make the right settings for the PLC-address in the PLC-ANALYZER pro under Extras/PLC-Driver / Properties (MPI-, Profibus or TCP/IP-address)? Did you make the right settings for the slot of the CPU under Extras/PLC-Driver / Properties? A connection via Ethernet to SIMATIC S7 cannot be made If you made the right settings for an „Industrial Ethernet“ connection under „PG/PC-set interface“, you have to enter the MAC-address in the S7-driver of the PLC-ANALYZER pro (Format: xx.xx.xx.xx.xx.xx). If you use the connection „TCP/IP“ a TCP/IP-address has to be entered in the S7-driver of PLC-ANALYZER pro (Format: xxx.xxx.xxx.xxx) Pay attention, that you enter under slot the slot of the CPU and not the slot of the CP. A connection via MPI-USB-Cable cannot be made If you like to make a connection via USB, you need at least STEP7 Version 5.0 SP3 or 5.1 SP2 A connection to SIMATIC S7-200 cannot be made Step 7 has to be installed (S7-Micro-Win is not enough) Choose under PG/PC-interface an MPI-connection or a PPI-connection If you use MPI you have to adjust the MPI-speed to 19200 Baud Check, if you can see the S7-200 via the „accessible notes“ in STEP7. Use the shown address and enter it in the PLC-driver of the PLC-ANALYZER pro under the station address. A connection to SIMATIC S5 cannot be made If you are not able to make a connection to your PLC via Step5, check the hardware connection between PLC and PC. Did you choose the right COM-port under Extras/PLC-driver/properties? Close all programs, which interfere with the choosen COM-interface (e. g. Step5) A connection to Allen-Bradley-PLC (DH+) is not possible Did you insert the right DH+-address settings of that card into the driver properties? KTXD-Card: Enter the address, which you entered on the card. PCMK-Card: Open in the system control the program PCMKInfo. Enter the driver properties shown in the PCMK-Info. If you use a PCMK-Card the PLC-ANALYZER pro will only operate under Win9x 9-3 Appendix A - FAQ It is not possible to start data recording with the AD_USB-Box-Driver You need at least Win98 SE to make data recording There are interruptions during the recording with the AD_USB-Box Perhaps there are problems with other USB-units you use. Remove all other USB-units from your PC (e.g. your USB-mouse etc) and try it again General help for problems with connecting to the PLC If it is not possible to make a connection to your PLC via your programming software (Concept, Medoc, Modsoft…) check the hardware connection first. Did you make the right settings under Extras/PLC-driver/properties (COM-Port, Baudrate, PLC-adddress…)? Close all programs which are using the same interface, these were set under Extras/PLCdriver/properties There are interruptions during the recording Deactivate the Powermanager via the system control of your PC. Check the hardware connection. Take care for electromagnatic shielding against electrical and magnetical fields.