Hardware Commissioning

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
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Contents Page
Objectives .......................................................................................................................................... 2
Commissioning Checklist ……….................................................................................................... 3
From Process to Project .................................................................................................................. 4
SIMATIC S7 – Project Management ................................................................................................ 5
Connecting the PG/PC to Subnets .................................................................................................... 6
Setting the PG/PC Interface …......................................................................................................... 7
PG Routing ...................................................................................................................................... 8
Project: OFFLINE / ONLINE - View ……… ……............................................................................ 9
"Accessible Nodes": ONLINE View (project-independent) ............................................................... 10
Erasing a Memory Card (Memory or MMC Card) ........................................................................... 11
Performing a Memory Reset and Warm Restart ............................................................................. 12
Hardware Configuration and Parameter Assignment ...................................................................... 13
Inserting a Station and Generating a Setpoint Configuration ........................................................... 14
Configuring a PROFIBUS - DP Master System ................................................................................ 15
Configuring Compact and Modular DP Slaves …….......................................................................... 16
Monitoring and Modifying Variables ................................................................................................. 17
Opening a Variable Table and Establishing a Connection to the CPU ............................................. 18
Modifying Outputs in the STOP State ............................................................................................. 19
Exercise 1: Setting the PG Interface to MPI …………………………................................................. 20
Exercise 2: Performing a CPU Memory Reset and a Warm Restart .............................................. 21
Exercise 3: Retrieving a Project and Saving As ................................................................................. 22
Exercise 4: Uploading a Hardware Station in the PG and Copying "My_Program" .......................... 23
Exercise 5: Configuring the Hardware including the ET200 ............................................................. 24
Exercise 6: Testing the Conveyor Model‘s Sensor/Actuator Wiring ................................................. 25
WinCC flexible ................................................................................................................................. 26
Configuring Phase, Downloading Phase and Process Control Phase .............................................. 27
Exercise 7: Setting the Touch Panel Interface for Transfer ............................................................. 28
Exercise 8: Switching the PG Interface to PROFIBUS DP ............................................................... 29
Exercise 9: Checking the PROFIBUS DP ......................................................................................... 30
Exercise 10: Checking the RT Interface of the WinCC flexible Station ........................................... 31
Exercise 11: Checking the Connection to the Controller ................................................................. 32
Exercise 12: Transferring the WinCC flexible Project into the Touchpanel .................................... 33

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 Objectives

Upon completion of the chapter the participant will ...

… be able to establish an online connection to the controller

... be able to create a hardware station and assign parameters to it
… be able to integrate a DP station and assign parameters to it
... be able to carry out a wiring test using the "Monitor/Modify Variables"
tool
… be able to commission a touchpanel

SIMATIC S7 Date: 18.09.2009

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 Commissioning Checklist

• Perform a CPU memory reset.

• Carry out a CPU warm restart.

• Check the LEDs on the modules.

• Start the SIMATIC Manager.

• Configure the hardware.

• Check inputs using the Monitor/Modify Variable tool.

• Check outputs using Modify Outputs.

SIMATIC S7 Date: 18.09.2009

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Checklist The checklist shows the individual preparatory steps for commissioning the
hardware. If you do not want to use the default setting, it may be necessary to
assign parameters to the modules before you check the inputs and outputs.

The individual steps are described in more detail on the following pages.

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 From Process to Project

Project Management

SIMATIC Manager

Hardware
Communication

FB21
OB1

I 1.0 I 1.1 Q4.0

Prozess Software

SIMATIC S7 Date: 18.09.2009

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Process When you take a closer look at a process you want to automate, you will find
that it is made up of a multitude of smaller sections and sub-processes, which
are all interlinked and dependent on one another.
The first, most important task is to break down the automation process as a
whole into separate sub-tasks.

Hardware and Each sub-task defines certain hardware and software requirements which the
Software the automation system must fulfill:
• Hardware:
- Number and type of inputs and outputs
- Number and type of modules
- Number of racks
- Capacity and type of CPU
- HMI systems
- Communication structures
• Software:
- Program structure
- Data management for the automation process
- Configuration data and parameter assignment data
- Communication data
- Program and project documentation

Project In SIMATIC S7 all the hardware and software requirements of an automation

process are managed within a project.
A project includes the necessary hardware (+ configuration), networking
(+ configuration), all the programs, and the entire data management for an
automation solution.

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 SIMATIC S7 Project Management

Multiproject
“TIA_PRO2_solution“
S7 – Standard Projects

SIMATIC S7 Date: 18.09.2009

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Multiproject A multiproject folder is a folder for all projects and libraries of an automation
solution that contains one or more STEP 7 projects and, optionally, also
libraries. The projects within the multiproject can contain objects with cross-
project interrelations (such as cross-project S7 connections).

Benefits When projects are a component of a multiproject, their scope can be smaller
and easier to follow.
With the help of the multiproject you can, for example, create a project for every
operator for distributed editing and divide the stations according to their
operator between the projects.
Cross-project functions make sure that you can almost handle a multiproject
like one single project.
Examples of cross-project functions in STEP 7 (basic package):
• Save As (save multiproject with all projects in another location)
• Archiving (multiproject with all projects)
• Adjustment of cross-project networking (such as, bringing together subnets)
• Updating the view (all projects of a multiproject)

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 Connecting the PG/PC to Subnets
Subnets PG with STEP 7 PC with STEP 7 SW
MPI CP 5411 (ISA)
CP5412A2(ISA)
CP 5511(PCMCIA)
CP 5611(PCI)
CP 5511(PCMCIA) CP 5511 (PCMCIA) 1)
PROFIBUS
CP 5611 (PCI) CP 5611 (PCI) 1)
CP 5412 A2(ISA) CP 5412 A2 (ISA) 2)
CP 5613 (PCI) CP 5613 (PCI) 2)
CP 5614 (PCI) CP 5614 (PCI) 2)
Ethernet CP 1411 (ISA) CP 1411 (ISA) 2)
CP 1413 (ISA) CP 1413 (ISA) 2)
CP 1511 (PCMCIA) CP 1511 (PCMCIA) 2)
CP 1613 (PCI) CP 1613 (PCI) 2)

1) All drivers are included in STEP 7 and are already installed

2) One driver has to be installed, such as with the SIMATIC NET
CD

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General For troubleshooting in networked systems, you can connect the programming
device or PC directly to the various subnets, such as MPI, PROFIBUS or
Industrial Ethernet. You can see the modules that you need in order to do this in
the table in the slide above.

PG/PC Interface So that you can have an online connection with STEP 7, you have to set up the
PG/PC interface accordingly. In the slide on the right you can see an example
for connecting to Industrial Ethernet.

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 Setting the PG/PC Interface
Access Point
STEP 7 of the Application:
S7ONLINE

Interface Parameter
CP5611 Assignment Used:
CP5611 (MPI)

CPU

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General You use the "Set PG/PC Interface" tool to define the connection between an
application such as STEP 7 and a module such as CP 5611. The tool is
activated with Start Æ Settings Æ Control Panel .

Access Point Other examples of access points are:

• CP_H1_1 for SIMATIC NET (Ethernet)
• CP_L2_1 for SIMATIC NET (PROFIBUS)
• DPSONLINE for ProTool/Pro DP-Slave
• Micro/Win for the S7-200 software
• MPI (WinCC) for the WinCC Software

Interface Parameter Here, enter the module used, such as, CP5611 and the interface used, such
Assignment Used as, MPI. If you connect the PG to the PROFIBUS, use the setting CP5611
(PROFIBUS). To save a switch-over of the PG/PC interface, you can also use
the setting CP5611 (Auto). The bus parameters are then automatically
determined. With this setting, however, the connection takes longer.

Properties In this tab, you adapt the parameters of the interface. For "Address", enter the
MPI address of the PG. This must be unique in the network.
To make communication possible, the "Transmission Rate" and "Highest Node
Address" parameters must be the same for all nodes (stations).
The "PG/PC is the only master on the bus" setting is only activated if only
slaves are connected to the PG.

Diagnostics With this, you can check whether a connection can be made.

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 PG Routing
SIMATIC PG/PC SIMATIC Controller SIMATIC Controller
SIEMENS

PG 740

MPI
PROFIBUS/Ethernet

SIMATIC S7 Date: 18.09.2009

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Overview With PG Routing, you can use PG functions from a fixed location in the network
even across various subnets. During network configuration with STEP 7, special
routing tables are automatically generated for the gateways. These routing
tables contain system data and must be loaded in the S7-CPUs or CPs in the
associated gateways.

Properties With the PG, all S7 stations that were configured within an S7 project during
network configuration can be reached from a central location in the network that
you choose. User programs or a hardware configuration can be loaded with it or
test and diagnostic functions can be executed, for example.

Prerequisites • The PG Routing function can be used as of STEP 7 V5.0 + SP1.

• The communications-capable modules that the gateways are to establish
between the subnets must be routing-capable.
You can find out which modules these are from Customer Support under the
publication ID: 584459.
• All accessible automation devices (communications partners) of a system
network must be configured and loaded within an S7 project.
• During network configuration, the PG from which the S7 stations are to be
accessed also has to have been configured. Only one PG can be
parameterized as Master.
• The desired S7 station is networked and can be accessed by the PG using
gateways.
• The routing tables generated by NETPRO have to be loaded in the stations.
• The PG must be assigned to an interface.

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 Project: OFFLINE / ONLINE View

Project
OFFLINE

Project
ONLINE

SIMATIC S7 Date: 18.09.2009

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Offline View In the project window of the SIMATIC Manager, the offline view displays the
project structure stored on the hard disk of the programming device.
• The "S7 Program" folder contains the "Sources" and "Blocks" objects.
• The "Blocks" folder contains the system data created with the HWConfig
tool and the blocks created with the LAD/STL/FBD Editor.

Online View The online view shows the offline project structure in the left window and in the
right window it shows the blocks stored online in the selected CPU.
As a result, the "S7 Program" seen in the online view only contains the "Blocks"
folder which contains the following objects:
• System data (SDB)
• User blocks (OB, FC, FB)
• System blocks (SFC, SFB).
The title bar in the online window is highlighted in color.

Changing Views Changing between offline and online view takes place:
• through the View Æ Offline or View Æ Online menu items
or
• with the corresponding icon in the toolbar:
- Online

- Offline

Note You can arrange the "ONLINE" and "OFFLINE" views next to each other (as in
the slide) or under each other with Window Æ Arrange Æ vertical
(horizontal)

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 "Accessible Nodes": ONLINE View (project-independent)

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Area of Use This type of connection provides you with quick access, such as for service
purposes. You can access all accessible programmable modules (CPUs, FMs,
CPs) in the network. You choose this method when you don‘t have any project
data about the target systems on your PG.

What to Do You can activate the "Accessible Nodes" window with the menu options PLC Æ
Display Accessible Nodes. In the "Accessible Nodes" object, all accessible
programmable blocks in the network are displayed with their address.

Note Nodes (stations) that are not programmable with STEP 7 can also be displayed
(such as programming devices or operator panels). On the CPU to which the
PG is connected, the addition (directly) is displayed. In the slide, the CPU with
the MPI address =2.

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 Erasing a Memory Card (Memory or MMC Card)

Memory card is inserted in the CPU:

right
Memory card is inserted in the PG: mouse button

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Reason During a CPU memory reset, only the RAM work memory of the CPU is reset,
not the memory of the possibly inserted memory or MMC card. That means
that the user program stored on the inserted memory card is retained.

Erasing the memory card can be done in the following ways:

Memory Card is The memory card can be erased online directly on the CPU using the function
Inserted in the CPU "Accessible Nodes":
SIMATIC Manager Æ PLC Æ Display Accessible Nodes Æ
then select all blocks Æ Delete

Memory Card The memory card can be erased using a programming device with a suitable
interface. For this, the memory card must be inserted in the module slot and a
new window has to be opened that displays the contents of the memory card.
SIMATIC Manager Æ File Æ S7 Memory Card Æ Delete…

Note The data format of SIMATIC MMCs does not correspond to the data format that
is used by MS Windows. Accordingly, SIMATIC MMCs can not be read, written
or erased with the Windows Explorer!

Caution If SIMATIC MMCs are formatted in MS Windows, then they can no longer be
used in a SIMATIC S7!

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 Performing a Memory Reset and a Warm Restart
Until Oct. 2002 After Oct. 2002
RUN-P

RUN 1. Set the mode selector switch to STOP RUN

STOP
STOP MRES

MRES

RUN-P
2. Hold (Press) the mode selector switch in the MRES
RUN RUN
position until the STOP LED has flashed twice slowly.
STOP
Release the mode selector switch so that it returns to MRES
STOP the STOP position.
MRES
within 1 sec
RUN-P

RUN 3. Turn (press) the mode selector switch to the MRES posi- RUN
-tion once more until the STOP LED begins to flash quickly. STOP
STOP
Release the mode selector switch so that it returns to MRES
the STOP position.
MRES

RUN-P

RUN RUN
4. Set the mode selector switch to the RUN-P (RUN)
STOP
STOP
position. (A warm restart is carried out in the transition MRES
from STOP to RUN/RUN-P)
MRES

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Memory Reset When a memory reset is performed on an S7 CPU, the following happens:
• all CPU user data as well as the entire load and work memory are cleared
• the CPU interrupts all connections to other communications partners
• the CPU parameters and all modules are set to default values
• in the case that a memory card is used, the CPU copies the relevant portion
of the stored program needed for execution into the internal RAM

Attention During a memory reset, only the work memory and the RAM load memory (if it
exists) of the CPU are cleared, not the contents of the inserted memory card
(EEPROM or MMC)!
If the inserted memory card contains a user program, it is automatically
reloaded into the CPU work memory after the memory reset and subsequent
warm restart. If this is not wanted, you must explicitly erase the memory card
before the memory reset as previously described.

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 Hardware Configuration and Parameter Assignment

Configuration Assignment of racks, cards, blocks and

distributed I/O in the station window of the
Hardware Configuration tool.
You can select the components from a
hardware catalog.

Parameter assignment Specifying the behavior of parameter

assignable modules such as startup behavior,
retentive areas, etc.

Planned hardware configuration and

Setpoint configuration parameter assignment using the Hardware
configuration tool.

Actual configuration Actual configuration and parameter assignment

of existing hardware.

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HW Configuration The modules are supplied from the factory with preset parameters. If these
default settings are OK, a hardware configuration is not necessary.
A configuration is necessary:
• if you want to modify preset parameters or addresses of a module (such as
to enable the hardware interrupt of a module)
• if you want to configure communication connections
• with stations that have distributed peripherals (PROFIBUS-DP)
• with S7-400 stations that have several CPUs (multicomputing) or
expansion racks
• with fault-tolerant programmable logic controllers (option package).

Setpoint When you configure a system, a setpoint configuration is created. It contains a

Configuration hardware station with the planned modules and the associated parameters.
The PLC system is assembled according to the setpoint configuration. During
commissioning, the setpoint configuration is downloaded to the CPU.

Actual Configuration In an assembled system, the actual existing configuration and parameter
assignment of the modules can be uploaded from the CPU. This creates a new
HW station in the project.
A configuration upload is necessary, for example, if the project structure does
not exist locally at the PG. After the actual configuration is read out, you can set
parameters and add part numbers.

Notes With the S7-400, the CPU can be assigned parameters in such a way, that
when there are differences between the setpoint configuration and the actual
configuration, the CPU startup is interrupted.
To call the HW Config tool, there must be a hardware station in the SIMATIC
Manager.

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 Inserting a Station and Generating a Setpoint Configuration

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Inserting a Station You insert a new station in the current project by selecting the menu options
Insert Æ Station Æ SIMATIC 300 Station or SIMATIC 400 Station.

Generating a This means specifying how the modules are to be arranged in the rack. This
Setpoint configuration, specified by you, is referred to as the setpoint configuration.
Configuration

Rack For example, you open a SIMATIC 300 station in the Hardware Catalog.
Opening the "RACK-300" folder shows the icon for a DIN rail. You can insert
this in the "Hardware Configuration" window by double-clicking on it (or using
drag & drop).
Two rack component lists then appear in the two-part window: a plain list in the
top part and a detailed view with order numbers, MPI addresses and I/O
addresses in the bottom part.

Power Supply If a load current power supply is required double click or use drag & drop to
insert the appropriate "PS-300" module from the catalog in slot no.1 in the list.

CPU You select the CPU from the "CPU-300" folder, for example, and insert it in slot
no. 2.

Slot No. 3 Slot no. 3 is reserved as the logical address for an interface module (for multi-
tier configurations). If this position is to be reserved in the actual configuration
for the later installation of an IM, you must insert a dummy module DM370
(DUMMY).

"Inserting" Modules From slot no. 4 onwards, you can insert a choice of up to 8 signal modules
(SM), communications processors (CP) or function modules (FM) from the
Hardware Catalog using drag & drop or with a double-click. The slots on which
the selected module can be inserted are automatically highlighted in green.

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 Configuring a PROFIBUS DP Master System

Result

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Distributed I/O All master systems consisting of a DP master and DP slaves that are connected
using a bus cable and that communicate via the PROFIBUS-DP protocol are
designated as distributed I/Os.

DP Master As DP master you can install:

• S7-CPU with integrated DP master interface (such as CPU 414-2, etc.)
• CP in connection with a CPU (such as CP 443-5, etc.)

Setting Up DP Master To configure a master system, proceed as follows:

1. Select the PROFIBUS interface X2 of your CPU and insert a master system
(Menu Insert Æ Master System)
2. Double-click on the DP interface of the CPU to define the properties of the
PROFIBUS network. The dialog box "Properties - PROFIBUS interface DP"
is opened.
In this dialog you can define the following properties:
• set up a new PROFIBUS subnet or open an existing one
• set the properties of the PROFIBUS subnet (baud rate, etc.).
• define the PROFIBUS address of the DP master.
3. Acknowledge the settings with "OK". The following symbol appears:
for the DP master system. This symbol is used as a
"hanger " for the DP slaves.

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 Configuring Compact and Modular DP Slaves

DP Slave

Configure rack like central hardware

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DP Slaves • Modules with integrated digital/analog inputs and outputs

(compact DP slaves, such as ET200B).
• Interface modules with assigned S5 or S7 modules
(modular DP slaves, such as ET200M, ET 200S).
• S7-200/300 stations with modules that support the "Intelligent Slave"
function (such as CPU 215-DP, CPU 315-2).

Selecting DP Slaves To configure a DP slave, proceed as follows:

1. From the "Hardware Catalog" select the desired compact DP slave (such as
ET200B) or the interface module (such as IM151-1 Standard for ET200S) for
a modular slave.
2. Drag the symbol (such as IM151-1 Standard for ET200S) onto the symbol for
the master system:
The dialog box "Properties – PROFIBUS interface DP" is opened. Here you
can set the following properties:
• properties of the PROFIBUS subnet (baud rate, etc.).
• the PROFIBUS address of the DP slave.
3. Acknowledge the settings with "OK". A configuration table is attached to
the symbol (icon) that represents the I/O configuration of the compact
slave or the rack of the modular slave.
4. For a modular DP slave, you now insert the desired modules from the
"Hardware Catalog" into the configuration table.
The addressing and parameter assignment of the modules is then handled
similar to the configuration of the centrally inserted modules.

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 Monitoring and Modifying Variables

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Trigger When you define the trigger points, you determine when the values are to be
assigned to the variables to be controlled or when the values of the variables to
be monitored are to be updated. You must set the trigger point for "Controlling"
and "Monitoring" separately.

Monitor You can monitor variables in two ways:

• The (monitor) status values are updated once when you select the
Variable Æ Update Monitor Values menu option or click the icon (Update
Monitor Values).
• The (monitor) status values are updated every cycle when you select the
Variable Æ Monitor menu option or click the icon (Monitor Variables).

Modify Procedure for modifying variables:

1. Enter the value in the correct form for the data type selected.
2a. To activate the modify values once, select the Variable Æ Activate Modify
Values menu option or click the icon (Activate Modify Variables) OR
2b. To activate the modify values every cycle, select the Variable Æ Modify
menu option or click the icon (Modify Variables).
3. Use the "Monitor" function to confirm that the modify value has been
entered in the variable you selected.

Modify Value Valid You can make the "Modify value" entered in a table invalid by selecting that
value and clicking on the icon. The now "invalid" value is displayed like a
comment. You can make the modify value "valid" again when you click on the
icon again. Only valid modify values can be activated.

Saving the You can save an inputted variable table via Table Æ Save or Table Æ Save As.
Variable Table You can choose any name you like for the variable table and it is inserted as a
symbolic name in the symbol table. Saved variable tables can be re-used for
monitoring and controlling so that it is not necessary to re-enter the variables to
be monitored.
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 Opening a Variable Table and Establishing a Connection to the CPU

Accessible CPUs
Configured
Directly CPU
connected
Station 1 (VAT from Station 2 Station 3
CPU HW Station
"Station 2")

PG

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Area of Use Variable tables that are stored in a Blocks folder of an S7 program can be
reopened at a later time for test purposes by double-clicking on them.
However, before you can activate the "Monitor" and "Modify" functions, an
online connection to a CPU has to be established.
For this purpose, the menu commands PLC Æ Connect to . . . or the
associated icons in the toolbar provide the following possibilities:

Configured CPU If the variable table is stored in the Blocks folder of a hardware-dependent S7
program (assigned to a CPU in the project view), a connection to the station
with the MPI address is established. This station was also assigned to the
higher-level CPU with the help of the HW Config tool.

MPI Address of an If the variable table is stored in the Blocks folder of a hardware-independent S7
S7 Program program folder (assigned directly to the project root in the project view), the
MPI address of the hardware-independent S7 program can be established
using the Properties dialog of the program folder while in the online view of the
SIMATIC Manager.

Direct... A connection is established to the CPU that is directly connected to the PG/PC
via the PG-MPI cable. The PG can determine to which PLC it is connected
through the MPI cable.

Accessible CPU In this case, a dialog is displayed with the project view. In this dialog, you can
select a program folder. An online connection can then be established to its
configured CPU.

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 Modifying Outputs in the STOP State

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Function and The "Enable Peripheral Outputs" function can only be activated when the CPU
Area of Use is in the STOP state.
It switches off the output disable of the peripheral outputs (PQ). This enables
you to modify the peripheral output even though the CPU is in the STOP mode.
The "Enable Peripheral Outputs" function is used to check the functioning of the
output modules and the wiring of the peripheral outputs.

What To Do To enable the peripheral outputs, proceed as follows:

1. Open or edit a variable table (VAT) that contains the peripheral outputs that
you want to test or modify
(specify the peripheral outputs byte-by-byte, word-by-word or doubleword-
by- doubleword; you cannot modify individual output bits!)
2. Select the PLC Æ Connect to… menu option to establish a connection to
the CPU you want
3. Switch the CPU to the STOP state
4. Enter the appropriate values for the peripheral outputs you want to modify in
the "Modify Value" column.
Examples: PQB 7 Modify Value: 2#01000011
PQW 2 W#16#0027
5. Activate the "Enable Peripheral Outputs" via Variable Æ Enable Peripheral
Outputs
6. Activate the Modify value via Variable Æ Activate Modify Values
7. To assign new modify values, enter these and then activate them with
Variable Æ Activate Modify Values
Modifying or "Enable Peripheral Outputs" remains active until you deactivate it
using Variable Æ Enable Peripheral Outputs or you press the ESC key.

Note When you change the operating mode of the CPU from STOP to RUN or
STARTUP, the Enable Peripheral Outputs is deactivated and a message
appears.

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Automation and Industrial Solutions Page 19 Hardware and Software Commissioning
 Exercise 1: Setting the PG Interface to MPI

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.20

Task The PG‘s interface is to be switched to MPI so that an online connection to the
CPU can be established.

What to Do 1. Activate the "Set PG/PC Interface" function

SIMATIC Manager Æ Options Æ Set PG/PC Interface
2. In the Properties dialog, change the properties so that they appear as those
shown in the slide

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Automation and Industrial Solutions Page 20 Hardware and Software Commissioning
 Exercise 2: Performing a CPU Memory Reset and a Warm Restart
Until Oct. 2002 After Oct. 2002
RUN-P

RUN 1. Set the mode selector switch to STOP RUN

STOP
STOP MRES

MRES

RUN-P
2. Hold (Press) the mode selector switch in the MRES
RUN RUN
position until the STOP LED has flashed twice slowly.
STOP
Release the mode selector switch so that it returns to MRES
STOP the STOP position.
MRES
within 1 sec
RUN-P

RUN 3. Turn (press) the mode selector switch to the MRES posi- RUN
-tion once more until the STOP LED begins to flash quickly. STOP
STOP
Release the mode selector switch so that it returns to MRES
the STOP position.
MRES

RUN-P

RUN RUN
4. Set the mode selector switch to the RUN-P (RUN)
STOP
STOP
position. (A warm restart is carried out in the transition MRES
from STOP to RUN/RUN-P)
MRES

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
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Task You are to perform a CPU memory reset and check whether the memory reset
was successful.

What to Do 1. If a CPU with MMC is used at your training area, the MMC must first be
explicitly erased.
For example, SIMATIC Manager Æ Accessible Nodes Æ in the Blocks
folder select all blocks Æ Delete
2. Carry out the memory reset according to the steps in the slide above
(manually and from the PG).
3. Check if the memory reset was successful. It was successful if only system
blocks (SDBs, SFCs, SFBs) are left in the CPU
SIMATIC Manager Æ Accessible Nodes Æ Double-click on MPI=2
Æ Click on Blocks

Notes To make sure that no "old" blocks are left in the CPU, a memory reset of the
CPU should be performed. The following steps are carried out during a
memory reset:
• All user data is deleted (Exception: MPI parameter assignments and the
contents of the diagnostic buffer are retained).
• Hardware test and initialization
• If an Eprom memory card or a Micro Memory Card (MMC) is installed, the
CPU copies all data on the cards that is relevant for execution back into the
internal RAM after the memory reset.
• If you are using an "old" (before Oct. 2002) CPU and no memory card is
installed, the preset MPI address on the CPU is retained. If, however, a
memory card is installed, the MPI address stored on it is loaded.

SITRAIN Training for ST-PRO2

Automation and Industrial Solutions Page 21 Hardware and Software Commissioning
 Exercise 3: Retrieving a Project and Saving As

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.22

Task You are to retrieve a project and save it under the name "My_Project".

What to Do 1. Start the SIMATIC Manager

2. Delete – should they exist – the old projects "My_Project", "PRO2_A"
File Æ Delete... Æ User Projects Æ select the projects from the list Æ
confirm
3. Retrieve (unzip) the project "PRO2_A.zip"
FileÆ Retrieve... Æ Look In: <Drive>:\Archives\PRO2
Select and choose "PRO2_A.ZIP" from the list Æ acknowledge with "OK"
4. Save the project under the name "My_Project"
File Æ Save As... Æ User projects Æ enter "My_Project" as the file name Æ
as the Storage Path choose <Drive>:\S7_Courses Æ confirm
Notes The project contains a WinCC flexible project for the touchpanel as well as a
hardware-independent S7 program with prepared blocks and a symbol table.

SITRAIN Training for ST-PRO2

Automation and Industrial Solutions Page 22 Hardware and Software Commissioning
 Exercise 4: Uploading a Hardware Station in the PG and Copying
“Chap03_Program_draft"

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.23

Task A new hardware station is to be created in the project and the already existing
S7 program "My_Program" is to be assigned to the CPU of the hardware station.

Note When assigning an S7 program to a CPU, its complete program folder with all
blocks including the system data and the symbol table are overwritten. The
system data lost in the process must then be regenerated with the "HW Config"
tool.
Open the HW Station with HW Config Æ Menu Station Æ Save and Compile

What to Do (also see the steps to be done that are shown in the slide)
1. In your project, create a hardware station by reading out your training unit
PLC Æ Upload Station Æ in the dialog box that follows, show the list of
accessible nodes by clicking "Update" and select the station Æ OK
2. Copy or pull, using drag&drop, the S7 program called
“Chap03_Program_draft" to the CPU and rename it to “My_Program”.
3. Delete the hardware-independent program called "Chap03_Program_draft".
Check whether the structure of your project corresponds to the one shown in
Picture 3.

Result Your project structure corresponds to the structure of your training unit. It
includes an S7 station with a CPU that contains an S7 program with prepared
blocks and a symbol table.

SITRAIN Training for ST-PRO2

Automation and Industrial Solutions Page 23 Hardware and Software Commissioning
 Exercise 5: Configuring the Hardware including the ET200

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.24

Task The hardware configuration of the S7 station in the project is to correspond

exactly to your training unit with ET200S and the modules are to be assigned the
following parameters.

What to Do 1. Complete the actual configuration in such a way that it corresponds exactly to
your training station (with power supply module and the order numbers of all
modules).
2. Parameterize the MB 10 memory byte as CPU clock memory byte.
3. Parameterize the measuring range ±10V for the input channels 0 and 1 of the
OFF ON analog input module and deactivate (if they exist) all other input and output
channels.
64
32 4. Expand the existing configuration to include the distributed (remote) station
ET 200S (additional connection possibility for the conveyor model).
16
5. On the IM 151-1‘s address switches, set the Slave Address to 4
8
(see slide left) and check the PROFIBUS cabling.
4
Note: Changes to the slave address only take effect after Power ON/OFF!
2
1 6. Change the addresses of the mixed DI/DO module in the UR0 Universal
Rack to IB 88 and QB 88.
7. As the input and output addresses in the ET200 S, configure the addresses
IB 8 and QB 8.
Note: So that the 8 channels of a module are located in one byte, you have to
pack the addresses. To do so, select both modules and then click on "Pack
Addresses" (see slide)
8. After "Save and Compile" download the configuration into the CPU.
9. Verify that the configuration is error-free. The error LEDs – Group error (SF)
and bus error (BUSF) must be dark on the CPU.

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Automation and Industrial Solutions Page 24 Hardware and Software Commissioning
 Exercise 6: Testing the Conveyor Model‘s Sensor/Actuator Wiring

ET200S

Example: Q 8.5
(Conveyor to right)

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.25

Task The wiring of the conveyor model‘s sensors and actuators to the distributed
peripheral station ET200S is to be checked.

What to Do 1. Connect the conveyor model to the ET200S

2. Switch the conveyor model on (pushbutton "ON" on the conveyor model)
3. Start the "Monitor/Modify Variables" function, enter the addresses shown in
the slide and save the variable table as "VAT_I/O_conveyor"
4. Using "Monitor Variables" check the wiring of the conveyor model‘s sensors.
5. Using "Enable Peripheral Outputs" check the wiring of the conveyor model‘s
actuators.

If you should encounter any kind of error, please let your instructor know!

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Automation and Industrial Solutions Page 25 Hardware and Software Commissioning
 WinCC flexible

Advanced
Advanced Demo
- Complete functional scope
Standard - Limited to a max. 30 days

Compact
*) Options *) Options *) Options
Micro

E n g i n e e r i n g (ES)

SIMATIC PANEL SIMATIC PANEL SIMATIC PANEL PC - based

Micro 70 / 170 270 / 370 Windows 2000
Windows XP

R u n t i m e (RT)

RT Options
SIMATIC S7 Date: 18.09.2009
SITRAIN Training for
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Siemens AG 2008. All rights reserved. File: PRO2_02E.26

WinCC flexible The Engineering System (ES) is the software with which you carry out all the
Engineering System necessary configuring tasks in order to create an interface for controlling and monitoring
machines and systems.

Editions The Engineering System of WinCC flexible is modularly graded into different editions.
The edition determines which operator panels of the SIMATIC HMI spectrum can be
configured.
With each higher edition, a wider range of target devices and functions is supported. The
configuration data is compatible.
Micro: Configuring the micro panels
Compact: Configuring the micro panels and panels of the 70 and 170 series
Standard: Configuring all panels (micro panels, panels of the 70/170/270 and 370
series)
Advanced: Configuring the PC-based and all other panels (micro panels, panels of the
70/170/270/370 series and PC Runtime)
Advanced Demo:Test version limited to 30 days

Changing the With the WinCC flexible Compact edition and above, you can change to a higher
WinCC flexible Edition WinCC flexible edition with a "Powerpack".

Runtime WinCC flexible Runtime (RT) is the software for process visualization on the operator
panel. With Runtime, you execute the project during process operation.
The various panels already come delivered with operating system and the appropriate
Rutime version. Possible, additionally required Runtime components are loaded along
with the project onto the panel.

Options Both components can be expanded through Options (licenses).

The options depend on the target system used. An operator panel that doesn‘t support a
specific functionality also cannot use the associated option.

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Automation and Industrial Solutions Page 26 Hardware and Software Commissioning
 Configuring Phase, Downloading Phase and Process Control Phase

Configuring phase Transfer Process control phase

(Offline)

PC/PG
WinCC flexible
PC/OP/TP
Configuration Configuration
data data Flash Flash
Source file
<Name>.hmi
Ethernet MPI
DP

PLC

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.27

Introduction You configure your project on a PC or programming device (PG). You then
generate the configuration under WinCC flexible and download it to the
PC/OP/TP.
If the PC/OP/TP is connected to the PLC, the PC/OP/TP displays the current
values in the tags and graphics. The three phases of working with the
configuration data are shown in the slide.

Configuring The configuring process consists of various partial steps:

1. Defining the PLC and the type of connection (MPI, PROFIBUS DP,
Industrial Ethernet etc.)
2. Making general settings for the PC/OP/TP (defining the current
connections etc.)
3. Generating objects such as tags, screens, messages etc.
4. Downloading (transferring) the generated database to the HMI system via
MPI, PROFIBUS DP, or Industrial Ethernet

The configuration is stored in source files in your S7 project (Directory

…\HmiEs). In the compiling phase, a file of the type fwx is created which is later
transferred to the target device
• <Name>.fwx for Windows-based HMI systems

Editors WinCC flexible includes a set of editors (tools) for configuring the different types
of objects. You create each object under a symbolic name. You must specify
this symbolic name time and again, for example, when creating, editing,
referencing or deleting the object.

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Automation and Industrial Solutions Page 27 Hardware and Software Commissioning
 Exercise 7: Setting the Touch Panel Interface for Transfer
Loader V07.01.01.00_01.34

Transfer PROFIBUS OK X
Panel is the only master on bus
Start
Station Parameters
Address: 1
Control
Panel Time-out: 1s

NetworkParameters
Transmission Rate: 1,5 Mbits/s

Highest Station: 126

Profile: DP

Bus Parameters…

S7-Transfer Settings OK X

MPI
Profibus

Properties...

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
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Siemens AG 2008. All rights reserved. File: PRO2_02E.28

Task The interface of the touchpanel is to be set up as in the slide, so that the WinCC
flexible project can then be downloaded from the PG to the panel.
Before you can parameterize the interface, you must exit Runtime. For this,
there is, as a rule, a button in the Start screen for doing so. After exiting
Runtime, the "Loader" appears through which the "Control Panel" (see slide)
can be activated. The Loader also appears after every voltage recovery.

What to Do 1. Exit the touch panel‘s Runtime

2. Activate the "Control Panel"
3. Double-click on "Transfer" to select
4. Make the settings as shown in the slide and accept these by pressing the
"OK" button until the "Control Panel" reappears
5. Double-click on the icon "OP"
6. Press the "Save Registry" button
7. Go back to the Loader by closing the Control Panel.
8. Via "Transfer", activate the "Transfer Mode". In this mode, the touchpanel
waits for a connection set up through the PG.
9. Check the PROFIBUS cabling.

Notes Channel: In addition to the serial transfer channel (Channel 1), a

second channel (Channel 2) can be selected for
downloading the project onto the operator panel.
Remote Control: The loading of the WinCC flexible project can be triggered
without first having to manually exit Runtime. The panel
automatically exits Runtime and switches to the Transfer
mode.
Advanced: Setting of transmission parameters for MPI or PROFIBUS
DP.

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Automation and Industrial Solutions Page 28 Hardware and Software Commissioning
 Exercise 8: Switching the PG Interface to PROFIBUS DP
SIMATIC Manager
Options

Set PG/PC Interface

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.29

Task So that the WinCC flexible project can be downloaded from the PG onto the
touchpanel, the PG‘s interface parameters and the transfer settings of the
touchpanel must both be parameterized to PROFIBUS DP.

What to Do 1. Change the PG‘s interface to PROFIBUS DP. Use the parameters shown in
the slide.
Important:
For "Interface Parameter Assignment Used" DO NOT select
"PROFIBUS-DP Slave", since the PG is not used as a PROFIBUS slave.
2. Connect the online cable of the PG with a PROFIBUS DP interface.

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Automation and Industrial Solutions Page 29 Hardware and Software Commissioning
 Exercise 9: Checking the PROFIBUS DP
SIMATIC Manager
Options

Set PG/PC Interface

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.30

Task Now connected to the PROFIBUS are:

- the PG (address 0, active)
- the touchpanel (address 1, active)
- the S7 controller (address 2, active)
- the ET200S (address 4, passive)
Using the function "SIMATIC NET Diagnostics" (see slide), check whether all
nodes are accessible via the PROFIBUS DP.

What to Do 1. Start the diagnostic function

SIMATIC Manager Æ Options Æ Set PG/PC Interface Æ Diagnostics...
2. Check the PROFIBUS network using the "Test" button
3. Using the "Read" button, determine which nodes are accessible via the
PROFIBUS.

Note The "active" and "passive" node properties indicate whether a node can (active)
or cannot (passive) initiate communication to another node.

SITRAIN Training for ST-PRO2

Automation and Industrial Solutions Page 30 Hardware and Software Commissioning
 Exercise 10: Checking the RT Interface of the WinCC flexible Station

SIMATIC S7 Date: 18.09.2009

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Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.31

Task So that the panel‘s Runtime can communicate with the S7 station during the
process control phase, the panel‘s interface must be parameterized with the
HW Config tool.

What to Do Using the HW Config tool, check the parmeterization of the panel‘s interface. If
necessary (see slide) make the appropriate corrections.

SITRAIN Training for ST-PRO2

Automation and Industrial Solutions Page 31 Hardware and Software Commissioning
 Exercise 11: Checking the Connection to the Controller

2xL

1xR

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.32

Task Make a connection so that the panel‘s Runtime communicates with your training
unit.

What to Do 1. Start WinCC flexible by opening the WinCC flexible station "Touchpanel" in
the SIMATIC Manager (right mouse click "Open object" )
2. Open the object "Connections" and check whether your S7 station is
specified as connection partner and activate this.
3. Check your connection at the tags.
4. Connect the WinCC flexible tags with the controller’s variables
right mouse button on "Connections" Æ Reconnect…
5. Complete the dialog that appears as follows:

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Automation and Industrial Solutions Page 32 Hardware and Software Commissioning
 Exercise 12: Transferring the WinCC flexible Project into the
Touchpanel

SIMATIC S7 Date: 18.09.2009

SITRAIN Training for
Automation and Industrial Solutions
Siemens AG 2008. All rights reserved. File: PRO2_02E.33

Task The given WinCC flexible project "Touchpanel" is to be downloaded into the
panel.

What to Do 1. Activate the Transfer function and make the settings as shown in the slide
2. Start the data transfer to the panel using "Transfer"
3. Save the project.

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Automation and Industrial Solutions Page 33 Hardware and Software Commissioning