Serv2 02e HW Sw-Comm

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Hardware and Software Commissioning Page 1

SITRAIN Training for
Automation and Drives
Date: 02.12.2005
File: SERV2_02E.1
SIMATIC S7
Siemens AG 2005. All rights reserved.
SIMATIC S7
Hardware and Software Commissioning
Contents Page
Objectives .......................................................................................................................................... 2
Commissioning Checklist ............................................................................................................... 3
LEDs on the S7-300Power Supply ............................................................................................. 4
LEDs on the S7-300CPU ............................................................................................................ 5
LEDs on Digital Modules ................................................................................................................. 6
LEDs on the S7-400Power Supply ............................................................................................ 7
LEDs on the S7-400CPU ............................................................................................................. 8
Performinga Memory Reset and Warm Restart .............................................................................. 9
Hardware Configuration and Parameter Assignment ....................................................................... 10
Insertinga Station .......................................................................................................................... 11
Starting the HW Config Editor ........................................................................................................... 12
Generating a Hardware Setpoint Configuration ................................................................................. 13
CPU Properties: Cycle/Clock Memory ........................................................................................... 14
Saving the HW Setpoint Configurationand Downloading it in Module ............................................. 15
Uploading the Actual HW Configuration into the PG/PC ................................................................... 16
Module Address Overview ............................................................................................................... 17
HW Config: Edit Symbolic Names, Monitor / ModifyVariables ...................................................... 18
Monitoring and Modifying Variables ................................................................................................. 19
Saving the Variable Table ............................................................................................................... 20
Openinga Variable Table and Establishinga Connection to the CPU ............................................. 21
ModifyingOutputs in the Stop State ................................................................................................ 22
Exercise 1: Performing a CPU MemoryReset and Warm Restart ...................................................... 23
Exercise 2: Retrieving a Project and Save As .................................................................................... 24
Exercise 3: Adapting the Setpoint Configuration................................................................................. 25
Exercise Preparation: Attaching the Fault Simulation Connector ..................................................... 26
Exercise 4: Testing the Sensors Wiringon the Conveyor Model ....................................................... 27
Exercise 5: Testing the Actuators Wiring on the Conveyor Model .................................................. 28
Exercise 6: Checking the Interface of the TP170B.............................................................................. 29
Exercise 7: Downloadinga ProTool Project........................................................................................ 30
Exercise 8: Downloadingthe Program................................................................................................ 31
Exercise 9: Function Test of the Conveyor Model............................................................................... 32
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SIMATIC S7
Objectives
Upon completion of this chapter the participant will ...
... knowthe meanings of the LEDs on the S7 modules
... be able to performa CPU memoryreset
... with the "Monitor/ModifyVariables" tool...
...be able to create and save a variable table
...be able to check the wiring of the sensors
...be able to check the wiring of the actuators
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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 andoutputs.
The individual steps are described in more detail on the following pages.
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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.
Download the hardware configuration
Check inputs using the Monitor/Modify Variable tool.
Check outputs using the Monitor/Modify Variable tool.
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LED The power supplyhas a diagnostic LED "DC24V" on the front side of the
module. Use this LED to determine the state of the power supply.
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LEDs on the S7-300Power Supply
LED " DC24V" State Reaction of the Power Supply
Continuous On 24 V available 24 V available
Flashing
Voltage dip,
voltage recovery when
overload no longer exists
up to 130% (static)
voltage depression,
reduces the service life
Output circuit is overloaded:
up to 130% (dynamic)
up to 130% (static)
Off Short circuit in output circuit
Voltage interruption, automatic
recovery when short circuit
eliminated
Off
Overvoltage or undervoltage on the
primary side
(permissible range: 187V to 264 VAC)
Overvoltage can cause destruction.
With undervoltage, automatic
interruption.
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Status Displays SF = System Fault: grouperror, programmingerror or fault froma
( LEDs ) diagnostics-capable module
BATF = Battery fault: battery is emptyor is not present
DC 5V = 5V supply voltage present.
FRCE = Lights up when a forcing is active.
RUN = Flashes whenthe CPU starts up and
is steadyon in the RUN mode.
STOP = Is steadyon in the STOP mode,
Flashes slowly whena memory reset is requestedand
flashes quickly whena memory reset is carriedout.
SF DP = System Fault DP: grouperror in the DistributedPeripherals
is steadyon when there is a fault in the distributedperipherals
BUSF (BF) = Bus fault, is steadyon when there is an interruptedcable, for
example.
Flashes whenthere is a station failure, for example
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LEDs on the S7-300 CPU
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Status LEDs There are LEDs for diagnostics purposes for every input and output channel on
the module. These LEDs can be helpful in locating program errors.
The LEDs indicate:
the process state for digital inputs
the process state for S7-300 digital outputs
the internal state before the optocoupler for S7-400 digital outputs.
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LEDs on Digital Modules
S7-400 S7-300
Status LEDs for every individual channel
Signal state
at the terminals
Signal state
at the terminals
(for digital inputs)
Internal state,
before the opto-
coupler
(for digital outputs)
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"INTF" ->internal fault
"BAF" ->batteryfault
"BATT1F"->Battery1 emptyor missing
"BATT2F"->Battery2 emptyor missing
"DC 5V" ->5 V OK
"DC 24V"->24 V OK
LEDs on the S7-400 Power Supply
"FMR" Acknowl. switch (Fault Message Reset)
On/Off switch
(Standby)
Batterycompartment
Selection switch for batterymonitoring
"BATT INDIC"
"VOLTAGE" selector
3-pin power connection
Power Supply The power supply (PS) supplies the internal 5V voltage for the modules.
Automatic adjustment is made for line frequencies from 48 to 64 Hz.
LED " INTF" Lights up in the event of internal faults, such as
Short circuit or overload at 5V/24V
Standby switch on "0" and impermissible external supply
Battery fault
LED " BAF" Battery fault. Lights up if the battery voltage on the backplane bus is too low.
Example: No batteries present or battery failure and there is no external power
supply available.
LED " BATT1F/ Lights up in the case of battery reversal, if no battery is present, or the battery
BATT2F" is half discharged. The BATT.INDIC switch for batterymonitoring is set to the
1BATT position (for one battery), the 2BATT position (for 2 batteries) or OFF (no
battery monitoring).
LED " DC 5V/DC 24V" Is lit when the 5V/24V DC output voltage is within the tolerance limits and
flashes to indicate voltage recoveryafter a short circuit or overload.
" FMR" Ackn.Switch Acknowledgement switch for acknowledgingand resettinga fault message
when the fault has beeneliminated.
ON/OFF Switch Switches the output voltage (5/24 VDC) to 0V and switches off the LEDs by
(Standby) interrupting the control current circuit. (The power supply is then in standby
mode because the primary line voltage cannot be switched off.)
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LEDs on the S7-400 CPU
CPU with one interface
INTF
EXTF
FRCE
BUS1F
CPU with two interfaces
INTF
EXTF
FRCE
BUS1F
BUS2F
Fault LEDs CPUs have fault LEDs that provide first informationabout an occurrederror or
that give the CPU status:
LED " INTF" Indicates an internal fault (error in the user program).
LED " EXTF" Indicates an external fault (fault in an I/O module).
LED BUS1F" Indicates a bus fault of the MPI/DP interface.
LED BUS2F" Indicates a bus fault of the DP interface.
LED " FRCE" Indicates that inputs/outputs are forced.
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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 loadand 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
Warm Restart During a warm restart, the process images and the non-retentive data are
deleted. A new cycle begins after the process image input tables (PII) are read
in.
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Performing a Memory Reset and a Warm Restart
RUN-P
RUN
STOP
MRES
1. Set the mode selector switch to STOP
within 1 sec
RUN
STOP
MRES
RUN-P
RUN
STOP
MRES
2. Hold the mode selector switch in the MRES position until
the STOP LED has flashed twice slowly.
Release the mode selector switch so that it returns to
the STOP position.
RUN
STOP
MRES
RUN-P
RUN
STOP
MRES
3. Turn the mode selector switch to the MRES position once
more until the STOP LED begins to flash quickly.
Release the mode selector switch so that it returns to
the STOP position.
RUN
STOP
MRES
RUN-P
RUN
STOP
MRES
4. Set the mode selector switch to the RUN-P (RUN)
position ! (A warm restart is carried out in the transition
from STOP to RUN/RUN-P)
RUN
STOP
MRES
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Hardware Configuration and Parameter Assignment
Actual configuration Actual configuration and parameter assignment
of existing hardware.
Parameter assignment Parameter assignments such as retentive
areas, scan cycle time, and set-up of
analog input cards
Setpoint configuration Planned hardware configuration and
parameter assignment.
Configuration Assignment of racks, blocks and distributed
I/O in the Hardware Configuration tool.
You can select the components froma
hardware catalog.
HWConfiguration 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 S7-400stations 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 systemis 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 configurationandparameter
assignment of the modules can be uploaded from the CPU. This creates a new
HWstation 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 readout, you can set
parameters andadd 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 andthe actual
configuration, the CPU startup is interrupted.
To call the HWConfig tool, there must be a hardware station in the SIMATIC
Manager.
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Insert Station
You insert a new station in the current project by selecting the menu options
Insert -> Station -> SIMATIC
300 Station or SIMATIC
400 Station.
You can then change the name that is automatically given to this station -
"SIMATIC
300 (1)" - to one of your choice.

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Inserting a Station
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HWConfig This tool helps you configure, assign parameters to and diagnose the hardware.
Starting HWConfig To start the HWConfig tool:
select a hardware station in the SIMATIC
Manager andchoose the

Edit --> Open Object menuor
double-click the hardware object.
" Hardware This is a windowin the "HWConfigapplication you use for inserting
Configuration" components from the "Hardware Catalog" window.
The title bar of this window contains the name of the project and the station
name.
"Hardware Catalog" To open the catalog:
select the View -> Catalog menuor
click the icon in the toolbar.
If Standardis selected as the catalog profile, all racks, modules and interface
modules are available in the "Hardware Catalog" window.
You can create your own catalog profiles containing frequently used elements
by selecting the menu options Options -> Edit Catalog Profiles.
You can addProfibus Slaves that do not exist in the catalog later on. To add
slaves, you use GSE files that are provided by the manufacturer of the slave
device. The GSE file contains a description of the device. To include the slave in
the hardware catalog, use the Options -> Install New GSE Files menuand then
Options -> Update Catalog. You will find the new devices in the catalog under
Profibus, additional field devices.
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SIMATIC S7
Starting the HW Configuration Editor
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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
installationof an IM, you must insert a dummy module DM370 (DUMMY).
"Inserting" Modules From slot no. 4onwards, you can insert a choice of up to 8signal modules
(SM), communications processors (CP) or function modules (FM) from the
HardwareCatalog usingdrag & drop or with a double-click.
The slots onwhich the selected module can be inserted are automatically
highlighted in green.
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Generating a Hardware Setpoint Configuration
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Cycle "Scan cycle monitoring time (ms):"
- If this time is exceeded, the CPU goes into the STOP mode.
Possible causes why this time is exceeded: communications
processes,
frequently from interrupt events, errors in the CPU program.
- If you have programmed anerror OB 80, the scan cycle time is
doubled. After that, the CPU also goes into the STOP mode.
"Cycle load from communication (%):"
- Communication (suchas data transmission to another CPU through
MPI or test functions the PG/PC triggered) is restricted to the specified
percentage of the current scan cycle time.
- Restricting the cycle load can slowdowncommunication between the
CPU and PG.
- Example: Restricting communication to 20%results in a maximum
communication load of 20ms for a scan cycle time of 100ms.
Size of the With the CPU 318-2 andseveral S7-400CPUs, you can specify the size of
Process Image the process image (in bytes). The process image area always begins with input
andoutput byte 0.
Clock Memory Clock memories are bit memories that change their binary value periodically
(pulse-to-pause ratio 1:1).
Each bit in the clock memory byte is assigneda particular period/frequency.
Example of a flashing light with a flashing frequencyof 2Hz :
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CPU Properties: Cycle / Clock Memory
Clock MemoryBit 7 6 5 4 3 2 1 0
Frequency(Hz) 0.5 0.62 1 1.25 2 2.5 5 10
Period (s) 2 1.6 1 0.8 0.5 0.4 0.2 0.1
Double-click
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Save You select the Station->Save menu to save the current configuration in the
current project (without generatingsystemdata blocks).
Save and Compile When you select the Station->Save and Compile menu or click the
icon in the toolbar, the configurationandparameter assignment data are
also saved in systemdata blocks.
Consistency Check You select the Station -> Consistency Check menu to check whether it is
possible to generate configuration data from the entries made.
Download in Module You select the PLC -> Download menu or click the icon in the toolbar to
download the selected configuration to the PLC.
The PLC must be in "STOP" mode!
System Data Blocks The systemdata blocks (SDBs) are generated and modified when you configure
the hardware andcompile the hardware configuration. SDBs contain
configuration data and module parameters. Whena systemdata block is
downloaded, it is stored in the CPUs work memory.
This makes it easier to replace modules, because the parameter assignment
data is downloaded to the new module from the systemdata blocks onstartup.
In the programming device, the systemdata blocks are saved under: Project \
Station \ CPU \ S7_program\ Blocks \ System_data.
You double-click the Systemdata briefcase icon to see the list of
systemdata blocks.
If you use a memory card as Flash EPROM, you should save the SDBs there as
well. That way, the configuration is not lost if you operate without battery backup
and there is a power failure.
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Saving the HW Setpoint Configuration and Downloading it in Module
Download
(only when CPU
is in STOP mode)
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Introduction A configuration is necessary only in the following cases:
if you want to modify the basic module settings
for stations withdistributedI/O
for S7-400with several CPUs or with expansion racks
You can readout the actual configuration fromthe CPU and look at the set
parameters in an existing system.
Actual Configuration During startup, the CPU generates an actual configuration. That is, the CPU
saves the arrangement of the modules and allocates the addresses in
accordance with a fixed algorithm. If no parameters have been assigned, the
default parameters defined at the factory are used.
The system stores this actual configuration in system data blocks.
Uploading to PG/PC There are two ways of uploading the actual configuration to the PG/PC:
1. In the SIMATIC
Manager:
select the PLC -> Upload Station menu.
2. In the HW Config tool:
select the PLC -> Upload menuor click the icon.
Storage on PG/PC The actual configuration read fromthe hardware is insertedas a newstation in
the selected project on the PG/PC.
Note When you readout the actual configuration, the order numbers of the modules
cannot be completely identified. For this reason, you shouldcheck the
configuration. If required, insert the exact module type of the existing modules.
To do so, choose the module, and thenselect the Options -> Specify Module
menu.
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Uploading the Actual HW Configuration to the PG/PC
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Address Views the I/O addresses of the station configured.
Overview Select: View -> Address Overview
Abbreviations:
R Rack number
S Slot number of the relevant module
DP Relevant only when Distributed Peripherals (I/O) are used
IF Interface module IDwhen programming the M7 system (in C++).
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Module Address Overview
Address Overview
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HW Config: Edit Symbolic Names, Monitor/Modify Variables
Once with right
Edit Symbolic Names You can directly access the symbol table from the "HWConfig" tool. This allows
you to assign symbolic names to the inputs andoutputs during hardware
configuration or at a later date when you can make suppliments or changes.
You open the symbol table with a right mouse click onthe module. Select Edit
Symbolic Names in the follow-up box. A section of the symbol table with the
relevant addresses is then opened.
Monitor/Modify You can monitor or modify the addresses of the configured modules directly
Variables from the HWConfig tool. The signals of the input modules can be "checked" and
the signals of the output modules can be "controlled" using the Monitor/Modify
(Variables) function.
Product Support Directly from the Internet, you can fetch informationon modules or components
Information from the Product Support pages. As well, it is also possible to update HWConfig
by incorporating individual components such as newCPUs or newDP devices
into the current STEP 7version.
Requirements:
The PG/PC has an Internet connection, a browser for displaying Internet pages,
and the function is enabledin the HWConfig Settings along with the
specificationof the Internet address.
Note "Symbolic Addressing" andthe editingof symbol tables is dealt with in depth in
the "Symbols" chapter. The Monitor / ModifyVariables function is dealt with in
the "Troubleshooting" chapter.
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Monitor You can monitor variables in two ways:
The monitor values can be updated once when you select the Variable ->
Update Monitor Values menu optionor click the icon.
The monitor values can be updated every cycle when you select the
Variable -> Monitor menu option or click the icon.
Modify Procedure for modifying variables:
1. With the left mouse button, click the line in the Modify Valuecolumn for
the variable that you want to modify.
2. Enter the value in the correct formfor the data type selected.
3a. To activate the modify values once, select the Variable -> Activate Modify
Values menu option or click the icon (or item3b).
3b. To activate the modify values every cycle, select the Variable -> Modify
menu option or click the icon.
4. 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 andclickingon 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.
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Monitoring and Modifying Variables
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Saving the You canuse Table -> Save or Table -> Save as... to save a variable table.
Variable Table The first time a variable table is saved, the Save As... dialog windowopens.
The Save as ... windowallows the user to select the Blocks folder that the
variable table will be stored in.
You cangive the variable table anyname youchoose. The name is insertedas
the symbolic name in the symbol table.
You can reuse saved variable tables for monitoring and modifying, making it
unnecessaryto re-enter the variables.
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Saving the Variable Table
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Area of Use You candouble-click to reopen variable tables that are stored in a Blocks folder
of an S7programat a later time for test purposes.
However, before you can activate the "Monitor" and "Modify" functions, an online
connection to a CPU has to be established.
Using the menu commands PLC -> Connect to . . . provides three connection
choices: Configured CPU, Direct CPU and Accessible CPU. There are toolbar
icons for connecting to the Configured CPU or Direct CPU.
Configured CPU If the variable table is stored in the Blocks folder of a hardware-dependent S7
program(assignedto 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 HWConfig tool.
If the variable table is stored in the Blocks folder of a hardware-independent S7
program folder (assigned directly to the project root in the project view), the MPI
address of the hardware-independent S7program can be established using the
Properties dialog of the program folder while in the online viewof the SIMATIC
Manager.
Direct CPU This menu command establishes an online connection between the active
variable table and the CPU to which the MPI cable from the PG/PC to the
programmable controller is connected. The PG can determine to which PLC it is
connected through the MPI cable.
Accessible CPU This menu command establishes an online connection between the active
variable table and a CPU that you select. If the user program is already linked to
a CPU, this menu command can be used to change the CPU.
Select a CPU to which you want to establishan online connection in the dialog
box. You can choose between configuredandaccessible CPUs.
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SIMATIC S7
Opening a Variable Table and Establishing a Connection to the CPU
Configured
CPU
(VAT from
HW Station
" Station 2" )
Station 2 Station 1
Directly
connected
CPU
Station 1
PG
Station 3
Accessible CPUs
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SIMATIC S7
Modifying Outputs in the Stop State
Function and The "Enable Peripheral Outputs" function can only be activated when the CPU is
Area of Use in the STOP state. It switches off the output disable of the peripheral outputs
(PQ). This enables you to modify the peripheral output when the CPU is in the
STOP mode.
The "Enable Peripheral Outputs" function is used mainly to check the wiringof
the peripheral outputs. It can, however, also be used to continue to control
actuators in the process, even though the CPU has gone into the STOP mode
because anerror has occurred.
What To Do To enable the peripheral outputs, proceed as follows:
1. Openor 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 -> Connect tomenu 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
PQD 4 DW#16#0001
5. Use Variable -> Enable Peripheral Outputs to activate the modifyingof the
outputs
6. Use Variable -> Activate Modify Values to modify the peripheral outputs.
7. To assign new modify values, enter these andthen activate them with
Variable -> Activate Modify Values
Note Modifying or "Enable Peripheral Outputs" remains active until you deactivate it
using Variable -> Enable Peripheral Outputs or you press the ESC key. When
you change the operating mode of the CPU from STOP to RUN or STARTUP,
the Enable Peripheral Outputs is deactivatedanda message appears.
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SIMATIC S7
Exercise 1: Performing a CPU Memory Reset and Warm Restart
From the PG
- Mode selector
in RUN-Pposition
- Menu options:
PLC -> Diagnostic/Setting
-> Operating Mode -> Stop
- Menu options:
->Clear/Reset
- Confirmmemory reset
by clicking the OK
button (fast flashing of
"STOP" LED
indicates memory
reset being performed)
- Menu options:
->Operating Mode ->
Warm Restart
- Mode selector in
STOPposition
- Insert Memory Card
(slowflashing of
"STOP" LED indicates
request for memory
reset)
- Switch the mode
selector quickly to the
"MRES" position and
release (fast flashing
of "STOP" LED
indicates memory
After Inserting a
Memory Card
- Switch mode selector
to "RUN" or "RUN-P"
position
- Mode selector
in STOPposition
- Hold mode selector
in MRESposition
until the STOPLED
flashes twice (slowly)
- Release mode
selector (returns
automatically to the
STOPposition)
- Switch the mode
selector quickly to the
"MRES" again and
release (fast flashing of
"STOP" LED
indicates memory
Manually
- Switch mode selector
to "RUN" or "RUN-P"
position
Memory Re
set Function
Request
Memory
Reset
Perform
Memory
Reset
Perform
Warm Restart
Task You are to performa CPU memory reset and check whether the memory reset
was successful.
What to Do 1. Carry out the memory reset according to the steps in the slide above
2. Check the success of the memory reset (only if you have a CPU previous to
Oct. 2002. The memory reset was successful when only systemblocks
(SDBs, SFCs, SFBs) are left in the CPU .
In the SIMATIC Manager -> switch to the Online View using
-> double-click on MPI=2 -> double-click on Blocks
Notes When the CPU memory is reset, all user data in the CPU are deleted.
To make sure that no oldblocks are left in the CPU, a memory reset of the
CPU should be performed. The following takes place during a memory reset:
All user data are deleted
(with the exceptionof the MPI parameter assignments).
Hardware test and initialization
If an Eprom memory card or a Micro Memory Card is installed, the CPU
copies the memory card contents back into the internal RAMafter the
memory reset.
If no memory card or Micro Memory Cardis installed, the preset MPI
address is retained. If, however, a memory card is installed, the MPI address
storedon it is loaded.
The contents of the diagnostic buffer (which can be displayed with the PG)
are retained
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.24
SIMATIC S7
SIMATIC S7
Exercise 2: Retrieving a Project and Save As
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 the old project "My_Project" (should it exist):
File -> Delete -> User Projects -> select "My_Project" from the list ->
confirm
3. Retrieve the project SERV2_A":
File -> Retrieve -> select "SERV2_A.ZIP" from the list ->
acknowledge with "OK" -> select "S7-Courses" from the list of target
directories -> acknowledge message with "YES"
4. Save the project under the name "My_Project"
File -> Save as... -> User projects -> enter "My_Project" as the name ->
confirm
Notes The project contains the program for the conveyor model as you edited it in the
previous course - ST-SERV1, a hardware stationand a ProTool/Pro project for
the TP170B.
ST-SERV2
Task Since different training units and CPUs are used for the courses, the available
CPU has to be integrated into the setpoint configuration.
During the course, corrections to the hardware configurationalso have to be
made.
Note If you have an S7-400training unit, use the HW Station "S7-400".
What to Do 1. Start the "HWConf" tool
2. Adapt the hardware configuration for the training unit
3. Exchange the CPU for correct one
4. Save andcompile the configuration
5. Download the configuration into the CPU
Date: 02.12.2005
File: SERV2_02E.25
SIMATIC S7
SIMATIC S7
Exercise 3: Adapting the Setpoint Configuration
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.26
SIMATIC S7
SIMATIC S7
Exercise Preparation: Attaching the Fault Simulation Connector
Fault simulation connector
Task In the following two exercises, youare to check the wiring of the sensors and
actuators of the conveyor model to the digital input and output modules.
The errors that you are to determine are simulatedusinga fault simulation
connector. This connector must first be attached to the conveyor model.
What to Do 1. Remove the 32-pin Sub-D plugon the conveyor model
2. Attach the fault simulation connector to the conveyor model
3. Attach the 32-pin Sub-D plug to the fault simulation connector
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.27
SIMATIC S7
SIMATIC S7
Exercise 4: Testing the Sensors Wiring on the Conveyor Model
Task In this exercise, you are to check the wiringof the conveyor models sensors to
the digital input modules according to the symbol table (see slide). You will
check the wiringof the actuators in the next exercise.
Note The errors that occur are simulatedby the fault simulationunit that you just
attached. Your task is to determine the errors, not to eliminate them!
What to Do 1. Start the "Monitor/Modify Variable" function
SIMATIC
Manager -> PLC -> Monitor/Modify Variable

2. Enter the inputs shown in the slide into the variable table. Activate variable
monitoring using
Insert -> Range of Variables -> as of Address: I 4.0, Number: 8, Display
Format: BIN
3. To check the input wiring, press the sensors on the conveyor model one
after the other and observe whether the associated input states are
displayedon the screen
4. After youhave completed the input wiring test, save the variable table under
the name "I/O Conveyor Model"
Table -> Save as... -> in the dialog, open the Blocks folder of the HW
Station "S7_300 _Station" -> enter the object name "I/O Conveyor Model" ->
OK
5. Exit the Monitor / ModifyVariable function
Result 1st. error: ................................................................................................
Possible Cause: ................................................................................................
2nd. error: ................................................................................................
Possible Cause: ................................................................................................
.
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.28
SIMATIC S7
SIMATIC S7
Exercise 5: Testing the Actuators Wiring on the Conveyor Model
Example:
Conveyor to the right
Task Nowcheck the wiring of the conveyor models actuators to the digital output
modules using the function "Enable Peripheral Outputs" .
What to Do 1. Open the "I/O Conveyor Model" variable table fromthe previous exercise
SIMATIC
Manager -> open the Blocks folder of the HW Station

"S7_300_Station" -> double-click on "I/O Conveyor Model"
2. Add the peripheral output byte PAB 0 Display format "binary" to the variable
table
3. Even if it isnt necessaryhere:
Establish a connection to the directly connected CPU
PLC -> Connect to -> Direct CPU
4. Activate the function "Enable Peripheral Outputs"
Variable -> Enable Peripheral Outputs
5. To test the output wiring, enter the state 1 for the respective output in the
column "Modify Value", activate it using and observe whether the
associated actuator on the conveyor model is energized.
6. Exit the Monitor / ModifyVariable function.
Result 1st. error: ................................................................................................
Possible cause: ................................................................................................
2nd. error: ................................................................................................
Possible cause: ................................................................................................
3rd. error: ................................................................................................
Possible cause: ................................................................................................
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.29
SIMATIC S7
SIMATIC S7
Exercise 6: Checking the Interface of the TP170B
Loader B6.0.2.16
Transfer
Start
Control
Panel
Transfer Settings
Channel Directories
X OK
Advanced
Enable Channel
Remote Control
Serial:
Channel 1:
Enable Channel
Remote Control
Channel 2:
MPI
S7-Transfer Settings X OK
Properties...
MPI
Profibus
MPI X OK
Address:
Station Parameters
Panel is the only master on bus
1 s
Time-out:
Transmission Rate:
NetworkParameters
31 Highest Station:
1
187,5 kbits\s
Task The interface of the TP170B is to be set up as in the slide, so that the
ProTool/Pro project can then be downloaded fromthe PG.
What to Do 1. Exit Runtime on the TP170B
2. Press the "Control Panel" button
3. Double-click on the "Transfer" icon
4. Define the settings as in the slide
5. With "OK", accept the settings until youget back to the "Control Panel"
6. Double-click on the "OP" icon
7. Press the "Save Registry" button
8. With "OK", accept the settings until youget back to the screen with the
"Transfer", "Start" and "Control Panel" buttons
9. Press the "Transfer" button. The TP 170B then waits for a connection from
the PG.
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.30
SIMATIC S7
SIMATIC S7
Exercise 7: Downloading a ProTool Project
Task You are to download the ProTool/Pro project to the TP170B.
What to Do 1. Open the ProTool/Pro project bydouble-clicking on the object
"TP170B_Colour"
2. Click on the "Download" icon
3. Acknowledge the messages that follow
4. Exit ProTool/Pro.
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.31
SIMATIC S7
SIMATIC S7
Exercise 8: Downloading the Program
Task The "Demo_1" S7 programcontains the programfor the conveyor model from
the previous course - ST-SERV1.
This programis to be downloadedand in the next exercise the function is to be
tested.
What to Do 1. Select the "Blocks" object fromthe "Demo_1" S7 program
2. Click on the icon
3. Acknowledge the message "Do you want to load the system data?" with
"No".
4. Switchon the conveyor model with S5 =ON
5. Connect the TP 170B and the PG to the MPI interface and the
ET 200S and the Micromaster to the Profibus interface
6. Carry out a warm restart on the CPU.
ST-SERV2
Date: 02.12.2005
File: SERV2_02E.32
SIMATIC S7
SIMATIC S7
Exercise 9: Function Test of the Conveyor Model
System Function The conveyor model is to be operated througha screen on the TP170B as
follows.
System ON/OFF The system is switchedon through the "System On" button and off throughthe
"System Off" button.
When the system is on, you can thenset the manual mode or the automatic
mode.
Manual Mode The manual mode is selected with the "Auto/Manual" switchand is accepted
with the "Accept" button.
In manual mode, a part canbe moved in the direction of the light barrier with
"J og right" or in the other direction with "J og left" as longas the appropriate
button is pressed.
Automatic Mode When the system is on, automatic mode can be selected with the " Auto/Manual"
switchand can be accepted with the "Accept" button.
In automatic mode, the parts are placedon the conveyor in front of the proximity
sensor "Ini1" or "Ini2". After acknowledging with the appropriate "S1" or "S2"
momentary-contact switch, the conveyor moves until the part has crossed the
light barrier. If the conveyor doesnt reach the light barrier within6 seconds, the
conveyor stops and a fault is indicatedon an LED on the simulator. This fault
can be acknowledgedbypressing the momentary-contact switch I1.0
("T_Ackn_Fault).
The number of completedparts are countedas theycross the light barrier and
are displayedon the output field "Actual_Quantity". When the preset setpoint
quantity is reached, it is indicatedon the LED "H4" on the conveyor model. Until
this is acknowledgedwith the momentary-contact switch "S4", no newtransport
functioncan be started.

Serv2 02e HW Sw-Comm

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ST-SERV2

Hardware and Software Commissioning Page 1

300 Station or SIMATIC

300 (1)" - to one of your choice.

Manager andchoose the

300 station in the Hardware Catalog.

Manager -> PLC -> Monitor/Modify Variable

Manager -> open the Blocks folder of the HW Station

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