4.

User Guideline SICAR Standard

Disclaimer

Because of the variety of uses for SICAR described in this publication, those responsible for the use of

SICAR must satisfy themselves that all necessary steps have been taken to assure that each use meets all

performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for

purposes of example. Since there are many variables and requirements associated with any particular

installation Siemens does not assume responsibility or liability (to include intellectual property liability) for

actual use based upon the examples shown in this publication.

Reproduction of the contents of this copyrighted manual, in whole or in part, without the written permission of

Siemens, is prohibited.

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User Guideline 4

Table of contents

1. SICAR PLC basic 3

1.1 Guideline for PLC settings 3
1.1.1 System Resources 4
1.1.2 Clock memory 5
1.1.3 F-Parameters 5
1.1.4 Basic monitoring 6

2. SICAR HMI basic 8

2.1 Additional information for HMI project 8
2.1.1 Screen navigation 8
2.1.2 Manual operation 9
2.1.3 Additional screens 10
2.2 Guideline for HMI settings 13
2.2.1 Device Setting 14
2.2.2 Connection Setting 14
2.2.3 Configuration of movements 15
2.2.4 Implementation of a Tec_unit 21

3. Implementation of an additional HMI 35

3.1 Modification on PLC project 35
3.2 Modification on HMI project 39

4. Multilingual Step 7 41

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1. SICAR PLC basic

This S7-project should be the entrance to build up a PLC-project and contains all basic function
so that the project engineer can start to design the program without any ideas about the basic
structure.

1.1 Guideline for PLC settings

On the CD you will find a prepared basic project, as well as a sample project based on our demo kit.

Rename the SICAR basic project with your own project name

Hardware configuration
Important: Indicate MB1 as clock memory for the CPU-parameterization

Init FC981:
Adaptation of the initialisation FC999 if demanded, otherwise default input extension
Adjustment of FB981 depending on the parameterization of FC999
Parameterization FB300

FC983:
Reading in of all panels (operator panels, manual on-site panels, robots and so on) into the FC983 by
means of the FC996 / FC997.
Program the operating modes by means of FC995

For each mode (if required) the signals "Emergency stop", “Protection doors”, “Basic start conditions”,
“Initial position” / “Position stop end of cycle” must be programmed in a message block
(Zone 1 -> FB1001)

Program user sequence cascades

- Sequence -FC (FC1004, etc.)

- Call and parameterisation of the sequence cascades FB (FB1000) with generation of the sequence
cascades DB
- Load sequence flag
- Process outputs
- Call of the Tec-unit and Drive interface

- Sequence FB (FB1004, etc.)

- Automatic
- Monitoring times
- Branchings

Program in the FC986 the calls of the FCs for message block and user sequence cascades

Programming manual movements

Productiondatas

Program the FB981 user interface

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1.1.1 System Resources

Function Number Range

Blocks FB FC DB UDT
System Library:
HMI-Interface and 0-199 0-199 0-199
System-Diagnostics

User: Section 1 200-299 200-299 200-299

System Library:
Technological -Units
300-499 300-499 300-499
for Body & Assembly and
conveyors
User: Section 2
500-599 500-599 500-599
for Safety program
System Library:
600-799 -- 600-799
Safety Program

User: Section 3 800-899 600-899 To FB/FC

System Library:
Initialization and
900-1299 900-1299 900-1299 900-999
Sequence_Engine
incl. Process-Diagnostics

User Section 4 1300… 1300… 1300…

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1.1.2 Clock memory

In the hardware configuration it is mandatory to set the Clock memory on to memory byte 1
in the CPU properties.

1.1.3 F-Parameters
If you use a Failsafe-PLC adjust the suggested settings from the systemresources.

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1.1.4 Basic monitoring

The over all monitoring for zone_no1 will be programmed in the message block FB1001.

The following memory bits are relevant for starting an operation mode. If one is missing the
operation mode start will be switched off immediately.

M 10.0 Z1 emergency_stop
M 10.1 Z1 protection door
M 10.4 Z1 basic start condit

In the project SICAR_basic all these bits are pre-set with log1.
All project specific conditions has to be programmed instead of the log1 bit.
Additional messages can be programmed in following (those like safety messages,…)

The diagnosis of these messages will be displayed in the “Seq diag” screen.

The displayed message texts are generated automatically from the source of the S7-block FB1001.

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The messages can also be displayed in the WinCC flexible alarm window. For that purpose it is
necessary to type in the the message texts in the WinCC flexible project.

The WinCC flexible project SICAR_basic contains a prepared fault-/alarm list in discrete alarms.

Basic-Project

Demo-Project

The HMI interface for the discrete alarms is the DB126. Therefor the information must be transferred from
the message block DB to the HMI interface block.

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2. SICAR HMI basic

The WinCC flexible project SICAR_Basic_V1.x_HMI contains the following screen forms:

Standard screen forms as described in chapter 3.5.

Faceplates and diag_pics of the tec_units
Operation mode selection and Sequence diagnosis screen

2.1 Additional information for HMI project

2.1.1 Screen navigation

Main OEM
menu

Special User Manual Seq Process Hardware Main OP-Mode

Overview Overview_1 Overview_1 Diag Diagnostic Diagnostic menu

Special User Manual Seq Process Hardware Main Manual

Overview Overview_1 Overview_2 Diag Diagnostic Diagnostic menu Operation

Alarm Alarm Manual Detail Cursor Line Page Line Page Main Seq
History Operation Diag to right Up Up Dn Dn menu Diag

Alarm Manual Seq Interlocks Version Main Process

History Operation Diag menu Diagnostic

Web RF300 Manual Seq Process Drives Main Hardware

Server Diag Operations Diag Diagnostics menu Diagnostic

Manual Seq Process Hardware Main Production

Operation Diag Diagnostic Diagnostic menu data

Version Panel Manual Seq Process Save Monitor Main System

control Operation Diag Diagnostic Settings Variables menu

Submenus Main
menu
The screen navigation was modified as such that it is possible to change to the diagnosis
or manual operating screens from any active screen.

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2.1.2 Manual operation

For the manual operations, SICAR is using the following screen types

SS_11_ManualMovement with up to 100 lines (according to 20 screens)

SS_12_UserOperation with up to 64 lines (according to 13 screens)
SS_13_SpecialFunctions with up to 32 lines (according to 7 screens)

For each type an overview provides a direct access to a particular screen.

By pressing the Manual operation button the visualization will change to the screen Man_Overview_1.

From these screen you can select a manual operation screen directly by pressing the corresponding
button (1..10 in the overview_1 and 11…20 in the overview_2) or you can change to the overview of the
other types of manual operation.

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2.1.3 Additional screens

Additionally to the standard screens, SICAR provides a screen for operation mode selection
named “SS_91_OM_screen“

The OP-mode screen can be selected directly from header or from the main screen.

Additionally to the function open OM-screen, the button displays the operation-mode
status of the activate Zone

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Another additionally screen is the sequence diagnosis screen named “SS_94_seq_Diag_CE/_PC”

This screen provides a dignosis of the message blocks and

the sequence blocks.

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The screen can be selected with the button “Seq Diag”.

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2.2 Guideline for HMI settings

The prepared basic_project, as well as the demo_project contains a WinCC flexible

project.

Configuration of the HMI in menu “Device Settings/Device Settings”

Configuration of the PLC -> HMI connection in menu “Communication/connections”

Define the manual operations and type in the relevant texts in the corresponding
textlist in menu “Text and Graphics Lists/Text Lists”.

Create an overview screen

Integratation of the faceplates for the tec_units

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2.2.1 Device Setting

2.2.2 Connection Setting

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2.2.3 Configuration of movements

At first it is possible to assign a name for the screen in the Manual Overview.

The name of the screen will be assigned in the WinCC flexible project.
Select the textlist “SO_111_Man_overview”. In the text list there are placeholders for each possible screen.

The placeholder texts can be modified individually

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The configuration of movements will be described on a sample of the first movement screen of the
project SICAR_demo and there for the first line.

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2.2.3.1 Activities in the HMI project

The SICAR_HMI_basic project provides default textlists for the displayed texts of the movement lines.
The corresponding value is: Line 01 : 10…19,
:
Line10 : 100…109,
:
Line 100 : 1000…1009

SICAR_HMI_basic SICAR_HMI_demo
Default text mov_line_01 Project specific text mov_line_01

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2.2.3.2 Activities in the PLC project

The PLC project SICAR_basic provides a prepared interface to the movement lines.
For the “SO_11_ManualMovement” it is FC61 “FC_IF_screen_manual”. In this block an
interface for 25 lines is preconfigured and can be easily extended up to the maximum of 100 lines.
Each line uses 8 bits in the standard interface.
The first network contains the declaration of used numbers of movement lines. In this case
there are 25 lines declared which means that the HMI project will reserve 5 movement screens with
5 lines each.

The bits for the color change are preset by log0. The user has to program the relevant conditions
for color change (left ->yellow, right ->blue) and for the indication of executablity.
The bits representing the button left/right are assigned to a memory bit which is reserved in
the symbol list. This bits can be used as pushbuttons in the user program.

1. ROW[n, 0] -> executable left

2. ROW[n, 1] -> executable right
3. ROW[n, 2] -> action left
4. ROW[n, 3] -> action right
5. ROW[n, 4] -> position left
6. ROW[n, 5] -> position right
7. ROW[n, 6] -> button pressed left
8. ROW[n, 7] -> button pressed right

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Example for line 1:

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Additionally to the prepared interface of the active elements of the movement lines, the
FC61 provides a prepared interface for hiding not used elements as well.

The value B#16#40 effects that the indication of the position will not be displayed.

The procedure for the other types of movement screens will be the same.

“Manual operation” text list SO_111_Manual_overview

text list SO_11_ManualOperation
Interface block FC61

“User operation” text list SO_121_User_overview

text list SO_12_UserOperation
Interface block FC62

“Special function” text list SO_131_Special_overview

text list SO_13_SpecialFunction
Interface block FC63

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2.2.4 Implementation of a Tec_unit

2.2.4.1 Activities in the PLC project

The tec_unit FB has to be called in the FC of the corresponding sequence e.g. FC1004.
The block call needs an instance DB. The DB_No. range is from DB401…499.

The interface to HMI faceplates is defined with DB110 for the Interface_Visu (diag_pics)
and DB119 Interface Alarms (discrete alarms). The declaration (ARRAY) of the DBs has to be
modified according to the number of used Tec_units.

DB110 “Interface_Visu”

DB119 “Interface_Alarms”

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Example of a call of FB370 “PosDev_2D2S2P_PC”:

Enable Signal Interface

from sequence to Visu

Pushbutton Interface
from movement screen

Operation mode
from Zone 1

Reset from
OP-mode screen

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2.2.4.2 Activities in the HMI project

The implementation will be demonstrated based on the tec-unit PosDev_2S2D2P

Create a tag-folder with the name of the screen.

New tag folder named “Model”

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Create a tag for the “Model_Alarms” and a tag for the visu of the corresponding Diag_pic
“Diag_PosDev_2S2D2P”

The relation of the output-parameter of the tec_unit block FB370 to the projected tag will
be shown in the following figure.

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Connecting the tag “ST010_Carr_Visu” as a multiplex tag in tag-folder “Diag”, in this case as Index 1.

Open the tag folder “Diag”, select the corresponding Tec_unit, open the properties and
select “Multiplexing”

Note: Index 0 cannot be used and is reserved with the internal variable ULg_Dummy.

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Insert the tag “ST010_Carr_Visu” from the tag folder “Model” as Index 1.

Additional PosDev_2S2D2P types are added with there own Tagname and to the next free Index position.

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Open the Main screen and copy the faceplate from the project library into the screen.

Connect the faceplate with the tag “ST010_Carr_Visu”.

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To give the faceplate an individual name is mandatory

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To activate the Diag -and Statusscreen of the PosDev you have to do the following steps:

1. ActivateScreen: Select the Diag screen name

2. SetValue: Give the tag “DiagIndexDLG” a unique number corresponding to the multiplex
setting of the tec_unit tag

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Create a Tag “Model_Alarms” with a number of Arrays fitting to the used Tec-Unit blocks in the Station.

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In the Alarm management/Temp_Messages you can find prepared messages for each Tec-Unit block
naming is $Name of the FB$ message. (in this case $FB370$)

Copy all 16 Messages to the folder “Discrete alarms”

Replace the Class “Errors” with “Warnings”

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Replace the TriggerTag “Messages” with “Model_Alarms”

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Note: Relationship between Trigger Tag / Trigger bit and DB-Adress at TEC-Unit Output ALARMS
If you add an additional Tec-Unit in your project you use as a Trigger Tag e.g. again Model_Alarms.
Next step is to adjust the Trigger bit
The calculation of the start address of your first Trigger bit is DBW (X) * 2
1. Tec-Unit: DBx.DBW0 -> First Trigger bit 0
2. Tec-Unit: DBx.DBW2 -> First Trigger bit 16
3. Tec-Unit: DBx.DBW4 -> First Trigger bit 32
……..
8. Tec-Unit: DBx.DBW0 -> First Trigger bit 64

The calculation of the Trigger address reguarding to the Trigger bit is done automatically by WINCCflex.

Step7: Declaration of DB119 WINCCflex: Declaration of variable Model_Alarms

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Replace “$Name of FB$” in this case “$FB370$ with the right name e.g. “ST010_Carr” by using the search
and replace function

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3. Implementation of an additional HMI

If several SICAR operator panels are to be connected with a controller, a new DB interface must be provided
in the controller for the second and each additional operator panel. This requires the duplication of the
SICAR DBs and the modification of the numbers in Step7 and WinCC flexible.

3.1 Modification on PLC project

Duplicate the DB_HMI_DATA (DB67) as runtime interface for the second operator panel.(e.g. DB70)

Duplicate the DB_HMI_CONFIG (DB68) for the configuration of the second operator panel.(e.g.DB71)

All following modifications must be done in FC67

The FC_HMILITE_BASIC (FC68) must be called once in the program for each operator panel. The
"HMI_DATA_DB" and "HMI_CONFIG_DB" input parameters must be supplied with the appropriate DB
numbers.

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The FC_HMILITE_MANUAL (FC69) must be called once in the program for each operator panel. The
"HMI_DATA_DB" and "HMI_CONFIG_DB" input parameters must be supplied with the appropriate DB
numbers

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Change the interface for the screen name in the header

The interface for the manual operation screens FC61,FC62,FC63 needs to be duplicated.
Internally the interface address must be supplied with the appropriate DBNo.

The duplicated FCs (e.g. FC64,65,66) must be called in the FC67

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In FC983 an additional call of FC997 for HMI_2 is necessary.

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3.2 Modification on HMI project

Make a copy of the current HMI project and make the following modifications

The number of the DB_HMILITE_DATA (DB67) is parameterized in the WinCC flexible

"SO_00_DBNumberData" variable. This number must be changed in the corresponding WinCC flexible
configuration. The new number of the duplicated DB_HMILITE_DATA must be entered as start value in the
properties dialog of the WinCC flexible "SO_00_ DBNumberData" variable for the "initial settings".

Change base value of this variable from DB67 to e.g. DB70

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The number of the DB_HMILITE_CONFIG (DB68) is parameterized in the WinCC flexible

"SO_00_DBNumberData" variable. This number must be changed in the corresponding WinCC flexible
configuration. The new number of the duplicated DB_HMILITE_CONFIG must be entered as start value in
the properties dialog of the WinCC flexible "SO_00_DBNumberConfiguration" variable for the "initial settings

Change base value of this variable from DB68 to e.g. DB71

The WinCC flexible area pointers with the DB67 (DB_HMILITE_DATA) absolute address must receive the
duplicated DB_HMILITE_DATA as new absolute address.

Change base value of this variable from DB67 to e.g. DB70

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4. Multilingual Step 7
All S7-Projects are delivered with the languages english and german.
The language can be changed with the integrated Simatic Manager Function „Manage Multilingual texts“.

SICAR is using in Step7 and WinCC flexible the both languages

English (USA) -> Default
Deutsch (Deutschland)

With the language switching following comments will be changed:

Comments of the symbollist
Block comments
Variable comments in the Block declaration

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