Siemens Innovation Tour – TIA Portal

User manual

Assembling and operating the demo set

 Content

1 TOPIC OF THE DEMO SET 5

1.1 FUNCTIONALITY OF THE "STOCKING" AREA 6

1.2 FUNCTIONALITY OF THE "MIXING AND FILLING" AREA 6

2 COMPONENTS OF THE DEMO SET 7

2.1 OVERVIEW OF THE HARDWARE 7

2.2 SIMULATION OF THE BOTTLE FILLING PLANT 8

2.3 DEMO CASE 1 9

2.4 DEMO CASE 2 9

2.5 DEMO CASE 3 10

2.6 DEMO CASE 4 10

2.7 INTERACTION BETWEEN THE SIMULATION AND THE DEMO CASES 11

2.8 PRESENTATION OF THE LIVE DEMO 12

3 ASSEMBLING AND SWITCHING ON THE DEMO SET 14

3.1 SETTING UP AND SWITCHING ON THE CASES 14

3.2 CONNECTING THE FIELD PGS 14

3.2.1 Establish a connection to demo case 1 15
3.2.2 Establish a connection to the beamer 16

2 / 52 3.2.3 Switching on the Field PGs and changing the beamer settings 17
 4 OPERATING THE DEMO SET – QUICK START 19

4.1 STARTING AND SETTING UP SIMULATION 19

4.2 STARTING BOTTLE FILLING MACHINE 20

4.3 SELECTING THE SIMULATION VIEWS 21

4.3.1 Selection on the panel 21

4.4 SELECTING THE SOFT DRINK FOR FILLING 22

4.5 STOPPING BOTTLE FILLING MACHINE 23

5 OPERATING THE DEMO SET FROM A TO Z 24

5.1 STARTING SIMULATION ON THE FIELD PG 24

5.2 OPENING OVERVIEW SCREEN ON THE PANEL 25

5.3 SETTING THE OPERATING LANGUAGE 25

5.4 STARTING, STOPPING AND RESETTING PLANT 26

5.5 SELECTING THE SIMULATION VIEWS 27

5.5.1 Selection on the panel of demo case 1 27
5.5.2 Selection on the keypad of demo case 1 28

5.6 SPECIFYING SOFT DRINKS FOR FILLING 29

5.6.1 Selecting soft drinks 30
5.6.2 Changing the recipes for the soft drinks 31

5.7 VIEWING INFORMATION ABOUT PRODUCTION 32

5.7.1 Status LEDs on the cases 32
5.7.2 Current plant status 32

3 / 52 5.7.3 Production data 33

 5.7.4 Time sequence for tank fill levels 34
5.7.5 Checking tank fill levels 36

5.8 DIAGNOSTICS OPTIONS 38

5.9 SIMULATING FAILURE 39

5.9.1 Simulating overvoltage 39
5.9.2 Simulating module failure 41

5.10 SYSTEM SETTINGS 42

6 FIRST COMMISSIONING OF THE FIELD PG 43

6.1 BURNING BOOT CD 43

6.2 DOWNLOADING AND INSTALLING IMAGES 43

6.3 LOADING PROJECT 49

7 RECTIFYING FAULTS ON THE DEMO SET 50

7.1 SIMULATION WITHOUT CONNECTION TO THE HMI PANEL 50

7.2 SIMULATION IS NOT FUNCTIONING CORRECTLY 50

7.3 BEAMER IS NOT FUNCTIONING CORRECTLY 50

7.4 PROBLEMS WITH THE PLC 50

8 TECHNICAL DATA OF THE DEMO SET 51

8.1 IP ADDRESSES OF THE DEMO SET 51

8.2 ACCESS POSSIBILITIES FOR THE DEMO SET 51

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 1 TOPIC OF THE DEMO SET

The industrial topic of this innovation tour is simulation of an industrial bottling plant for various fruit juice drinks. The virtual plant comprises a tank
system, a mixing vessel and a bottling machine comprising an infeed conveyor, filling station, labeling unit and an outgoing conveyor.

For the purposes of clarity, the plant is subdivided into two functional areas:

• Stocking

• Mixing and filling

The plant described here is presented in a simplified manner, because the objective is not to emphasize production details, but instead to de-
monstrate the functional scope of the engineering software "TIA Portal V11" in the course of an industrial production lifecyle.
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 1.1 Functionality of the "Stocking" area
In soft drink stocking, there is an external area that lies outside the production area. There are five tanks in this area for storing different soft drink in-
gredients. Each tank is controlled via a separate valve. The fill level of the individual tanks will drop in accordance with the recipe that is made up in
the mixing tank.

A separate supply line is provided for filling the tanks.

1.2 Functionality of the "Mixing and filling" area

In the mixing tank, the soft drink is mixed from the individual ingredients in accordance with the recipe, and the fill level rises.

Every time the recipe changes, the mixing tank is emptied (the rinsing process is omitted). The mixing tank has a drain valve for this purpose (fill le-
vel falls to zero). The fill level of the mixing tank also depends on the bottle filling process. When a bottle is filled, the fill level of the mixing tank falls.
When the mixing process is completed, bottle filling can start.

The actual bottle filling machine comprises five separate parts:

• Conveyor belt 1 transfers empty bottles from storage to turntable 1. The turntable can accept a specific number of bottles and holds the
bottles in place during the filling process.

• The filling station is located above turntable 1; it fills the bottles with the soft drink provided in the mixing tank, and seals them.

• Conveyor belt 2 transfers the sealed bottles to turntable 2. This turntable can also accept a specific number of bottles and holds the bottles
in place during the labeling process.

• The labeling station is located at turntable 2. This glues a printed label to the bottle.

• The bottle is then removed via conveyor belt 3.

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 2 COMPONENTS OF THE DEMO SET

The industrial process described above is demonstrated by means of demo cases and a PC simulation. The demo cases do not contain any function
elements, only automation components.

2.1 Overview of the hardware

The demo set comprises the following components:

• Demo case 1

• Demo case 2

• Demo case 3

• Field PG M3 (2)

• Full HD beamer (2)

7 / 52 The connections between components are described in the following chapters.

 2.2 Simulation of the bottle filling plant
The PC simulation that forms the basis of all control processes is shown in the figure below.

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 2.3 Demo case 1
Demo case 1 contains two S7-300 PLCs and a Comfort Panel. It is used to control and operate the plant.

2.4 Demo case 2

Demo case 2 contains an S7-1200 PLC, a KP300 panel as well as communications processors and PROFIBUS-DP modules.

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 2.5 Demo case 3
Demo case 3 contains Safety functions. This case will not function with TIA Portal Version 11 (Build 25 & 36).

2.6 Demo case 4

Demo case 4 completes the tour equipment as a stand-alone training case. It is not used in conjunction with the plant simulation, but it can be used
for accompanying presentations. The case can be used for both standard and Safety topics.

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 2.7 Interaction between the simulation and the demo cases
The demo cases are assigned to different areas of the plant simulation:

• Demo case 1 -> Mixing and filling

• Demo case 2 -> Stocking

• Demo case 3 -> Safety switching devices (not used with TIA Portal V11, Build 25 & 36)

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 2.8 Presentation of the live demo
For presentation of the live demo, two Field PG M3s are available that are thematically assigned, one to the engineering and one to the plant simula-
tion. Each PG is equipped with its own beamer, so that independent presentations are possible.

The basic arrangement of the equipment is shown in the figure below:

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 The sequence of the live demo alternates between the two PGs. The following diagram shows the time sequence, on the basis of a use case.

The engineering PG is used in steps 1 and 3, and the PG with the plant simulation is used in step 2.

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 3 ASSEMBLING AND SWITCHING ON THE DEMO SET

3.1 Setting up and switching on the cases

After unpacking the cases, place them in the following order from left to right:

Connect the cases to a suitable 230 V AC socket outlet using the supplied mains cables at the back.

Switch the demo cases on, one after the other, at the illuminated rocker switch on the back of the case. The switch-on sequence can be random.

3.2 Connecting the Field PGs

You connect both cases to demo case 1 and the beamer in an identical manner. Whether the Field PG, on which the presentation and engineering
are shown, also has to be connected to demo case 1 is decided on the basis of the content of the live demos to be shown. If online passages are in-
cluded, a LAN connection to demo case 1 is required.

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 3.2.1 Establish a connection to demo case 1
Connect the Field PG M3 and the Scalance XF208 in demo case 1 with a suitable network cable.

You must use the Ethernet interface shown on the Field PG for this purpose.

PLEASE NOTE: A WLAN connection between the demo case and the Field PG is not possible.

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 3.2.2 Establish a connection to the beamer
Connect the Field PGs and the beamer using the supplied HDMI cable and the HDMI/DVI adapter.

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 3.2.3 Switching on the Field PGs and changing the beamer settings
Switch on the Field PG and the beamer. After the start-up procedure, the desktop is displayed.

Right-click the desktop and select the Graphics Properties... item in the shortcut menu.

Ensure that the frequency of the beamer is set to 30 Hz.

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 Select the Multiple Display item.

Set the displays as shown.

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 4 OPERATING THE DEMO SET – QUICK START

In this chapter, you will find out the main steps required for starting the plant quickly. Perform the following steps in the order given. For more exten-
sive and detailed information on the functions or on operating the equipment, please refer to chapter 5.

4.1 Starting and setting up simulation

Start the simulation software by double-clicking the corresponding desktop icon:

After starting the simulation, press the space bar on your keyboard to switch simulation to full-screen mode.

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 4.2 Starting bottle filling machine
On the HMI, tap the screen once to display the overview screen:

Tap Settings and select the Factory Start item from the drop-down menu.

The plant in the simulation then starts to run. Close the menu again by tapping .

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 4.3 Selecting the simulation views

4.3.1 Selection on the panel

On the panel of demo case 1, in the navigation column, select the following icon:

The different camera positions that are available are shown.

Click the respective icon to activate this view in the simulation.

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 4.4 Selecting the soft drink for filling
To change the soft drink for filling, select the Ingredients entry from the navigation column.

Tap Recipes to open the recipe management.

Select the required soft drink from the list box and load it onto the PLC.

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 4.5 Stopping bottle filling machine
Tap Settings on the HMI and select the Factory Stop item from the drop-down menu.

The plant is then stopped in the simulation. Close the menu again by tapping .

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 5 OPERATING THE DEMO SET FROM A TO Z

5.1 Starting simulation on the Field PG

After all the services have been automatically started on the PG, start the simulation software on the engineering PG by double-clicking the ap-
propriate desktop icon:

After starting the simulation, press the space bar on your keyboard to switch simulation to full-screen mode.

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 5.2 Opening overview screen on the panel
When the panel has started up, tap the start screen once to display the overview screen.

5.3 Setting the operating language

To set the operating language, tap the flag in the bottom border of the navigation column:

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 5.4 Starting, stopping and resetting plant
Tap Settings in the header of the panel.

From the dropdown menu, select the Factory Start item. The plant in the simulation then starts to run.

To stop the plant, select the Factory Stop item.

Use Reset to set the plant to the initial values.

Close the menu again by tapping .

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 5.5 Selecting the simulation views

5.5.1 Selection on the panel of demo case 1

On the panel, in the navigation column, select the following icon:

The different camera positions that are available are shown.

Tap the respective icon to activate this view in the simulation.

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 5.5.2 Selection on the keypad of demo case 1
You can also set up the views for the simulation using the built-in keypad.

The following figure shows the assignment of keys to the simulation views:

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 5.6 Specifying soft drinks for filling
Select the Ingredients entry in the navigation column of the panel.

You can monitor the fill levels of the individual tanks and the positions of the valves here.

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 5.6.1 Selecting soft drinks

To change the type of soft drink to be filled, select .

You can select from the list box of available soft drinks and then transfer this to the PLC with .

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 5.6.2 Changing the recipes for the soft drinks
To change the components for a selected recipe, tap a value in the Value column.

Using the screen keyboard, you can enter a new value and load it with
. Then you have to transfer the modified

recipe to the PLC again with .

If the recipe has to be permanently saved, you must answer the relevant confirmation prompt with Yes.

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 5.7 Viewing information about production

5.7.1 Status LEDs on the cases

The meanings of the colors and the difference between continuous and flashing light on the cases are as follows:

Lamp status Production status

Green - continuous Plant is running
Yellow - continuous Plant ready
Yellow - flashing Plant ready - product changeover
Red - continuous Failure

5.7.2 Current plant status

The current status of the plant is permanently displayed in the header of the panel.

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 5.7.3 Production data
To view the production data, tap Factory Data in the navigation column of the panel.

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 5.7.4 Time sequence for tank fill levels
To analyze the time sequence for the tank fill levels, select the Ingredients entry from the navigation column.

Click the icon .

In the "Trend" view, you can follow accurately what quantity of the ingredient is in the stocking tank at what time.

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 You can start and stop logging, page forwards/backwards and zoom in/out using the control keys .

Tap to return to the ingredients overview.

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 5.7.5 Checking tank fill levels
On the panel of demo case 2, press the F1 key to enter the tank overview.

You can see all the tanks here with their current fill levels.

To view the details for a tank, select it by means of the associated key.

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 In the detail view, the respective fill level for the tank is highlighted in color on the panel:

Full tank:

Half-full tank:

Almost empty tank:

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 5.8 Diagnostics options
In the navigation column, select the Alarms / Diagnostics entry to open the diagnostics display.

You can use the list box to select whether alarms or system diagnostics should be displayed.

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 5.9 Simulating failure
In the navigation column, select the Simulate Failure entry to open the screen for simulating failure.

5.9.1 Simulating overvoltage

Tap the slider and move it up into the overvoltage range.

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 To open the diagnostics view, click on .

To close the window again, click on .

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 5.9.2 Simulating module failure

Under simulate failure, tap to page to the next screen.

Create a module failure by dragging the analog module of the CPU 317F in demo case 1.

To open the diagnostics view, click on .

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 5.10 System settings
On the panel, in the navigation column, select the following icon:

You can start system services here, such as the screen keyboard, screen calibration and the task manager, or stop runtime.

You can also see the current system alarms.

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 6 FIRST COMMISSIONING OF THE F IELD PG

6.1 Burning boot CD

Download the ISO image for the image software ("SIMATIC-IPC_Image&Partition Creator_V3.1_xx.nrg") and burn it on a CD.

6.2 Downloading and installing images

Download the image for the respective Field PG and save it on a USB data carrier.

Insert the boot CD in the PG and connect the USB memory stick containing the image to the PG.

Start the PG again and boot it from the CD.

Carry out the following steps in the correct sequence:

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 6.3 Loading project
Download the TIA Portal project and open it with the TIA Portal. Load the project onto the PLC.

For the Comfort Panel KP700, use the supplied Pack&Go file.

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 7 RECTIFYING FAULTS ON THE DEMO SET

7.1 Simulation without connection to the HMI panel

When you start the simulation after the PG has started up, before the component configurator has been loaded, the simulation has no access to the
OPC server. You will notice this, for example, if no bottles are transferred on the conveyor in the simulation.

In this case, switch from 3D to 2D simulation by pressing the space bar, and start the OPC server.

7.2 Simulation is not functioning correctly

If the simulation is not functioning correctly, restart the bottle filling machine on the panel. Refer to chapter 5.4.

7.3 Beamer is not functioning correctly

Ensure that the frequency of the beamer is 30 Hz. Refer to chapter 3.2.3.

7.4 Problems with the PLC

If problems occur with the PLC, it is recommended to switch the CPU to STOP using the mode switch, and then back to RUN again.

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 8 TECHNICAL DATA OF THE DEMO SET

8.1 IP addresses of the demo set

Component Case Address Subnet mask
PLC S7-317 F 1 192.168.70.1 255.255.255.0
PLC S7-315 1 192.168.70.2 255.255.255.0
HMI Comfort Panel 7" 1 192.168.70.10 255.255.255.0
ET200 pro 3 192.168.70.20 255.255.255.0
PLC S7-1214C 2 192.168.70.30 255.255.255.0
HMI KP300 2 192.168.70.31 255.255.255.0
Scalance XF208F 1 192.168.70.40 255.255.255.0
Scalance W788-2 RR 1 192.168.70.41 255.255.255.0
Scalance W784-1 2 192.168.70.42 255.255.255.0
Field-PG M3 – programming and presentation 192.168.70.50 255.255.255.0
Field-PG M3 – simulation 192.168.70.51 255.255.255.0

8.2 Access possibilities for the demo set

Component Type Password Note
SCALANCE W788-2 RR Europe admin
SCALANCE W788-2 RR US scalance-wlan
Sm@rtService access to KP700 100
External mobile device (iPhone etc.) WiFi (2.4 GHz) Innovation Select IP address from 192.168.70.20x

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Siemens AG Manual_Demoequipment_en.doc
Industry Sector Version 03/11
Industry Automation and Drive Technologies I IA AS SM MP1
Postfach 4848
90026 NÜRNBERG, GERMANY

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