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ST-SERV2Hardware and Software CommissioningPage 1

SITRAIN Training forAutomation and Drives

Date: 02.12.2005File: SERV2_02E.1

SIMATIC S7Siemens AG 2005. All rights reserved.

SIMATIC S7 SITRAIN Training forAutomation and Drives

Hardware and Software Commissioning

Contents PageObjectives .......................................................................................................................................... 2Commissioning Checklist ............................................................................................................... 3

LEDs on the S7-300 Power Supply ............................................................................................. 4LEDs on the S7-300 CPU ............................................................................................................ 5LEDs on Digital Modules ................................................................................................................. 6LEDs on the S7-400 Power Supply ............................................................................................ 7LEDs on the S7-400 CPU ............................................................................................................. 8Performing a Memory Reset and Warm Restart .............................................................................. 9Hardware Configuration and Parameter Assignment ....................................................................... 10Inserting a Station .......................................................................................................................... 11Starting the HW Config Editor ........................................................................................................... 12Generating a Hardware Setpoint Configuration ................................................................................. 13CPU Properties: Cycle/Clock Memory ........................................................................................... 14Saving the HW Setpoint Configuration and Downloading it in Module ............................................. 15Uploading the Actual HW Configuration into the PG/PC ................................................................... 16

Module Address Overview ............................................................................................................... 17HW Config: Edit Symbolic Names, Monitor / Modify Variables ...................................................... 18Monitoring and Modifying Variables ................................................................................................. 19Saving the Variable Table ............................................................................................................... 20Opening a Variable Table and Establishing a Connection to the CPU ............................................. 21Modifying Outputs in the Stop State ................................................................................................ 22Exercise 1: Performing a CPU Memory Reset and Warm Restart ...................................................... 23Exercise 2: Retrieving a Project and Save As .................................................................................... 24Exercise 3: Adapting the Setpoint Configuration................................................................................. 25Exercise Preparation: Attaching the Fault Simulation Connector ..................................................... 26Exercise 4: Testing the Sensors Wiring on the Conveyor Model ....................................................... 27Exercise 5: Testing the Actuators Wiring on the Conveyor Model .................................................. 28Exercise 6: Checking the Interface of the TP170B.............................................................................. 29

Exercise 7: Downloading a ProTool Project ........................................................................................ 30Exercise 8: Downloading the Program ................................................................................................ 31Exercise 9: Function Test of the Conveyor Model............................................................................... 32


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Date: 02.12.2005File: SERV2_02E.2



Objectives

Upon completion of this chapter the participant will ...

... know the meanings of the LEDs on the S7 modules

... be able to perform a CPU memory reset

... with the "Monitor/Modify Variables" 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 thehardware. If you do not want to use the default setting, it may be necessary toassign 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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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 supply has a diagnostic LED "DC24V" on the front side of themodule. Use this LED to determine the state of the power supply.

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LEDs on the S7-300 Power Supply

LED "DC24V" State Reaction of the Power Supply

Continuous On 24 V available 24 V available

Flashing

Vo ltaged ip,voltage recovery whenoverload 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 circuitVoltage interruption, automaticrecovery when short circuiteliminated

OffOvervoltage or undervoltage on theprimary side(permissib le range: 187V to 264 VAC)

Overvoltage can cause destruction.With undervoltage, automaticinterruption.


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Status Displays SF = System Fault: group error, programming error or fault from a( LEDs ) diagnostics-capable module

BATF = Battery fault: battery is empty or is not present

DC 5V = 5V supply voltage present.

FRCE = Lights up when a forcing is active.

RUN = Flashes when the CPU starts up andis steady on in the RUN mode.

STOP = Is steady on in the STOP mode,Flashes slowly when a memory reset is requested andflashes quickly when a memory reset is carried out.

SF DP = System Fault DP: group error in the Distributed Peripheralsis steady on when there is a fault in the distributed peripherals

BUSF (BF) = Bus fault, is steady on when there is an interrupted cable, forexample.

Flashes when there 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 onthe 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

S7-400S7-300Status LEDs for every individual channel

Signal stateat the terminals

Signal stateat the terminals(for digital inputs)

Internal state,before the opto-coupler(for digital outputs)


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"INTF" -> internal fault"BAF" -> battery fault"BATT1F"-> Battery 1 empty or missing"BATT2F"-> Battery 2 empty or 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)

Battery compartment

Selection switch for battery monitoring"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 powersupply available.

LED "BATT1F/ Lights up in the case of battery reversal, if no battery is present, or the batteryBATT2F" is half discharged. The BATT.INDIC switch for battery monitoring is set to the

1BATT position (for one battery), the 2BATT position (for 2 batteries) or OFF (nobattery monitoring).

LED "DC 5V/DC 24V" Is lit when the 5V/24V DC output voltage is within the tolerance limits andflashes to indicate voltage recovery after a short circuit or overload.

"FMR" Ackn.Switch Acknowledgement switch for acknowledging and resetting a fault messagewhen the fault has been eliminated.

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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Date: 02.12.2005File: SERV2_02E.8



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 information about an occurred error orthat 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 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 portionof the stored program needed for execution into the internal RAM

Warm Restart During a warm restart, the process images and the non-retentive data aredeleted. A new cycle begins after the process image input tables (PII) are readin.

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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 oncemore until the STOP LED begins to flash quickly.Release the mode selector switch so that it returns tothe 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 transitionfrom STOP to RUN/RUN-P)

RUN

STOP

MRES


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Hardware Configuration and Parameter Assignment

Actual configuration Actual configuration and parameter assignmentof existing hardware.

Parameter assignment Parameter assignments such as retentiveareas, scan cycle time, and set-up ofanalog input cards

Setpoint configuration Planned hardware configuration and

parameter assignment.

Configuration Assignment of racks, blocks and distributedI/O in the Hardware Configuration tool.You can select the components from ahardware catalog.

HW Configuration The modules are supplied from the factory with preset parameters. If thesedefault 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 aConfiguration hardware station with the planned modules and the associated parameters. The

PLC system is assembled according to the setpoint configuration. Duringcommissioning, the setpoint configuration is downloaded to the CPU.

Actual Configuration In an assembled system, the actual existing configuration and parameterassignment of the modules can be uploaded from the CPU. This creates a newHW station in the project.

A configuration upload is necessary, for example, if the project structure doesnot exist locally at the PG. After the actual configuration is read out, you can setparameters and add part numbers.

Notes With the S7-400, the CPU can be assigned parameters in such a way, thatwhen there are differences between the setpoint configuration and the actualconfiguration, 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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Insert Station

You insert a new station in the current project by selecting the menu optionsInsert -> 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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HW Config This tool helps you configure, assign parameters to and diagnose the hardware.

Starting HW Config To start the HW Config tool:

select a hardware station in the SIMATIC

Manager and choose theEdit --> Open Object menu or

double-click the hardware object.

"Hardware This is a window in the "HW Config application you use for insertingConfiguration" components from the "Hardware Catalog" window.

The title bar of this window contains the name of the project and the stationname.

"Hardware Catalog" To open the catalog:

select the View -> Catalog menu or

click the icon in the toolbar.If Standard is selected as the catalog profile, all racks, modules and interfacemodules are available in the "Hardware Catalog" window.

You can create your own catalog profiles containing frequently used elementsby selecting the menu options Options -> Edit Catalog Profiles.

You can add Profibus Slaves that do not exist in the catalog later on. To addslaves, you use GSE files that are provided by the manufacturer of the slavedevice. The GSE file contains a description of the device. To include the slave inthe hardware catalog, use the Options -> Install New GSE Files menu and thenOptions -> Update Catalog. You will find the new devices in the catalog underProfibus, additional field devices.

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Starting the HW Configuration Editor


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Generating a This means specifying how the modules are to be arranged in the rack. ThisSetpoint 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 thisin 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 thetop part and a detailed view with order numbers, MPI addresses and I/Oaddresses in the bottom part.

Power Supply If a load current power supply is required double click or use drag & drop toinsert 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 slotno. 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 laterinstallation 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 theHardwareCatalog using drag & drop or with a double-click.

The slots on which the selected module can be inserted are automaticallyhighlighted 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: communicationsprocesses,frequently from interrupt events, errors in the CPU program.

- If you have programmed an error OB 80, the scan cycle time isdoubled. After that, the CPU also goes into the STOP mode.

"Cycle load from communication (%):"

- Communication (such as data transmission to another CPU throughMPI or test functions the PG/PC triggered) is restricted to the specifiedpercentage of the current scan cycle time.

- Restricting the cycle load can slow down communication between theCPU and PG.

- Example: Restricting communication to 20% results in a maximumcommunication load of 20ms for a scan cycle time of 100ms.

Size of the With the CPU 318-2 and several S7-400 CPUs, you can specify the size ofProcess Image the process image (in bytes). The process image area always begins with input

and output 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 assigned a particular period/frequency.

Example of a flashing light with a flashing frequency of 2Hz :

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CPU Properties: Cycle / Clock Memory

Clock Memory Bit 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 thecurrent project (without generating system data blocks).

Save and Compile When you select the Station->Save and Compile menu or click theicon in the toolbar, the configuration and parameter assignment data arealso saved in system data blocks.

Consistency Check You select the Station -> Consistency Check menu to check whether it ispossible to generate configuration data from the entries made.

Download in Module You select the PLC -> Download menu or click the icon in the toolbar todownload the selected configuration to the PLC.

The PLC must be in "STOP" mode!

System Data Blocks The system data blocks (SDBs) are generated and modified when you configurethe hardware and compile the hardware configuration. SDBs contain

configuration data and module parameters. When a system data block isdownloaded, it is stored in the CPUs work memory.This makes it easier to replace modules, because the parameter assignmentdata is downloaded to the new module from the system data blocks on startup.

In the programming device, the system data blocks are saved under: Project \Station \ CPU \ S7_program \ Blocks \ System_data.You double-click the System data briefcase icon to see the list ofsystem data blocks.

If you use a memory card as Flash EPROM, you should save the SDBs there aswell. That way, the configuration is not lost if you operate without battery backupand there is a power failure.

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Saving the HW Setpoint Configuration and Downloading it in Module

Download(only when CPUis 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 with distributed I/O for S7-400 with several CPUs or with expansion racks

You can read out the actual configuration from the CPU and look at the setparameters in an existing system.

Actual Configuration During startup, the CPU generates an actual configuration. That is, the CPUsaves the arrangement of the modules and allocates the addresses inaccordance with a fixed algorithm. If no parameters have been assigned, thedefault 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 menu or click the icon.

Storage on PG/PC The actual configuration read from the hardware is inserted as a new station inthe selected project on the PG/PC.

Note When you read out the actual configuration, the order numbers of the modulescannot be completely identified. For this reason, you should check theconfiguration. If required, insert the exact module type of the existing modules.To do so, choose the module, and then select 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 ID when 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

Oncewith r ight

Edit Symbolic Names You can directly access the symbol table from the "HW Config" tool. This allowsyou to assign symbolic names to the inputs and outputs during hardwareconfiguration or at a later date when you can make suppliments or changes.

You open the symbol table with a right mouse click on the module. Select EditSymbolic Names in the follow-up box. A section of the symbol table with therelevant addresses is then opened.

Monitor/Modify You can monitor or modify the addresses of the configured modules directlyVariables from the HW Config 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 information on modules or componentsInformation from the Product Support pages. As well, it is also possible to update HW Config

by incorporating individual components such as new CPUs or new DP devices

into the current STEP 7 version.Requirements:

The PG/PC has an Internet connection, a browser for displaying Internet pages,and the function is enabled in the HW Config Settings along with thespecification of the Internet address.

Note "Symbolic Addressing" and the editing of symbol tables is dealt with in depth inthe "Symbols" chapter. The Monitor / Modify Variables function is dealt with inthe "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 option or click the icon.

The monitor values can be updated every cycle when you select theVariable -> Monitormenu option or click the icon.

Modify Procedure for modifying variables:

1. With the left mouse button, click the line in the Modify Value column forthe variable that you want to modify.

2. Enter the value in the correct form for the data type selected.

3a. To activate the modify values once, select the Variable -> Activate ModifyValues menu option or click the icon (or item 3b).

3b. To activate the modify values every cycle, select the Variable -> Modifymenu option or click the icon.

4. Use the "Monitor" function to confirm that the modify value has beenentered in the variable you selected.

Modify Value Valid You can make the "Modify value" entered in a table invalid by selecting thatvalue and clicking on the icon.

The now "invalid" value is displayed like a comment. You can make the modifyvalue "valid" again when you click on the icon again. Only valid modifyvalues can be activated.

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Monitoring and Modifying Variables


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Saving the You can use Table -> Save orTable -> Save as... to save a variable table.Variable Table The first time a variable table is saved, the Save As... dialog window opens.

The Save as ... window allows the user to select the Blocks folder that the

variable table will be stored in.You can give the variable table any name you choose. The name is inserted asthe symbolic name in the symbol table.

You can reuse saved variable tables for monitoring and modifying, making itunnecessary to re-enter the variables.

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Saving the Variable Table


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Area of Use You can double-click to reopen variable tables that are stored in a Blocks folderof an S7 program at a later time for test purposes.

However, before you can activate the "Monitor" and "Modify" functions, an onlineconnection to a CPU has to be established.

Using the menu commands PLC -> Connect to . . . provides three connectionchoices: Configured CPU, Direct CPU and Accessible CPU. There are toolbaricons 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 S7program (assigned to a CPU in the project view), a connection to the station withthe MPI address is established. This station was also assigned to the higher-level CPU with the help of the HW Config tool.

If the variable table is stored in the Blocks folder of a hardware-independent S7program folder (assigned directly to the project root in the project view), the MPIaddress of the hardware-independent S7 program can be established using the

Properties dialog of the program folder while in the online view of the SIMATICManager.

Direct CPU This menu command establishes an online connection between the activevariable table and the CPU to which the MPI cable from the PG/PC to theprogrammable controller is connected. The PG can determine to which PLC it isconnected through the MPI cable.

Accessible CPU This menu command establishes an online connection between the activevariable table and a CPU that you select. If the user program is already linked toa CPU, this menu command can be used to change the CPU.

Select a CPU to which you want to establish an online connection in the dialogbox. You can choose between configured and accessible CPUs.

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Opening a Variable Table and Establishing a Connection to the CPU

ConfiguredCPU

(VAT from

HW Station"Station 2")

Station 2Station 1Directlyconnected

CPU

Station 1

PG

Station 3

Accessibl e CPUs


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Modifying Outputs in the Stop State

Function and The "Enable Peripheral Outputs" function can only be activated when the CPU isArea 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 theSTOP mode.

The "Enable Peripheral Outputs" function is used mainly to check the wiring ofthe peripheral outputs. It can, however, also be used to continue to controlactuators in the process, even though the CPU has gone into the STOP modebecause an error has occurred.

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

1. Open or edit a variable table (VAT) that contains the peripheral outputs thatyou 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 to menu option to establish a connection to theCPU you want

3. Switch the CPU to the STOP state

4. Enter the appropriate values for the peripheral outputs you want to modify inthe "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 modifying of theoutputs

6. Use Variable -> Activate Modify Values to modify the peripheral outputs.

7. To assign new modify values, enter these and then activate them withVariable -> 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. Whenyou 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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Exercise 1: Performing a CPU Memory Reset and Warm Restart

From the PG

- Mode selectorin RUN-P position

- Menu options:PLC -> Diagnostic/Setting-> Operating Mode -> Stop

- Menu options:PLC -> Diagnostic/Setting-> Clear/Reset

- Confirm memory resetby clicking the OKbutton (fast flashing of"STOP" LEDindicates memory

reset being performed)

- Menu options:PLC -> Diagnostic/Setting-> Operating Mode ->Warm Restart

- Mode selector inSTOP position

- Insert Memory Card(slow flashing of"STOP" LED indicatesrequest for memoryreset)

- Switch the modeselector quickly to the"MRES" position andrelease (fast flashingof "STOP" LED

indicates memoryreset being performed)

After Inser ting aMemory Card

- Switch mode selectorto "RUN" or "RUN-P"position

- Mode selectorin STOP position

- Hold mode selectorin MRES positionuntil the STOP LEDflashes twice (slowly)

- Release modeselector (returnsautomatically to theSTOP position)

- Switch the modeselector quickly to the"MRES" again andrelease (fast flashing of"STOP" LED

indicates memoryreset being performed)

Manually

- Switch mode selectorto "RUN" or "RUN-P"position

Memory Reset Function

RequestMemoryReset

PerformMemoryReset

PerformWarm Restart

Task You are to perform a CPU memory reset and check whether the memory resetwas 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 toOct. 2002. The memory reset was successful when only system blocks(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 old blocks are left in the CPU, a memory reset of theCPU should be performed. The following takes place during a memory reset:

All user data are deleted(with the exception of the MPI parameter assignments).

Hardware test and initialization

If an Eprom memory card or a Micro Memory Card is installed, the CPUcopies the memory card contents back into the internal RAM after thememory reset.

If no memory card or Micro Memory Card is installed, the preset MPIaddress is retained. If, however, a memory card is installed, the MPI addressstored on it is loaded.

The contents of the diagnostic buffer (which can be displayed with the PG)are retained


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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 targetdirectories -> 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 station and a ProTool/Pro project forthe TP170B.


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Task Since different training units and CPUs are used for the courses, the availableCPU has to be integrated into the setpoint configuration.

During the course, corrections to the hardware configuration also have to bemade.

Note If you have an S7-400 training unit, use the HW Station "S7-400".

What to Do 1. Start the "HW Conf" tool

2. Adapt the hardware configuration for the training unit

3. Exchange the CPU for correct one

4. Save and compile the configuration

5. Download the configuration into the CPU

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Exercise 3: Adapting the Setpoint Configuration


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Exercise Preparation: Attaching the Fault Simulation Connector

Fault simulation connector

Task In the following two exercises, you are to check the wiring of the sensors andactuators of the conveyor model to the digital input and output modules.

The errors that you are to determine are simulated using a fault simulationconnector. This connector must first be attached to the conveyor model.

What to Do 1. Remove the 32-pin Sub-D plug on 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


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Exercise 4: Testing the Sensors Wiring on the Conveyor Model

Task In this exercise, you are to check the wiring of the conveyor models sensors tothe digital input modules according to the symbol table (see slide). You willcheck the wiring of the actuators in the next exercise.

Note The errors that occur are simulated by the fault simulation unit that you justattached. Your task is to determine the errors, not to eliminate them!

What to Do 1. Start the "Monitor/Modify Variable" functionSIMATIC Manager -> PLC -> Monitor/Modify Variable

2. Enter the inputs shown in the slide into the variable table. Activate variablemonitoring using

Insert -> Range of Variables -> as of Address: I 4.0, Number: 8, DisplayFormat: BIN

3. To check the input wiring, press the sensors on the conveyor model oneafter the other and observe whether the associated input states aredisplayed on the screen

4. After you have completed the input wiring test, save the variable table underthe name "I/O Conveyor Model"Table -> Save as... -> in the dialog, open the Blocks folder of the HWStation "S7_300 _Station" -> enter the object name "I/O Conveyor Model" ->OK

5. Exit the Monitor / Modify Variable function

Result 1st. error: ................................................................................................

Possible Cause: ................................................................................................

2nd. error: ................................................................................................

Possible Cause: ................................................................................................

.


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Exercise 5: Testing the Actuators Wiring on the Conveyor Model

Example:Conveyor to the right

Task Now check the wiring of the conveyor models actuators to the digital outputmodules using the function "Enable Peripheral Outputs" .

What to Do 1. Open the "I/O Conveyor Model" variable table from the previous exerciseSIMATIC 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 variabletable

3. Even if it isnt necessary here:Establish a connection to the directly connected CPUPLC -> 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 thecolumn "Modify Value", activate it using and observe whether the

associated actuator on the conveyor model is energized.

6. Exit the Monitor / Modify Variable function.

Result 1st. error: ................................................................................................

Possible cause: ................................................................................................

2nd. error: ................................................................................................

Possible cause: ................................................................................................

3rd. error: ................................................................................................

Possible cause: ................................................................................................


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Exercise 6: Checking the Interface of the TP170B

Loader B6.0.2.16

Transfer

Start

ControlPanel

Transfer Settings

Ch an nel Di rect ories

XOK

Advanced

Enable Channel

Remote Control

Serial:

Channel 1:

Enable Channel

Remote Control

Channel 2:

MPI

S7-Transfer Settings XOK

Properties...

MPI

Profibus

MPI XOK

Add ress :

Station Parameters

Panel is the only master on bus

1 sTime-out:

Transmission Rate:

NetworkParameters

31Highest Station:

1

187,5 kbits\s

Task The interface of the TP170B is to be set up as in the slide, so that theProTool/Pro project can then be downloaded from the 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 you get 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 you get 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 fromthe PG.


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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 by double-clicking on the object"TP170B_Colour"

2. Click on the "Download" icon

3. Acknowledge the messages that follow

4. Exit ProTool/Pro.


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Exercise 8: Downloading the Program

Task The "Demo_1" S7 program contains the program for the conveyor model fromthe previous course - ST-SERV1.This program is to be downloaded and in the next exercise the function is to be

tested.

What to Do 1. Select the "Blocks" object from the "Demo_1" S7 program

2. Click on the icon

3. Acknowledge the message "Do you want to load the system data?" with"No".

4. Switch on the conveyor model with S5 = ON

5. Connect the TP 170B and the PG to the MPI interface and theET 200S and the Micromaster to the Profibus interface

6. Carry out a warm restart on the CPU.


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Exercise 9: Function Test of the Conveyor Model

System Function The conveyor model is to be operated through a screen on the TP170B asfollows.

System ON/OFF The system is switched on through the "System On" button and off through the"System Off" button.

When the system is on, you can then set the manual mode or the automaticmode.

Manual Mode The manual mode is selected with the "Auto/Manual" switch and is acceptedwith the "Accept" button.In manual mode, a part can be moved in the direction of the light barrier with"Jog right" or in the other direction with "Jog left" as long as the appropriatebutton is pressed.

Automatic Mode When the system is on, automatic mode can be selected with the "Auto/Manual"

switch and can be accepted with the "Accept" button.In automatic mode, the parts are placed on the conveyor in front of the proximitysensor "Ini1" or "Ini2". After acknowledging with the appropriate "S1" or "S2"momentary-contact switch, the conveyor moves until the part has crossed thelight barrier. If the conveyor doesnt reach the light barrier within 6 seconds, theconveyor stops and a fault is indicated on an LED on the simulator. This faultcan be acknowledged by pressing the momentary-contact switch I1.0("T_Ackn_Fault).The number of completed parts are counted as they cross the light barrier andare displayed on the output field "Actual_Quantity". When the preset setpointquantity is reached, it is indicated on the LED "H4" on the conveyor model. Untilthis is acknowledged with the momentary-contact switch "S4", no new transportfunction can be started.

Serv2 02e Hw Sw-comm

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