000 B3.026.02.00 GL-EN Software PLC Part2 CPU319F V50.00

000_B3.26.02.
00_GL-
EN_Software_PLC_part2_CPU319F
Version
50.00
Author
Peter Stocker (Fa. APM) i.A. PWT/ VAS
Phone: +49 (0)7031-90-81372

Fax: +49 (0)711-3052 18 1623
Email: apm.stocker@daimler.com
Document Identification
Project name Daimler AG, Standard integra
Document designation 000_B3.26.02.00_GL-EN_Software_PLC_part2_CPU319F
File name 000_B3.26.02.00_GL-EN_Software_PLC_part2_CPU319F_V50.00
Version 50.00
Creation date 2011-12-12
Transmission Only with written permission of Daimler AG
Author Peter Stocker (Fa. APM) i.A. PWT/ VAS 2011-12-12
Checked for content by H.P. Müller, FP/ SNT 2011-12-12
Klaus Haigis, PWT/ VAS 2011-12-12
Responsible for document Wolfgang Kochs, FP/ SNT
The original documents can be viewed by arrangement with the person

responsible for the document
This document was generated in collaboration with:

name, first name plant department phone e-mail
Klaus Haigis 050 PWT/VAS +49 7031/90-71721 klaus.haigisl@daimler.com
Ernst-Martin Bradfisch 050 PWT/VAS +49 7031/90-5316 ernst.bradfisch@daimler.com
Hans-Peter Müller 050 FP-SNT +49 7031/90-86531 hans-peter müller@daimler.com
Martin Matz 050 FP-SNT +49 7031/90-83105 martin.matz@daimler.com
Contact persons in the plant:

name, first name plant department phone e-mail
Example, Toni 050 PKL/K3 +49 7031/90-xxxxx Toni.Examplel@daimler.com
Typographical Conventions
Header – Level 1 List – Main categories
Header – Level 2 List – Subcategories
Header – Level 3 Italics Term is explained in the glossary
Header – Level 4 Bold Highlight
Document Note
Figure / Table [1] Reference to "References”
Project: Daimler AG, Standard integra

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Page 2 of 159
Reproduction, transmission or use of this document or its contents is not permitted. Offenders will be liable for damages. All rights, including rights created
by patent grant or registration of a utility model or design, are reserved.
Update Service
Author Telephone E-mail
Peter Stocker (Fa. APM) i.A. PWT/ VAS +49 (0)7031-90-81372 apm.stocker@daimler.com
Update journal
No. Chapter P. Reason for change Change content V. Date Handled by
1 First issue Interga 4th wave 40.00 05.05.11 Müller/Kall
Integra 5. Wave
Version 40.23 adopted and formal
2 All ECM-Release 50.00 04.12.22 Müller
adaption
GL replaced with GL-EN
The current changes are marked in yellow in comparison to the older edition
No. = Serial number P. = Page number V. = Version of change (document version)

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Contents
Document Identification ......................................................................................................... 2
Typographical Conventions ................................................................................................... 2
Update Service ...................................................................................................................... 3
Update journal ....................................................................................................................... 3
Contents ................................................................................................................................ 4
Foreword ............................................................................................................................... 8
Contents of this Document .................................................................................................... 8
1. Setting Up a New Project with integra .......................................................................... 9
1.1. Prerequisites .......................................................................................................... 9
1.2. Project language english .......................................................................................13

1.2.1. Creating Project in English language ............................................................................ 13
1.2.2. Copying parts of the program from a German Step 7 project ....................................... 15
1.3. Settings on the Programming Device ....................................................................16

1.3.1. Symbolic address operand field width ........................................................................... 16
1.3.2. Set PG/PC interface ...................................................................................................... 16
1.4. Entering the Application Creation ..........................................................................17

1.4.1. SIMATIC Manager View: S7 319F-3PN/DP .................................................................. 17
1.5. Hardware Configuration Adaptations S7-300 ........................................................18

1.5.1. Adaptations for the S7-project ....................................................................................... 18
1.5.2. Setting for Comment Management ............................................................................... 18
1.5.3. Adaptations for CPU319F-3PN/DP ............................................................................... 19
1.5.4. PROFINET I/O adaptations ........................................................................................... 28
1.5.5. Ethernet connection adaptations ................................................................................... 29
2. Software Structure ......................................................................................................34
2.1. From the System Structure to the Software Structure ...........................................34
2.2. Number Ranges of the Modules ............................................................................34
2.3. Allocation in the User Area ....................................................................................35
2.4. Structure of the Symbols .......................................................................................36

2.4.1. Adapting symbol table ................................................................................................... 36

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2.4.2. Designation specification for function modules symbols (FB) ....................................... 37
2.4.3. Designation specification for data module (DB) symbols .............................................. 38
2.4.4. Designation specification of symbols for bit memories (M) .......................................... 40
3. Software Project Planning with integra ........................................................................41
3.1. Basic Application Software Packages ...................................................................42

3.1.1. CPU basic functions: OB1 ............................................................................................. 42
3.1.2. Editing the switching on of the first system: FB101....................................................... 44
3.1.2.1. Number of FC4027-calls depending on the integra powersupply concept .............. 45
3.1.3. Energy efficient switching .............................................................................................. 46
3.1.3.1. Devices with PROFIenergy ...................................................................................... 46
3.1.3.2. Energy-efficient switching by direct potential shutdown .......................................... 46
3.1.3.3. Energy-efficient switching with PROFIenergy at intelligent PN-Devices ................. 47
3.1.4. PROFINET diagnosis: FB54 ......................................................................................... 49
3.1.4.1. Structure of PN node error alarm texts in PN diagnostic DBs (1080-1083) ........... 50
3.1.5. Safety testing of safety equipment: FB97 ..................................................................... 51
3.1.6. Communication with digital plant interface (control technology): FB61 ........................ 53
3.1.6.1. FETCH/WRITE for the control technology/control stand communication (FB44).... 53
3.1.6.2. Function group DFI-COM (FC38) ............................................................................ 57
3.1.6.3. Switching times: ....................................................................................................... 57
3.1.7. Interface to the F program ............................................................................................. 58
3.1.8. Communication for PLUS .............................................................................................. 61
3.1.9. Communication with another S7 ................................................................................... 61
3.1.10. Console area module .................................................................................................. 62
3.2. System-specific Program Area ..............................................................................63

3.2.1. Connection of the standard parameter “release inputs” (FEin) ..................................... 64
3.2.1.1. Conveyor technology systems (FT): ........................................................................ 65
3.2.1.2. Mechanization systems (ME): .................................................................................. 67
3.2.1.3. Process technology system (VT): ............................................................................ 68
3.2.2. Additional errors (ZS_) .................................................................................................. 70
3.2.3. Additional warnings (ZW_) ............................................................................................ 72
3.2.4. Auxiliary initiators (ZI_) .................................................................................................. 73
3.2.5. Auxiliary alarms (ZM_) .................................................................................................. 74
3.2.6. Externally logged alarms (XM_) .................................................................................... 75
3.2.7. Additional parameters (ZP_) ......................................................................................... 75
3.3. Guide Sequencer with S7-GRAPH ........................................................................77

3.3.1. Overview........................................................................................................................ 77
3.3.2. Function group S7-GRAPH sequencer ......................................................................... 78
3.3.3. Incorporation of the FG S7-GRAPH sequencer organization ....................................... 79
3.3.4. Calling the “FG-S7G sequencer” ................................................................................... 80
3.3.5. Calling the S7-GRAPH guide sequencer ...................................................................... 83
3.3.6. Functioning method of the S7-GRAPH guide sequencer ............................................. 83

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3.3.7. Basic programming rules ............................................................................................... 84
3.3.8. Handling rules for S7-GRAPH modules (FB, DB) ......................................................... 85
3.3.9. Application and sequencer properties: settings ............................................................ 86
3.3.10. Sequencer functionalities ............................................................................................ 91
3.3.11. Graphical elements for sequence structures............................................................... 94
3.3.12. Steps ........................................................................................................................... 96
3.3.13. Transition ..................................................................................................................... 97
3.3.13.1. Waiting time ........................................................................................................... 97
3.3.13.2. Monitoring time ...................................................................................................... 98
3.3.14. Immediate error ........................................................................................................... 99
3.3.15. Connection to action modules ..................................................................................... 99
3.3.16. Alternative branching = EXOR sequences within one sequencer ............................ 100
3.3.17. Simultaneous branching = AND sequences within one sequence ........................... 101
3.3.18. Sequence representation in operation on the visual display..................................... 102
3.3.19. SmartSync (guided step selection) ........................................................................... 108
3.4. Special Cases .....................................................................................................109

3.4.1. Stations........................................................................................................................ 109
3.4.2. Function group expansion ........................................................................................... 110
3.4.3. Mechanization special functions.................................................................................. 111
3.4.4. Motion control screen .................................................................................................. 112
3.4.5 Interfaces to third-party systems .................................................................................. 113
4. F Programming .........................................................................................................114
4.1. F Program Structure............................................................................................114

4.1.1. Specifications for the programmer .............................................................................. 115
4.1.2. F program/suggestion for DB distribution according to basic application ................... 116
4.1.3. Call of the safety program in the OB35 ....................................................................... 118
4.1.4. F_CALL FC1600 ......................................................................................................... 119
4.1.5. Sequence group FC1601 ............................................................................................ 120
4.1.5.1. Example call of a safe RCV communication to the third-party programmable
controller .................................................................................................................................. 120
4.1.5.2. Function of the signal “Safety ALIVE” .................................................................... 121
4.1.5.3. Preparation of signals from the non-safe program section .................................... 122
4.1.5.4. Preparation of additional safety-oriented signals for the F program ...................... 123
4.1.5.5. Global reintegration after HW module errors of F modules ................................... 124
4.1.5.6. Input recording, group alarm variable and output connection ............................... 125
4.1.5.7. Example call of a safe SEND communication to the third-party programmable
controller .................................................................................................................................. 126
4.2. Safety Program ...................................................................................................127

4.2.1. Input recording FC1700, FC1701 – FC1732 ............................................................... 128
4.2.1.1. FC1700 “Formation of acknowledgement signal types for safety elements”......... 129
4.2.1.2. Input recording, emergency OFF for KP32F on EBF ............................................ 130
4.2.1.3. Input recording, VI maintenance switch for PP17-I on EBF .................................. 132

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4.2.2. Output shutoff FC1801 – FC1832 / group alarms FC1800 ......................................... 134
4.2.3. Connection of the safety modules ............................................................................... 136
4.2.4. Safe interface to third-party systems ........................................................................... 139
4.2.4.1. Interface to the third-party system PROFISAFE to PNOZ ..................................... 139
4.2.4.2. Interface to the third-party system PROFISAFE via DP/DP coupler ..................... 140
4.2.4.3. Interface to third-party system PROFISAFE via PN/PN coupler ........................... 142
4.2.5. Emergency OFF signals to the third-party system ...................................................... 144
4.2.6. Emergency OFF signals from the third-party system .................................................. 145
4.2.7. Parameterizing for the function modules ..................................................................... 146
4.3. Alarm structure of the safety program .................................................................147

4.3.1. Safety element emergency OFF alarm ....................................................................... 148
4.3.2. Safety element error alarm .......................................................................................... 149
4.3.3. Structure of emergency OFF and error alarm texts .................................................... 150
4.4. Interface to the standard (non-safe) program ......................................................152

4.4.1. Release signal “KeinStop” ........................................................................................... 153
4.4.1.1. With the use of FB1620, FB1622 ........................................................................... 153
4.4.1.2. With the use of FB1623/FB1624 ............................................................................ 154
5. Exporting Simatic sources for Integra ........................................................................155
Index of Abbreviations, Glossary ........................................................................................156
Index of Illustrations ...........................................................................................................156
Index of Tables ...................................................................................................................159

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Foreword
All available project engineering guidelines and approved materials lists in their entirety form
the basis for the overall standardization of all technological scopes for manufacturing and
factory technology at Daimler AG.
Points of detail for which precise information is not given in this project engineering guideline,
or also points that are not covered in the associated electrical or mechanical standard
documentation and in the appropriate software standard must be clarified with the person
responsible at Daimler AG.
Suggestions based on the existing project engineering guidelines, hardware standard
documentation and software standards must be worked out by the supplier and presented to
the person responsible at Daimler AG for approval.
The supplier is under obligation to inform Daimler AG about any improvements, modifications
and supplements that should be implemented in this project engineering guideline.
Approved improvements, modifications and supplements will be integrated into a subsequent
version of this project engineering guideline by Daimler AG when updating the
documentation.
This project engineering guideline does not release the supplier from the
responsibility for proper design of the equipment and documentation to be
supplied, taking into account the laws, regulations, conditions and requirements
that apply at the respective manufacturing site.
In the event of a contradiction in the project engineering guidelines or tender specifications,

the more stringent requirement shall apply.
Contents of this Document

The present guideline defines guidelines and procedures for programmable controller
software creation.

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1. Setting Up a New Project with integra
1.1. Prerequisites
a) The following software packages must be used

STEP 7
S7- GRAPH
S7 Distributed Safety Programming
The valid versions must be taken from the current edition of the file
„000_B3.26.03_Projektierversion-Profinet-Komponenten_V5x.xx.xls“.
b) integra software packages
Basic application S7-319F-3PN/DP: intP5_0x

Default CPU password: integra
Default F password: integra
Standard modules library: intL5_0x

F modules library: intF5_0x
Application examples APPL_PN5
Muster programs iRB_PN5

iMO_PN5
iFT_PN5
specific
The integra PLC program is always based on a Muster program. If there no shop
Master program available, the start with the Basis application.
(intP5_0x, iRB_PN5, iMO_PN5, IFT_PN5) (intL5_0x, intF5_0x) (APPL_PN5)

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An overview of the existing application templates can be found in the file
„000_B3.026.10.02.01.10_Applikationsvorlagen xxxx-xx-xx.xls“
The application templates is to

adopt and adopt according to the
network comments!

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Please note the reference to Application example:

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C1) GSDML – files for PROFINET:
The table of GSDML files for the integra project can be found in the file
„000_B3.26.03_Projektierversion-Profinet-Komponenten_V5x.xx.xls“.
Is an example from a device exists, then

you must use the example!
C2) HW updates – files for PROFINET
d) CAD files
RUPLAN hardware plan templates and master data for the system project planning
(including the PROFIBUS and the PROFINET components) can be found on the ECM Server
in Chapter 03. CAD Specifications / 01. CAD – Electrical – Fluid.

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1.2. Project language english
1.2.1. Creating Project in English language

Start programming with an English-based application or with an English-based master
template from bodyshop. (Simatic project is automatically set with the language "English")
Further blocks take from English standard library or integra Safety Library.
(Libraries have the language "English")
Continue the Application Creation in English according to specification of the basic
application intP4_0a_xxx_e.zip" or Master Template body shop "Irb_pn4_xxx_e.zip"
Create Network comments in english
Indication:
Name of variables and parameters form
Integra blocks remain in the German language
Figure 1 Change language to english (South Africa)

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Do not change existing german name of variables inside the
FGDB
If you create other application variables inside the FGDB e.g.

ZI -> Supplementary initiator
ZM -> Supplementary message
ZS -> Supplementary fault
The name and the comment has to be written in English
Figure 2 Name of variables in the FGDB

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1.2.2. Copying parts of the program from a German Step 7 project
a.) Before copying parts of the program, the German base project has to be changed to the
English (South Africa) language.
Figure 3 Change language to english (South Africa)
b.) When copying the required program components

All German application variables and application comments must be fully replaced by
English.
It is not allowed to copy standard blocks from the user project.

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1.3. Settings on the Programming Device
1.3.1. Symbolic address operand field width
For the programming in FUP respectively LAD in Tuscaloosa, the representation of the
operand field width must be set up with 18 characters.
Figure 4 Setting the operand field width
1.3.2. Set PG/PC interface

The interface of PG/PC interface has to be set to TCP/IP + (name of network card).
The setting TCP/IP (Auto) is not correct
Figure 5 setting the PG/PC interface

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1.4. Entering the Application Creation
Entering the application creation by using integra, the following steps must be performed in
the STEP 7 Manager:
1. Installation of the project-specific GSD files

2. Retrieving of the module library integra
3. Retrieving of the F modules library integra
4. Retrieving of the corresponding required basic application
1.4.1. SIMATIC Manager View: S7 319F-3PN/DP
Rename the basic application using the programmable controller name (e.g.,
ATVM101)
Please have the corresponding programmable controller name assigned by your Daimler
support person. However, it is necessary to note that the S7 project name must be no longer
than eight characters. Normally the system code “Axxx” is obtained from the system
designation. During archiving of the project, the project name is maintained.
Coordinate with your Daimler support person using the specified checklists regarding the
network parameters (e.g. IP address, naming, etc.)
The programmable controller name must also be used in the VISU.

In the basic application, one program container is present:
• The container S7 program contains a symbol table and all modules that are
necessary for a system with a PROFINET controller.
Figure 6 Basic application S7 319F-3PN/DP

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1.5. Hardware Configuration Adaptations S7-300
1.5.1. Adaptations for the S7-project

The adjustments of the hardware configuration described below have already been
configured appropriately in the basic application to accelerate the download time of the
hardware configuration.
Figure 7 project adjustments within the hardware configuration
1.5.2. Setting for Comment Management

The following settings for the hardware configuration are already configured in the basic
application.
Figure 8 Setting for Comment Management

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1.5.3. Adaptations for CPU319F-3PN/DP
The hardware settings described below (parameter settings for the modules) have already
been configured appropriately in the basic application.
Figure 9 Hardware configuration S7 319F-3PN/DP
The system-specific adaptations described below

1. Enter system identification in CPU properties
2. PROFINET-IO system settings
3. Ethernet address settings
still have to be performed. In the following, the most important settings and steps will be
shown.
Itproject
is necessary to agree with the responsible Daimler AG engineer on whether a
planning specification has to be considered for the module version to be
planned (e.g., firmware version ET200S).

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In the CPU property screen, in the menu item “General,” the system identification of the
system for which the project is being planned must be entered. The system identification can
be taken from the hardware plans (RUPLAN).
InPLCaddition to the system identification, a PLC number must be entered, too (e.g.
1). There may be systems with one power feed (thus it has one system
identification) and multiple programmable controllers.
Figure 10 Properties S7 319F-3PN/DP, General
Additional screenshots of the individual tabs follow in order to illustrate the CPU properties
completely.
Figure 11 Properties S7 319F-3PN/DP, Start-up

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Figure 12 Properties S7 319F-3PN/DP, Synchronous cycle interrupts

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The following screenshot represents the most important properties of the CPU 319F-
3PN/DP. The most important settings are in the Properties window and there, in the tab
“Cycle/clock memory”:
Size of the process image of the inputs = 8000 bytes

Size of the process image of the outputs = 8000 bytes
Clock memory = Bit memory byte 0
The basic application is prepared with the correct settings.
Figure 13 Properties S7 319F-3PN/DP, Cycle/clock memory
Figure 14 Properties S7 319F-3PN/DP, Retentive memory

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Figure 15 Properties S7 319F-3PN/DP, Interrupts
Figure 16 Properties S7 319F-3PN/DP, Time-of-day interrupts

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Figure 17 Properties S7 319F-3PN/DP, Cyclic interrupts
Figure 18 Properties S7 319F-3PN/DP, Diagnostics/Clock

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The general password for the basic application is integra and absolutely must be
modified to a system-specific password.
During assignment of system-specific CPU passwords, the following rule applies:
Figure 19 Properties S7 319F-3PN/DP, Protection

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Figure 20 Properties S7 319F-3PN/DP, Communication
Figure 21 Properties S7 319F-3PN/DP, F parameters

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Figure 22 Properties S7 319F-3PN/DP, Webserver deactivated

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1.5.4. PROFINET I/O adaptations
Inapproved
principle, the PROFINET field bus system has to be used; exceptions must be
by the responsible engineering department at Daimler.
In principle, the settings for the PROFINET are described explicitly in the FG-PN diagnostic
module description and in the Project Planning Guidelines “000_B3.26.03_GL-
EN_HWKonfig_PROFINET_...”

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1.5.5. Ethernet connection adaptations
With the use of PROFINET, the IP address classification and the device name
from the document “000_B3.26.03_GL-EN_HW_PROFINET” must be considered.
The Ethernet interface integrated in the PN-CPU is used; an additional CP343-1
Advanced may only be used for communication purposes after consultation with
the responsible control engineering project manager.
An additional CP343-1 Advanced for PN-IO connection of field bus components
is not permitted since the I/O data do not lie in the direct process image of the
CPU.
All letters in the network name and device name are written in lower case
The IP addresses, sub-network mask and router IP address must be entered by
the programmer.
Innecessary
order to prevent communication errors and collisions, the IP addresses
for parameterizing must be clarified with the responsible network
administrator of Daimler AG.
IP-Addresses + Subnet
allocation Selection +
Entering of Router
address
Figure 23 Properties of PN-IO, General

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In the Addresses tab, no change is required.
Figure 24 Properties of PN-IO, Addresses
In the PROFINET tab, the CBA communication is deactivated in the basic application and,
therefore, no change by the programmer is required.
Figure 25 Properties of PN-IO, PROFINET

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Figure 26 Properties of PN-IO – Synchronization
In the Media Redundancy tab, no change is required.
Figure 27 Properties of Media Redundancy

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In the time-of-day synchronization tab, no change is required.
Figure 28 Properties of PN-IO, Time-of-day synchronization

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The network name must be clarified with the responsible Daimler AG network
administrator. (e.g.: m050xxxxx)
Detailed explanations on the subject of naming/designation systems are

described on Volume III / 04 Designations and Identifications / 03 Designation
System for programmable controller.
This name must then be entered in the HW config (PROFINET-IO system object properties).
Example: m<plant code>g<building designation>s<control area>
(Special characters are replaced with “-“)
Plant designation: 050 (Sindelfingen Plant 050)
Building designation: 7-4 (Building 7/4)
Control range: wabl11 (programmable controller project name)
The option “Use name in IO device” is already activated in the basic application so that the
network name goes into the device name (separated by a period).
Figure 29 Properties of PN-IO-System, General

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2. Software Structure
2.1. From the System Structure to the Software Structure

The software structure is generally identified by the system area, the console and station
areas and the program modules with the calls for the function groups.
The system area is the higher-level area that is present in each system (e.g. body shop,
Paint, Assembly and in the auxiliary plants. In the system area, the function groups required
for management of the system will be called.
With the console areas (e.g. conveyor technology) and/or station areas (body shop), the
systems are divided into smaller areas. While the console area additionally describes an
area that can be controlled autonomously using its own operating modes, the station area
only forms a management technology unit.
Console and/or station areas are generally subdivided further into program modules in which
the calls of the individual function groups are contained.
Because of the use of the program modules, a better and more transparent structure of the
program is achieved. Program modules are implemented as SIMATIC STEP 7 FBs without
instance DB.
In systems with sequence control by sequential function charts (welding systems in body-in-
white or mechanization of final assembly); the procedures are implemented with S7-GRAPH.
The different console areas and/or station areas can be combined or even in some cases
omitted (e.g., for small systems).
See level model in “000_B3.26.01.01_Steuerungsarchitektur_gesamt.”
2.2. Number Ranges of the Modules

The following number ranges are specified for the respective module types:
FC FB DB at 319F
Total 2048 2048 4096
integra from 1 1
integra to 100 100
User from 110 110

User to 1399 1999
F user from 1600 1400 2500
F Siemens from 1500

F integra from 1600
F autom from 1638 3276
END 2047 2047 4095

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2.3. Allocation in the User Area
The allocation of the module numbers in the user area is oriented to the structure of the
system. The levels should be reflected in the number ranges.
A possible recommendation for this can be found in Chapter 26. Control Technology\10. SW
Libraries\02. Software\01. Software Control\00. S7 General Information in the Module List in
“000_B3.26.10.02.01.00_integra_Bausteinliste” in the table sheets “User” and “DB user.”
The structuring of the system must be agreed on with the Daimler person responsible for the
project.
If this recommendation cannot be used because of the system size or other requirements, a
suitable suggestion must be presented to the person responsible for the project at Daimler
for release.

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2.4. Structure of the Symbols
2.4.1. Adapting symbol table
The standard areas of the symbol list are completely prepared in the basic application.
The inputs and outputs are entered from the hardware plans with symbols and comments.
All signals that are used in the program must be documented:
Bit / I, Q, M, etc.
Byte
Words
Double words
For components that are only used in the overview and installation plans and/or PROFINET
routing for RUPLAN like:
Key-panel
Frequency converter
Motor starter
PN/PN coupler (PROFINET I/O)
Robots
Subsystems
etc.
the I/O addresses must also be entered in the symbol list. The symbols are assigned by the
user according to the specifications of the designation system for integra.
(Visual Enterprise Server: Volume III / 04. Designations and Identifications)

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2.4.2. Designation specification for function modules symbols (FB)
• The absolute address of the FB modules can be freely assigned from FB101 – FB999
• The range FB1 - 100 is reserved for system links, controllers and system-specific
modules
• The assignment occurs using the symbols
FB_XXXNNN T23456789012 K
K Sequence Graph (S7G)

Max. 12-digit comment
No comment for station and console
modules
3-digit number of the station or the
operating station/computer or of the
Allgemeinteils
ALG General modules
ASY General system modules
ANL TGA PLC area
BR Operating computer (for FB
modules that are assigned directly
to an operating computer)
XBR Console w/o hardware plan
BS_ Operating station (for FB modules
that are assigned directly to an
operating station)
S__ Station (for modules that are
assigned module
FB_ Function to a station)
For the 12-digit comment, it is recommended that the first FG programmed in the FB is
indicated.
Example: first area in console 2 starts with 012RF_005:
Module: FB121
Symbol: “FB_BS_002 012RF_005”
Comment: “Pult 2 Aufruf: 012RF_005”
All the FG called in this FB will be entered with their designations in the first comment field of
the FB.

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symbolic name of
user FB
Figure 30 Symbols for function modules
2.4.3. Designation specification for data module (DB) symbols
• The absolute address of the FGDB modules can be freely assigned from DB101 –
DB1999
• The assignment occurs using the symbols
Function group designation (9 digits)
FGDB for function group data module

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Example of the FGDB designation for a roller conveyor:
Module: DB 532
Symbol: “FGDB_012RF_005”
Comment: “FGDB for roller conveyor 2R2G with FU Lenze”
Example of the FGDB designation for a valve control on a valve terminal:

Module: DB 521
Symbol: “FGDB_013VE_001-MB2”
Comment: “FGDB for valve”
Since several valves are located on one valve terminal, the entire valve terminal can be
combined as FG. However, for the software, the individual valve is required as FG. For this
reason, on the HW designation of the FG, the operating equipment code of the actuator is
appended, in this example –MB2.
For data modules that are not FGDB, instead of FGDB the following abbreviations are used:
Abbreviation Application
FGDB Function Group DB
S7G S7 Graph instance DB
TLG DB for alarms (communication)
TV DB for transport tracking data
IDB Instance DB of a standard FB
DB DB for other data
SEDB Safety element DB (F program)

F-DB Global DB for safety program (emergency OFF areas)
Table 1 Abbreviation for symbols for DB
Function group designation
Figure 31 Symbols for data modules

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2.4.4. Designation specification of symbols for bit memories (M)
Normally no bit memories are used, rather the transfer bits of the FGDB (U_..).
If bit memories are used, the symbols always start with the FG designation.
Example:
Bit memory: M 400.4

Symbol: 012RF_002-B1MV_PF
Comment: Positive edge of BG11
(The FG designation does not have to appear again in the comment
field)
Abbreviation Application
nnnAAAnnn-ffffff nnnAAAnnn= FG designation
ffff = function of the bit memory
Table 2 Abbreviations for symbols for bit memories

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3. Software Project Planning with integra
The following illustration shows the module overview of the basic configuration of an integra
system using the OB1 as an example. The standard calls that must be contained in every
integra system are prepared in the basic application.

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Figure 32 Module overview of basic applications
In addition to the system-specific calls for the console areas and function groups in the
console areas, the user must also call additional communication modules like PLUS
communication, etc., if necessary.
3.1.
Basic Application Software Packages
3.1.1. CPU basic functions: OB1
The module supplies S7 CPU basic functions like cycle time measurements, setting and
reading out date/time and formation of flash cycles, pulses and general bit memories. In
addition, with the use of the error organization modules integrated in S7, hardware errors can
be localized and evaluated.

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The module must be called one time in the first network of the OB1.
Figure 33 Module call FG_CPU-DIAGNOSE

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3.1.2. Editing the switching on of the first system: FB101
The execution occurs using the module description FC15 (FG_SCHRANK; see Chapter 26,
Control Technology\10. SW Libraries\01. Documentation\21. S7 Doc Basic Software (BS).
At the FC15 the enabling of the inputs „FEin“ will be released via the input parameters „St_E“
und „St_A“ for the Switching on of the desk areas and the function groups.
For each system area, a cabinet call must occur.
Shut-off mechanisms because of energy efficiency savings will be described in the module
description for the FC297 (FG_PEC_PE).
The error alarms for circuit breakers or the potential supply and/or the general backup will be
assigned to FG Schrank using the FC17.
(24V potential supply, that is linked on the LOCC-Box-fusemodules of the “Lütze company”
will be visualized by calling the block FC4036 (LUETZE-LOCC-Box)).
Figure 34 Module call FG_Schrank

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3.1.2.1. Number of FC4027-calls depending on the integra powersupply concept
In the following schematic figure the interaction of the motorized main switches, optional
existing welding motorized main switches and the auxiliary block FC4027 (PEC_PE_HS) for
controlling the motorized switches is shown. For each main switch the FC4027 has to be
called in the application program.
Figure 35 calling of FC4027 depending on the number of main switches and the power
supply concept

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3.1.3. Energy efficient switching
3.1.3.1. Devices with PROFIenergy

The following devices support PROFIenergy:
• …..
•
For these devices the switching has to be planned as shown in section 3.1.3.3.
3.1.3.2. Energy-efficient switching by direct potential shutdown

If no devices capable of PROFIenergy are present in the plant, only the motorized main
switches are controlled in the plant. Following software package.
Block diagram:
Request HNT
Plant ON/OFF FC297 2 FGDB
shut down FG_PEC_PE3 HNT reached
FC15
FG_Schrank
switch on DB-PEC_
DB- Control voltage ON/ OFF
Schaltzeiten
PE_Schalten 3 4
DB29701
I&C 1 FC64 1
000XWS001 Switch group Call 1 x per
Plant ON/OFF 1
- Switch times main switch
OFF time
Switch bit OFF
ON time
Switch bit ON
Interval length
- Switch on FC4027
max 4
Motorized
- Console
max 32 2 5 main switches
- Default e.g. plant main switch
Interval length
Shut-down plant Switch on plant
1 Switch time: request plant shut-down 1 Switch time: request switch on plant
2 Set request special function HNT = “1” 2 Switch on motorized main switches
complete plant
3 special function HNT reached for complete 3 Switch on control voltage
plant =“1”
4 Switch off control voltage
5 Switch off motorized main switches

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3.1.3.3. Energy-efficient switching with PROFIenergy at intelligent PN-Devices
There are two switching versions for shutdown with PROFIenergy:

Plant ON / OFF
Intervals ON / OFF
Variant Plant ON / OFF:
Shut-down plant Switch on plant
1 Switch time: request plant shut-down 1 Switch time: request switch on plant
2 Set request special function HNT = “1” 2 Switch on motorized main switches
3 special function HNT reached =“1” 3 - Sent PROFIenergy Telegrams End_Pause to

the devices
4 Energy shut-down activate = “1” set to all -Set Energy shut-down deactivate = “1” to the
robots robots
5 Energy shut-down activated =“1” received from 4 Feedback from robots: Energy shut-down
all robots deactivated
And
6 Switch-off control voltage PROFIenergy Message ready_to_operate from
(activate error suppression) all devices
7 Send PROFIenergy Telegrams Start_Pause 5 Switch on control voltage
to devices with WoL activated
8 Devices are shut down by PROFIenergy

Switch-off motorized main switches

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Variant Intervals ON / OFF
Interval shut down console areas Interval: switch on console areas:

1 Switch time: Request Interval shut down 1 Switch time: Request Interval switch on console
console areas XX areas XX
2 Set request Stop to console area XX 2 Send PROFIenergy Telegrams End_Pause to

devices in console areas
3 Feedback console areas XX in Stop
PROFIenergy devices in console areas XX signal
3
status ready_to_operate
4 Set error suppression for console areas XX
5 Send PROFIenergy Telegrams Start_Pause with 4 Delete error suppression for console areas XX
WOL deactivated to devices in console areas
XX
Using the function block FC297 only switching action with direct voltage shut down is
actually supported.
Switching action using PROFIEnergy-mechanisms (“Plant On/Off” - “interval On/Off”) will be

supported with interaction between FC297 und FC298.
The block Fc298 is in progress and will be submitted at the start of project BR205

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3.1.4. PROFINET diagnosis: FB54
The basic application includes the complete PROFINET diagnosis with the function group
“FG_PN-DIAGNOSE” (FC98).
The FC98 is called in the FB54 (cyclic program section).
Figure 36 Preliminary links for “FG_PN-DIAGNOSE” in FB54

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Figure 37 Module call of the “FG_PN-DIAGNOSE” in FB54
3.1.4.1. Structure of PN node error alarm texts in PN diagnostic DBs (1080-1083)

RUPLAN designation system:
Explanation:
+Installation location = line, station no. / function group abbreviation / terminal box no. –A0
code
Example texts/comments for PN node error alarms (DB1080 -1083)
+X CPX -036GST001-KF072 =036GST001

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+H011 IM 151-3PN HF-000EEA011-KF025 =000EEA011
+P102 SCALANCE-X208 -001EK_111-XF006 =001EK_111
+P101 KP32F -001BR_010-KF21 =001BR_010
+H101 SCALANCE-X414-3E 001SPS101-XF004 =001SPS101
+P100 MGB Türbox -001WAS001-FN029 =001WAS001
+H901 KUKA-KRC4 -010RB_1008400-KF080 =010RB_100
1. 2. 3. 4.
1. Installation location, e.g. operator console cabinet, terminal box or X if set up directly in
the field.
2. Device abbreviation (device type identification)
3. Designation from RUPLAN (-FG –classification-code;
For direct field installation = FG designation should be the FG to which the module
belongs functionally.
For cabinet installation = FG designation corresponds to the switchgear cabinet.
For terminal box installation = FG designation should correspond to the FG terminal box.
For console installation = FG designation should correspond to the FG console.
For installation in the KRC cabinet = FG designation should correspond to the FG robot.
4. Function group that can be assigned spatially (normally the function group in which the
module is found)
For further details, see:

ECM Chapter 04. Designations and Identifications\01. Designation System\01. GDL
Designation System \ 000_B3.004.01.01_Functiongroupshortcut_V40.xx.xls or
000_B3.004.01.01_classificationtable_IEC81346-2_V40.xx.xls
ECM Chapter 26. Control Technology\10. SW Libraries\01. Documentation\21. S7

Basic Software (BS) Documentation\Description of FC98
3.1.5. Safety testing of safety equipment: FB97
The owner/operator of a machine must ensure that the safety devices installed in the
machine, as well as their functions, are maintained as long as the machine is operated. In
order to ensure this, the function of the safety elements must be checked using actuation. In
order to reduce the human factor in the inspection of the shutoff function, in the basic
application FC97 is called for this. During actuation of the safety elements as in production,
FC97 handles this control and monitoring function. Application-specifically, the associated
data modules must be adapted according to the shutoff matrix. (For more detailed functional
explanations, see ECM Server Vol. III / Chapter 26. Control Technology / 04. Safety
Technology / Prüfung von Sicherheitsfunktionen xxxxxxx.pdf [Testing of Safety Function
xxxxxxx]/ …Prüfung von Sicherheitseinrichtungen xxxxxxx.pdf [Testing of Safety Equipment
xxxxxxx]).
In the basic application (OB1 NW5), the call of FB (FB97) by FC97 has comments to make
the start-up easier.

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FC97 must be called at the latest at acceptance in order to activate the function
of the automatic testing of the safety devices in the programmable controller
program.
Figure 38 Module call FG_SICH_VI

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3.1.6. Communication with digital plant interface (control technology): FB61
In FB61 following function modules are called:
- FETCH/WRITE-connection projecting (FB44 and OC-Wizard)
- Integra function group DFI_COM (FC38)
- Default of middleware switching times (FC64)
3.1.6.1. FETCH/WRITE for the control technology/control stand communication
(FB44)
Each control stand connection requires a fetch and a write connection.
In the basic application, a control stand connection is planned as an example.
In the global connection data module “DB_TCON_Para_FW_ISOonTCP” in the basic
application both the connecting parameters for the fetch and also for the write connection are
configured/parameterized with the use of the OC Wizard.
1. FB44 call to realise the FETCH-functionality of the middleware connection with the
protocol ISOonTCP to the plc.
2. FB44 call to realise the FETCH-functionality of the middleware connection with the
protocol ISOonTCP to the plc.
Ifyouthehasmiddleware system has an emergency system (redundance computer) then

to edit a further FETCH- and WRITE connection to this emergency system.
You has edit this connection with the OC-Wizard by using the same global
connection-DB „DB_TCON_Para_FW_ISOonTCP“ (DB1125).
The FB44 “FB_ASY000 FW_ISOonTCP” starting from V2.1 is a standard module from
Siemens (starting from the Step 7 package V5.4 SP5 the original standard module is
included in the Siemens standard library “Step7/S7libs/stdlib30/Communication Blocks” and
there it has the module number FB220 / S5FW_IOT, V2.1).
An exact documentation of the parameters of “FB_ASY000 FW_ISOonTCP” starting from
V2.1 can be found in Simatic Step 7 package V5.4 SP5 by selecting the module within the
project and use of the Simatic function “help for the context menu F1.”
The module is called once each time for the fetch and write service and requires a separate
instance data module for each call.
In addition, for storing the connection parameters programmed for the project using the OC

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Wizard, a global connection parameter data module is required.
Figure 39 Call of Control stand coupling module with FB44

On “FB_ASY000 FW_ISOonTCP,” the parameter “ENABLE” is connected with a logical
“ON signal” so that a user-independent automatic “connection setup” is initiated by the
module.
On the parameter “CONNECT” the pointer (starting address) using the OC Wizard for the
associated connection parameter set is connected.
The pointer is calculated from the 64-word connection parameter set length within the
connection parameter data module.
E.g.: Starting address DBX 0.0 – connection ID 1
Starting address DBX 64.0 – connection ID 2
(E.g.: Starting adresse DBX 128.0 – connection ID 3 possibly emergency system connection
„FETCH“)
( Starting adresse DBX 192.0 – connection ID 4 possibly. emergency system connection
„WRITE“)
etc.
The parameter “ADDR MODE” is connected with the integer value 0
(0= S7 addressing mode of the parameter set/ 1= S5 addressing mode of the parameter set).

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The configuration/ parameterizing of FETCH/WRITE connections is performed
with the OC Wizard from Siemens. (Because of the use of the OC Wizard, the
connection configuration in NETPRO is eliminated).
The connection parameter data will be entered in the parameter data module
“DB_TCON_Para_FW_ISOonTCP” with the use of the OC Wizard.
Figure 40 DB_TCON_Para_RW_ISOonTCP / connection block OUCW1+OUCW2

In the basic application both the connection data for Fetch-/ and for WRITE-connection are
parametrized in the global connection datablock „DB_TCON_Para_FW_ISOonTCP“
(DB1125) by using the OC-Wizard.
The OC Wizard can be started from the Step 7 package.

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TSAP Fetch connection: LT-FETCH
TSAP Write connection: LT-WRITE
Figure 41 OC Wizard

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3.1.6.2. Function group DFI-COM (FC38)
The basic application, includes both the functional connection of the control technology and
the functional connection of the local DFI to the programmable controller by the FC38 using
the FKT parameter with the value 13.
Ifadapted
a communication channel is eliminated project-specifically, this must be
using the FKT parameter.
Figure 42 Module call FG_DFI-COM (FC38)
3.1.6.3. Switching times:

Then, for implementation of the switching times, the FC64 FG_WTS must be called. Calling
FC64 FG_WTS is essentially required for switching the system on/off by way of the control
stand functionality.
For other switching manipulations like line on/off, in each case an additional call of the FC64
FG_WTS is necessary. See also document “FC64_FG_WTS”
Figure 43 Module call FG_WTS

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3.1.7.
Interface to the F program
The communication with the safety program occurs in FB53. In the first two networks, there
is a routing of operands that are required in the F program but are not supported by the
safety program (system side) (i.e. there is no direct query of data bits from non-safe data
modules).
If other signals are necessary in the F program, these are routed to bit memories in
additional networks to be formed.
Operands supported by the safety program (system side) (E, A, M, etc.) from the non-safe
program section do not have to be routed since these can be queried directly in the F
program.
Figure 44 Routing binary signals for F program

The signal “F-QUIT” is formed after the control voltage is switched on, after expiration of
timer T4 of the FG Schrank. In the safety program (FC1601), the global F module
reintegration is triggered with this signal by way of the FB1591. After that, there is an option
in the application for automatically acknowledging any safety elements that may have been
triggered (e.g.: emergency OFF alarms, shutoffs, etc.) with the use of the signal “F-K1E”
(e.g.: FC1700, 1701, FC1800, etc.). The signal is formed one time after expiration of the
timer T5 of the FG Schrank and is only available after control voltage ON. (Safety program
reference: “Sequence group FC1601”/ Chapter 4.1.5)

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For each safety element (e.g. emergency OFF switch), an emergency OFF alarm and an
error alarm are available in the instance DB of the safety module.
In the following network, the error alarms from the instance DBs of the safety elements are
entered in the function group FG_F-SE.
The error texts of the safety elements must be entered in the function group and expansion
data modules (DB1140 – DB1147).
Figure 45 Entry of error alarms for the safety elements

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In the next network, the emergency OFF alarms from the instance DBs of the safety
elements are entered in the function group FG_NH-MELDUNGEN.
The emergency OFF texts must be entered in the function groups and expansion data
modules of the function group NOTHALT [emergency OFF] (DB1134 – DB1138).
Figure 46 Entry of error alarms for the safety elements
For simplified generation of the emergency OFF error tests, the Excel tool
“FGDB_Not-Aus_F-SE” is available. This tool can be found on the Visual
Enterprise Server in Volume III, Chapter 26. Control Technology\10. Software
Libraries\01. Documentation\21. S7 Basic Software (BS) Documentation.
To execute the tool, the safety settings in Microsoft Excel/Extras/Macro/Safety

must be set to “low.”
To do this, the user must search in his or her project in the symbol table according to the
symbolic name SEDB_* and then export the filtered table under the file name
SEDB_Symbole.sdf. The macro in the file “FGDB_Not-Aus_F-SE” automatically copies
the emergency OFF and error texts of the SE elements used into the function group and
expansion data modules. Then the macro generates two AWL sources with the FGDB F-SE
(DB1140 – 1147) with assigned comments and the FGDB_NOTHALT (DB1134 – DB1138)
with assigned comments. The user must import these AWL sources into the project, compile
and then supplement with project-specific designations.

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3.1.8.
Communication for PLUS
The communication for PLUS directly by way of the integrated IE interface of the CPU319F-
3PN/DP occurs with the FC169. A detailed description of the function can be found in the
document “FC169_FG_COM_TLG_PN.”
3.1.9. Communication with another S7

The communication between two S7 controls directly by way of the integrated IE interface of
the CPU319F-3PN/DP occurs with the FC169. A description of the FC169 can be found in
the document “FC169_FG_COM_TLG_PN.”
Communication with the FC169 is provided for the transmission of larger data
quantities. The exchange of binary signals or a few bytes occurs on the I/O level with
an IO coupler. A detailed description of the interface using the IO coupler is given in the
Project Guideline “000_B3.26.06.00_PRL_Anlagenschnittstellen”

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3.1.10. Console area module
In the basic application, the FB110 is used as an example for this. Execution occurs using
the module description FC18 (FG_Pult; see Chapter 26. Control Technology\10. Software
Libraries\01. Documentation\21. Basic Software S7 Documentation (BS)).
For each console with operating mode selector switch, a console call (FC18) must occur.
Conveyor technology and mechanization consoles must be connected differently. Example
circuits are included in the module description for the FC18 (and/or in sample programs of
the areas).
In previously connected networks, additional error alarms (ZS) of the potential supply and/or
of the general safeties that can be assigned to the console area are allocated using the
routing module FC17 of the FG console. In the same way, the variables for the additional
parameters (ZP) of the operating modes, the acknowledgement, and the variables for the
circuitry of the module parameters for automatic start, automatic off and release of the inputs
must be created.
In the function module FC18, the general release inputs, the operating modes
automatic/setup and the acknowledgement of the errors for all function groups of the console
area are formed.
Figure 47 Console area: call example for the console function group

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The digital output address for the controlling the indicator light (LED) VI switch interlocking
active must be adapted project-specifically.
Figure 48 Console area: call example of VI switch indicator light
The controlling of console lights (automatic, setup, emergency OFF, error) occurs using the
output parameters of the FC18 and in other downstream project-specific networks must be
connected to the actual digital output signals.
The controlling of a signal column assigned to the console is also implemented in a
downstream project-specific network by using a call of the integra standard module FC21.
The release and/or actual operation of moving images using button bars on the EBF must
occur by calling and connection of the integra standard module FC13 (managing moving
images) project-specifically in a downstream network.
3.2. System-specific Program Area

The system-specific part of the programs is called at the end of the console modules. In this
case, functional modules are called with the function groups of the corresponding console
area. Usually conveyor technology systems are structured in this way.
In order to achieve a detailed distribution of the system, the stations are available below the
console areas for further subdivision (see documentation FC19 FG_STATION). This
subdivision of the system is mainly used for mechanization systems.
Figure 49 Functional group calls in the console area
Within the functional modules, the function groups are called as shown in the module
descriptions using the examples.

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3.2.1. Connection of the standard parameter “release inputs” (FEin)
In principle, following fault messages has to be suppressed if there is a PROFINET device
failure or safety cases.
To this in integra following messages will be suppressed by using the function “release input
(FEin)
The function is divided hierarchically into several levels:
− Switching On level (Department)
the function “FEin” = 0 suppresses following fault messages in the level switch on and
in underlying levels.
− Console level
the function “FEin” = 0 suppresses following fault messages in the console level and
in underlying function groups.
− Function group level
the function “FEin” = 0 suppresses following fault messages in the function group
level.
For the „Switching On level“ no following message suppession has to be edited,

i.e. the function “Fein” has to be edited with VKE=1.
The failure of PROFINET-devices has to be registered by using the following data

structure (DB1080 / ab DBX692.0)
Display of active SFC51 index

Status PN IO-Devices: 1= available + active + not failed
Example for device 21:

DB1080.DBX694.5. "FGDB_001NET001".SZL294_Device[21] =TRUE
PN IO-Device accessible.
DB1080.DBX694.5. "FGDB_001NET001".SZL294_Device[21] =FALSE
PN IO-Device not failed.
In the following examples and tables, typical PROFINET nodes are listed and, in addition, in
which level the suppression has to become effective.
A differentiation is made between three system types:

- Conveyor technology systems (FT)
- Process technology systems (VT)
- Mechanization (ME)

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3.2.1.1. Conveyor technology systems (FT):
Switching Console FG
Field bus node
On level level level
Drives
-- X (X)
e.g. Lenze, SEW
Operating consoles
-- -- --
e.g.: : KP32F/KP8F
ET200 with sensors or actuators of function groups -- X --
ET200 only light controlling -- -- --

No fixed definition
possible Supplier
ET200 collector of I/O signals in the switchgear cabinet -- creates concept and
clarifies with planner
and operator
Valve terminal -- X --
IO coupler (Gateway) -- -- X (FAus)
Table 3 Conveyor technology field bus node error and associated shutoff level

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Program examples for FT system:
Switching On level release inputs (FEin):
Figure 50 FT: “U_FEin” of the “Switching On level” edited with VKE = 1
Console level release inputs (FEin):
In the example, field bus device failure of node (21) and node (22) is considered.
With the variable „001BR_010-STOER1“ all safe cases has to be collected, which would
cause following fault messages in the console level.
Figure 51 FT: “U_FEin” during node failure (e.g. of drives)

FG level release inputs (FEin):
Suppression of following fault messages or switching off a individual function group:
In the example, the node failure of device 149 suppresses the fault messages of a conveyor.
Figure 52 FT: “ZP_Freigabe_Eingänge” of a function group during node failure (e.g. drive)

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3.2.1.2. Mechanization systems (ME):
Switching Console FG
Field bus node
On level level level
Drives
-- X --
e.g. Lenze SEW
Operating consoles
-- -- --
e.g.: KP32F/KP8F
ET200 with sensors or actuators of function groups -- X --
ET200, lamp controlling only -- -- --

No fixed definition
possible Supplier
and operator
Valve terminal -- X --
IO coupler (third-party systems) -- -- X (FAus)
Subsystems, e.g. robots -- -- --
Table 4 Mechanization field bus node error and associated shutoff level
Program examples for ME system:
Figure 53 ME: “U_FEin” of the “Switching On level” edited with VKE = 1

In the example, node failure of PN-device (21) e.g. drive and PN-device (22) e.g. valve
terminal are considered.With the variable „001BR_010-STOER1“ all safe cases has to be
collected, which would cause following fault messages in the console level.
The consoles (KP32F), robots or other subsystems must not be considered.
Figure 54 ME: “U_FEin” of an FG during field bus errors of drives and valve terminal

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3.2.1.3. Process technology system (VT):
Switching Console
Field bus node FG \level
On level level
Drives,
-- -- X
e.g., Lenze SEW
Operating consoles
-- -- --
e.g.: KP32F/KP8F
ET200 with sensors or actuators of function groups -- -- X
ET200 lamp control only -- -- --

No fixed definition
possible Supplier
and operator
Shut-off of functions
that are locked with
IO Coupler --
the third-party
system.
Table 5 Process technology field bus node error and associated shutoff level
Program examples for VT system:
Figure 55 VT: “U_FEin” of the “Switching On level” edited with VKE = 1

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In the example, no connection of the release inputs is implemented – “FEin” is set with the
parameter “one.”
Figure 56 VT: “U_FEin” of the area level during field bus error of the ET200
FG level:
In the example, the node failure of two ET200 (PN-device 21 and PN-device 22) lock the
release inputs (FEin).of the function group drive in a RNV-plant via “ZP_Frei_Eingänge
Additional info:
In VT systems, the function parameters of consoles and switch-on modules are connected
with “10.” If release inputs is missing, the function groups blink in the overview images
between the color of the operating mode (“yellow” for setup, “green” for automatic) and “gray”
in the overview images.
RNV021-M25 Add On parameter release Input signals
FGDB_001NET001`.SZL294_Device [21] DB1080.DBX694.5 - - Status PN IO-Devicees: 1= available + activ + not failed

FGDB_001NET001`.SZL294_Device [22] DB1080.DBX694.6 - - Status PN IO-Devicees: 1= available + activ + not failed
Figure 57 VT: “U_FEin” of the function group level during node failure e.g. ET200 terminals

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3.2.2. Additional errors (ZS_)
Additional errors that are present as direct inputs, e.g. fuse openings, will be routed with the
FC 17 to the associated FGDB. The fuse openings are mainly assigned to the FG switching-
on, to the FG console, and to the FG station for more detailed subdivisions of the system.
Figure 58 Additional errors, power main switches 230V and fuse openings

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Some additional errors must first be created before they can be routed to the corresponding
function group with the use of the FC 17.
First the error, e.g. of a component control or of an auxiliary initiator, will be created using
combinational logic.
Figure 59 Creating additional general functions

After that, the error created in this way by FC 17 will be routed to the associated function
group. The error only needs to be assigned since the storage and acknowledgement of the
error is taken over by FC 17.
Figure 60 Routing general additional errors
Data bits of the additional errors are provided with symbols and comments in the
FGDB. The symbol must be a reasonable abbreviation of the alarm and must be
at least three characters long, whereby the first few characters up to the
underscore (type code) must not be changed. The comment is the plain text that
appears on the display.

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Figure 61 Example comments for additional errors in the FGDB
IfFG,executing the action of a function group is prevented by additional errors of the

the signal “additional error group alarm (U_ZStoer)” of the function group is
additionally linked in the formation of the signals “release for controlling the
outputs V and/or R (U_FAusV, U_FAusR)” are additionally linked in upstream
networks as a interlocking signal.
3.2.3. Additional warnings (ZW_)
Warnings are always only assigned and not programmed with saving. They also do not need
to be acknowledged. Additional warnings can be used for all function groups.
`001BR_010-SF8ABWNFT`
001BR_010-SF8ABWNFT E21. 0 -- deselection Q-Gate
Figure 62 Example of routing additional warnings
Data bits of the additional warnings are provided with symbols and comments in
the FGDB. The symbol must be a reasonable abbreviation of the alarm and must
be at least three characters long, whereby the first few characters up to the
appears on the display in the alarm line.

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3.2.4. Auxiliary initiators (ZI_)
During the formation of auxiliary initiators, the data bits in the FGDB will be assigned directly.
It is not necessary to save the statuses of the auxiliary initiators. The routing of auxiliary
initiators is possible for all function groups. This function is used for, e.g. component controls
and auxiliary initiators.
Figure 63 Routing auxiliary initiators
Data bits of the additional initiators are provided with symbols and comments in
appears on the visual display in the detail window.

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3.2.5. Auxiliary alarms (ZM_)
Auxiliary alarms are memories that are formed before the function group is called and can be
influenced in the detail window on the display. Possible auxiliary alarms include e.g. finished
alarms, etc. These functions are programmed for setting/resetting. Because of the routing of
the signals to auxiliary alarms, they can be operated automatically in the detail window of the
associated function group on the display.
Figure 64 Routing auxiliary alarm
Data bits of the additional warnings are provided with symbols and comments in
appears on the visual display in the detail window.

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3.2.6. Externally logged alarms (XM_)
For alarms that are also logged, i.e. stored directly in the alarm archive and do not have to be
displayed as error alarm or warning, this alarm type is to be used. These alarms will be
shown on the visual display only in the stored alarms.
Before a function group is called, the alarms are assigned in the FGDB area XM (DBX129.0
– DBX129.7). The comment for the alarm is entered in the data module.
`001BR_010-SF9QUTNFT`
001BR_010-SF9QUTNFT E21. 1 -- Acknowledgement Q-Gate
Figure 65 Routing externally logged alarms
Data bits of the externally logged alarms are provided with symbols and
comments in the FGDB. The symbol must be a reasonable abbreviation of the
alarm and must be at least three characters long, whereby the first few
characters up to the underscore (type code) must not be changed.
3.2.7. Additional parameters (ZP_)

Using the additional parameters, for function groups that are not console-specific, the
following signals are connected before the function group FCs is called:
DB address Symbol Comment
DBX113.0 ZP_Einrichten Additional parameter, setup
DBX113.1 ZP_Automatik Additional parameter, automatic
DBX113.2 ZP_Frei_Eingaenge Additional parameter, release inputs
DBX113.3 ZP_Quit Additional parameter, acknowledgement
DBX113.4 ZP_KeinStop_Ausbl Additional parameter, fade out KeinStop
The function group goes into the setup operating mode if the assigned console is on setup or
the setup additional parameter is set.
The function group goes into the automatic operating mode if the assigned console is on
automatic and the additional parameter automatic is set.
The release inputs is set if the assigned console release inputs is present and the additional
parameter release inputs is set.
With the use of the additional parameter acknowledgement, a selective acknowledgement of
the function group can occur.

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If a function group can only be operated from a console (normal case), no additional
parameters have to be connected since the bits ZP_Automatik and ZP_Frei_Eingaenge were
already preset with VKE1 in the data modules.
With the additional parameter “ZP_KeinStop_Ausbl,” the alarm KeinStop can be faded out if
required!
Figure 66 Connect additional parameters

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3.3. Guide Sequencer with S7-GRAPH
A graphical programming, start-up and visual display interface offers useful services during
creation of a process sequence and putting it into operation by using:
• Procedural structural elements according to IEC 1131-3:
Few, simple, easily understandable and uniform structural elements
• Automatically eliminate distortion and minimize the graphical structure to free areas
on the screen/printout
• No overlapping/over-displaying of graphical elements
• Full graphics with multiple zoom options for optimal display, e.g. with comfort settings
that can be used like width/area
• Multi-window technique of programming can be used throughout, up to operation
• Same sequencer with same tools can be used throughout:
From small (S7-300) to large (S7-400) programmable controller family
Also programmable controller (SPS) image/soft SPS/slot SPS
• Can be used from the first meeting/clarification until visual display/sequencer control
• Simple and fast change of the graphical sequence using automations
This will be used because of the implementation with S7-GRAPH. In this case, a few rules
and notes must be complied with so that only the important functionalities for a guide
sequencer in automation will be used optimally and uniformly.
3.3.1. Overview
The standard for the sequencer logic is completely embedded in the function group structure.
The controlling of motions and actions occurs using function groups, which in turn can be
triggered by a sequencer.
The sequencer is managed by the function group FG_S7G_Kette and the associated
function group data module (FGDB).
The general function groups from the software standard integra are the basis for the
operating mode formation, error diagnosis, etc. (FG switching on, FG console, FG station,
FG CPU basic functions, FG PROFIBUS diagnosis, FG control technology, FG TCP/IP, clock
pulse generation, safety technology, central management with FC2, etc.).
Figure 67 Overview of sequencer organization

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Other functionalities that are required for the sequencer logic are the motion control screens,
for implementation of the motions from the visual display and for controlling the actions in
manual operation, and the expert mode for communication and display of the missing
conditions (e.g. release and stepping conditions) on the visual display PC/EBF.
3.3.2. Function group S7-GRAPH sequencer

A sequencer can be controlled using the function group S7-GRAPH sequencer per function
group call. In this case, the procedural program per station is divided to at least one
sequencer. By multiple calls, many sequencers can be implemented in this way.
The programmed sequencers will be displayed automatically with a diagnostic system on the
screen of the visual display.
The function group S7-GRAPH sequencer is released for integra for linear and simultaneous
sequencer structures with up to 16 branches. In this case – as much as possible – simple
structures with unique function assignment should be used.
As a guide sequencer, the sequencer controls the sequence of the system parts with the
action bit memories in the steps and the stepping conditions in the transitions only in
automatic. Only the name extensions to the steps are used for the brief description of the
actions. The names of the steps and transitions are used in their original status, i.e.
according to IEC (Step x = Stepx and Transition X = Transx).
In the first steps, after an alternative opening branch, in the name extensions, the branching
reason and then the action(s) will be described in the step.
In this case, the character length – determined by the visual display of the sequencer
structure – will be limited to maximum 2 x 24 characters per name extension whereby all
characters are allowed including special characters. This name extension contains the FG
name of the controlling actions with a subsequent brief description of the function.
Because of the graphically oriented editor, it is very easy to change the

sequencer and/or sequencer structure. The logic section for the objects step and
transition will always automatically be included.
One step monitors, in automatic, the procedure by means of monitoring logic (default: two
minutes). It serves as an emergency strategy in that an error alarm is triggered at the latest
after two minutes of system shutdown. In normal cases, there should not be such a
sequencer error since the action modules monitor the actuators and sensors in the system.
In this case, it is important to note that all errors that belong to the function groups of a
sequencer should be prevented by appropriate connection of a sequencer interference
suppression. In addition, the actions to be executed for the automatic sequence are triggered
with action bit memories in the step, i.e. the action bit memories indicate start releases for
the function groups belonging to the sequencer, with its sensors and actuators in the system.
Manual operation is implemented in the triggered function groups.
During setup operation, the sequencer is used, with its operating options like step selection
or SmartSyn, for guided execution of the steps in automatic with the goal of being able to set
up as quickly as possible again and start.
Locks are not used in S7-GRAPH. Both for “automatic” and for “setup operation,” these are
programmed on the releases of the corresponding function groups (parameters FAusV,
FAusR, etc.).
A complete function group S7-GRAPH sequencer consists basically of the FC
<FG_S7G_Kette>, a parameterizable FGDB and the S7-GRAPH sequencer in the form of a
FB/DB pair, the control and monitoring of which starts internally from the FC
<FG_S7G_Kette>.

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Figure 68 Module structure of the FG S7-GRAPH sequencer organization
The command output of the sequencer forms the action variables that have to be
parameterized application-specifically in the FGDB starting from address 152.0. These are
used for initiating the actions for the function groups, i.e. the action variables are – if used
individually – programmed directly on the motion releases of the function groups.
Otherwise the action variables will be linked to a predefined transfer signal in an upstream
network and only the transfer signal will be parameterized starting release to the function
groups FC.
The sequencer is (as shown in the illustration) managed by the FG S7-GRAPH sequencer
organization. The complete sequencer organization can be – area-specifically – incorporated
differently in the programmable controller program structure, whereby this always represents
a basic incorporation into the basic software structure, i.e. with station structure after the
center branch.
3.3.3. Incorporation of the FG S7-GRAPH sequencer organization

There are several options for incorporating a sequencer in the program structure of the
system control
Sequencer in function group level (BA specification using station assignment)
Sequencer in station level (BA specification using console assignment)
Special case: sequencer in console level
(e.g. process technology: switching on, switching off, pause sequencer)
Special case: sequencer with operating mode that can be selected separately

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Figure 69 Options for incorporation of the FG S7-GRAPH sequencer organization
3.3.4. Calling the “FG-S7G sequencer”

For the correct functionality of the sequencer, first one call of the sequencer organization FC
and its parameterizing must be performed per sequencer.
This module controls all operating modes, e.g. automatic and setup, using the
system/console/station structure and also includes its status and alarm information –
integrated in the integra environment (special case: If the function parameter is connected to
the FC14 with “1”, the sequencer operating mode can be selected separately using
ZP_Einrichten and/or ZP_Automatik and is not specified by the operating mode of the
console and/or the station.)
The migration solution for integra includes the incorporation of S7-GRAPH as a

guide sequencer concept, whereby S7-GRAPH can be used as an engineering
and/or visual display tool on the basis of STEP7.
On a PC-based visual display system, in the run time environment of InTouch
Window Viewer integraGraph, with its graphical illustration and detail views,
(integrated in SIS) is available for operation and observation of the sequence on
site.

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Figure 70 Example of calling the function group “FG-S7G sequencer”
Input parameters
Parameterizing of the function group data module to be used.
FGDB
(Each S7-Graph module requires an integra FGDB)
The function parameters that can be used to activate special functions with their
Fkt
parameterizing.
Group alarm of all emergency OFF related signals that are valid for this area.
Parameters are set here for the signals of emergency OFF button, protective doors,
red lockouts, etc. If the signal is not present at the KeinStop parameter, the
KeinStop
sequencer will be blocked. The sequencer remains in the active step, but the
command output is blocked.
Note: KeinStop =1
OK
Group alarm of all general locks that are valid for this area. If the signal is not
FAusV present on the parameter FAusV, the sequencer is blocked. The sequencer remains
in the active step, but the command output is blocked.
Ketten_DB Parameterizing of the S7-Graph data module to be used.
Only valid in the setup operating mode:
Akt_Aus =1: Switch off actions and/or action variables
=0: Actions and/or action variables remain active
Jogging operating mode (special operation in automatic)
Prerequisite: Automatic active
The sequencer is inactive at first in this operating mode. The last step processed is
Tippen maintained while the command output is set to logical zero. The stepping condition
is inactive. Only after operation of the switch Plus_1 is the step switched to active
and the command output is set to logical one.
The stepping condition is now also active for the actively switched step.
Plus_1 Stepping in jogging operating mode
Grst Selection only active in setup operating mode:

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Input parameters
Reset of the sequencer to basic setting, i.e. on the initial steps of the sequencer.
The initial steps are defined by the user in the S7-GRAPH sequencer.
Selection only active in setup operating mode:
The sequencer runs in automatic up to a step in FGDB that been parameterized
BisS_n
“Fahre_bis_Sn” and stops there.
The function can be canceled at any time by changing the operating mode.
Output parameters
Stoer Group alarm of the errors formed internally in the sequencer organization module.
ZStoer Group alarm of the externally formed errors.
Table 6 Parameter “FG_S7G_Kette”
Consequential errors are to be prevented by corresponding connection, e.g.

using KeinStop.
Using the parameter “Akt_Aus,” a selection can now be made between the
previous behaviors of action variables shut off (depending on setup and
FAus/KeinStop) or action variables not shut off.
More details can be found in the module description “FC14_FG_S7G_Kette”

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Parameterizing information:
Signals relevant for the controlled system area (emergency OFF, red lockouts in mechanical
systems, etc.) should be used in the parameter KeinStop. In this way, if signals are not
present, the sequence of the guide sequencer can be blocked. The sequencer remains in
active operation, but the command output is blocked.
The errors and additional errors of all function groups controlled with the sequencer are
programmed in parameter FAus.
Here as well, if the signal is not present, the sequence of the guide sequencer can be
blocked. In this case, the sequencer remains in active operation but the command output is
blocked and the monitoring time of the sequencer is stopped.
On the parameter Ketten_DB, data module set up by the S7-GRAPH for the guide sequencer
is parameterized. The number of the “Ketten_DB” must be equal to the number of the
associated S7-GRAPH Ketten-FB (creation language “GRAPH”). Using the “Ketten_DB,” the
functionalities of the S7-GRAPH sequencer are controlled directly and monitored, The
information for this will be made available using an FGDB of the visual display.
3.3.5. Calling the S7-GRAPH guide sequencer

For the correct functionality of the sequencer, the S7-GRAPH sequencer must be called per
sequencer after calling the sequencer organization FC. In this case, no further parameters
have to be assigned – other than for a default parameter. The functionality is controlled and
monitored internally by the sequencer organization FC, whereby “EN” and “ENO” must not
be connected in process operation.
Figure 71 Example call of S7-GRAPH sequencer
The parameterizing of the S7-GRAPH guide sequencer is fixed – as shown above

– and only used with the parameter “Default.”
The same numbers are used for FB and DB of the S7-GRAPH guide sequencer.
The following call sequence is mandatory:
1. Function group “FG_S7G_Kette”
2. S7-GRAPH guide sequencer
3.3.6. Functioning method of the S7-GRAPH guide sequencer

The prerequisite is first the correct settings. In this case, it must be possible to differentiate
between application settings that apply to the tool and are not transferrable and the module

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settings that are secured with granular module and can be changed.
Operating method of the sequencer module.
The views are adjustable in many ways and can be used both in editing and in animation
mode (test/observe).
One example – as a representative – will be shown in the following illustration.
It represents the status display in the view “sequencer representation” in single window
technology.
In this case, the additional sequencer control panel in the S7-GRAPH is opened with which
the active functions are displayed and – thus released – can also be operated or use the
function of synchronization for initial start-up purposes.
Figure 72 Example status display and viewing modes in S7-GRAPH
The basic functionality of an S7-GRAPH sequencer module represents a

simplified, convenient sequence processor with up to 250 steps (in each case,
max. 1 lock, 1 monitor, 100 actions) and up to 25 transitions (in each case, max.
32 stepping conditions).
These basic elements can be structured graphically.
The sequencer module to be created by the user must comply with the following
specifications and instructions:
3.3.7. Basic programming rules

The rules for programming the sequencer must be complied with

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Sequencers must be structured clearly and agreed on with the Daimler contact
person.
For each sequencer, a separate FB and a DB with the same numbers are set up.
Mixed sequence structures with alternative and/or simultaneous displays up to max.
16 displays are allowed – otherwise a project error will be shown on the visual display
No interlocking is permissible in the steps
This function is shut off using “FG_S7G_Kette”
In the action block, action variables are programmed that are pre-defined in the
respective FGDB and designated system-specifically (reference to action).
Arithmetic functions in the action block are only permissible after consultation with
Daimler.
The call structure – first FG_S7G_Kette and then FB/DB of the S7-GRAPH
sequencer is called by the associated function groups.
In the transitions, the system feedbacks for the sequencer sequence are input,
whereby for a clear functionality of “SmartSyn” the transitions must also be
programmed unambiguously.
The programming of the continuous operations before and after the graphical
sequencer is only used for special sequencer functionalities.
Note: For the synchronization functionality in HAND, it is helpful
if the transitions are programmed as clearly as possible.
In the FGDB, no action variables may be deleted and also none may be added.
3.3.8. Handling rules for S7-GRAPH modules (FB, DB)
For handling S7-GRAPH modules, the following must be noted:
Creating, changing and loading the S7-GRAPH modules (FB, DB) only with S7-
GRAPH Editor. In this way the functionality, on one hand, and the offline/online data
consistency, on the other, is supported by notes/user prompts and thus at least a
minimum quality level is ensured. This applies to the functionality:
o Automatically track DB to FB (create)
o Loading the FB and – if required – automatically also loading DB
o Creation language GRAPH and recompiling capability
Other procedures are only recommended if the user knows the handling rules since in this
case no support is given with the use of notes/user prompts.
In principle, the following applies:
During loading of the instance DB in the programmable controller, the sequencer is
reset to the initial step(s).
A change of the sequencer structure, e.g. add/delete step, also requires a change of
the associated instance DB, which can be done automatically in the S7-GRAPH
Editor.
In the programmable controller, FB and DB must fit, otherwise the basic functionality
can no longer be ensured, which is usually reported by the “INTF” LED display on the
CPU and a corresponding alarm to the user on the visual display.
Test mode by observation, sequencer control, etc. can be performed between CPU
data management (online) and S7 project data management (offline) only if there is
data consistency.
A direct change of the S7-GRAPH sequencer in the CPU is not possible, rather it
must occur first in an S7 project offline and only after that can the S7-GRAPH
sequencer (guided FB and guided DB only if necessary) be loaded to the CPU.

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A return transfer, i.e. from a CPU (online) into an S7 project (offline) is – if necessary,
e.g. for a CPU program excerpt – only performed in a separate program container. In
this case, it is recommended that the program container name be adapted for the
purpose of later recognition.
This is also recommended for modules of other generation languages like FUP, AWL,
etc.
3.3.9. Application and sequencer properties: settings

Here the sequencer properties have to be defined first. To do this, the application settings
are made for the display, the documentation and the handling of global properties.
The application settings must be made manually once for each S7-GRAPH
installation. This applies above all to the registers “General” and “Editor.”
The following application settings must be made in the “General” register.

Conditions in new modules: FBD
During storage: also handle instance DB
Operands in sources: absolute
This is important for the S7-Graph export.
Determination of the synchronization steps:
“Previous transition has been fulfilled”
Store window arrangement with OK.
Figure 73 Application settings, General

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The following application settings must be made in the “Editor” register:
Operand field width: 18 (as for STEP7)
Conditions space saving
Action lists space saving
Figure 74 Application settings, Editor

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For the application settings in the “Compiling/Storage” register, the same settings are taken
over as are available as references in the sample sequencer in the “Compiling/Storage”
register module settings.
Figure 75 Application settings, Compiling/Storage
For the application settings in the “Alarms” register, the setting

• Alarm handling: none
is made.
Figure 76 Application settings, Alarms

For the application settings in the “Print” tap, the settings have to be configured as it is
defined by Daimler in the application range.
The following illustration is only an example for coordination.

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Figure 77 Application settings, Printing
Always check settings for printing first using print preview in order to save time,
print media, etc.
On all devices that use S7-GRAPH, the application settings must be made once
manually. This must be checked after each installation and/or update of
S7-GRAPH and if necessary performed again once manually.
The sequence granular settings regarding the module settings for execution capability of the
FB/DB pair are stored directly in the module of the module container and also in the GRAPH
source in the source container of the S7 project.
In this way, these settings are available, e.g. in the export file, and thus can also be
transported into other and/or from other S7 projects.
The following module settings and properties must be set:
An IN parameter “Default” (place holder) + no OUT parameter:
Functionalities are implemented by FGFC<S7GRAPH> directly using S7-GRAPH-DB
FB parameters
User defined (starting from V5.0)
Execution capability
Can be executed independently
(optimized min. CPU cycle time)
Warnings
All warnings (even references to blank elements)
Interface description
Individual structures

Load in AS (reason: recompiling capability from AS)
No criteria analysis
No MC7 code storage in S7G-DB
(memory space optimization)
No jumping steps
Step active min. 1 programmable controller cycle
No acknowledgement requirement for errors
S7G-Kette self-acknowledging
Synchronization (starting V4.0)
Select algorithm in application settings for

“SmartSyn” using FGFC<S7GRAPH>
No blocking of the
operating modes
Implemented internally using FGFC<S7GRAPH>
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Secured switching behavior
(starting V5.1)
Important, e.g. for step selection and structure
checking
Settings for taking over new sequencer modules as default
Figure 78 Module settings, Compile/Store

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No entries can be made in the module settings for Alarms and Process Diagnosis, since this
functionality is not used in integra.
Figure 79 Module settings, Alarms

No settings are made in the tab “Process Diagnosis,” i.e. these remain blank.
Figure 80 Module settings, Process Diagnosis
3.3.10. Sequencer functionalities

The basic functionality includes the step sequence system with its correct sequence
including branches. In this case, only the active steps/transitions and their functionalities
cause the sequence of the step.
The assignment of the object names and the object numbers for step and transition do not
influence the sequence, rather only the graphical structure and manual interventions like step

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selection.
The initial step (IEC recognition symbol: double borders) serves as the starting step, which
becomes active without query of transitions, e.g. at the start of the sequence, jump back
(from step x to initial step) or reset to the initial step. In this case, the sequence system
includes basically two basic elements “step” and “transition.”
Basis:
Synchronization Application settings/general:

Fixed integrated: Following transition is not fulfilled
SmartSyn Control and display on visual display (Visu) in coordination
with FGFC/FGDB
Algorithm: Sx = previousTy-1 = 1 and following Ty = 0
(Same algorithm as for S7-GRAPH Editor)
Operating mode selection Connection to FC integrated

Blocking of the functions internally for the
“sequence control” animation mode in S7-GRAPH
Number of steps To S7-GRAPH system limit
Number of transitions To S7-GRAPH system limit
Branches Use max. 16 branches

Reasonable structuring and representation limit
Number of sequences Use max. one step sequence per S7-GRAPH FB/DB
Animation transition Animation of all transitions and their
stepping conditions

Activation implemented in samples directly in sample
sequence
as “Previously connected continuous operation”
Alternative branches In each case, one step after opening transition is included in
the name extension as the first, the data of the
branching reason like Type x, only after that does the
description of the function follow in the step
Per step:
One step no. Use automatic numbering via module
Step
naming extension Max. 2 x 24 characters + 1 blank
(Visu line break)
All characters (including special characters) permissible

Use first priority!
One step name Max. 24 characters; 1 character = letter;
Last character letter/number; no umlauts (ä, ö, ü)
No special characters except for underscore

Basis: use default name (Stepx)
Use in agreement with your Daimler
contact person

Use second priority if necessary
Locks None

Implemented using FG-FCs (action modules)
Monitors Default: Global running time monitoring
active 2 minutes per step

Adapt system-specifically in FGDB
Deactivate
Delete monitoring logic in step
If necessary
Local monitoring
(Adapt parameter to comparison box)

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Actions For action variables, use only those preset in the
associated FGDB, max. 512 per sequencer
Per transition:
One trans. no. Use automatic numbering via module
One trans. name Max. 24 characters (rules as for step name)
Use in agreement with your Daimler
contact person

If necessary, use second priority
If not used

Leave default name <Transx>
(Visual display: not displayed)
Stepping condition Query of the stepping conditions in the
transition logic (max. 32 depending on the system)
During query of action variables, both that one
and also adjacent ones (other sequencers) can be queried
Waiting times Only if necessary:

Add transition logic as CMP box
All functionalities and settings are stored in a sample step sequence that is to be used as the
basis for the project planning.
InDaimler
addition, the other settings are made according to the specifications of your
contact person.

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3.3.11. Graphical elements for sequence structures
The two important basic elements of a sequencer structure include a “step” and a “transition.”
These two basic elements can be connected to each other graphically, horizontally and
vertically. A special step is used for the start of a sequencer, a so-called starting step that is
designated as initial step according to IEC1131-3. This step has no start transition, rather it is
activated either by the graphical sequence, e.g. jump to initial step, or by manual intervention
like resetting the sequencer in base position or start in automatic (without previously
activated step, e.g. by shutting off the sequencer). For the sequencer completion, two other
elements are available:
Jump back to stepxxx
Sequencer end Contains the shutoff of the sequencer

Only to be used for sequencers that have run once, since
the sequencer runs only once and then has to be started
again selectively by intervention
Initial step:
Start of the processing without query of a start transition after sequencer RESET
Initial Step The initial step is the step in a sequencer that becomes active without
(INIT_SQ) and/or jump back to the initial start of the sequencer
previously querying conditions after Sequence Reset (INIT_SQ) or jump back or
first start of the sequence
Step: step no. (no. max. 999) and step name (max. 24 characters, no spaces)
Step Step No. ( No max 999) and Step name max 25 Char. coherently
Transition
A transition
In the transition,is the
the part of the
conditions aresequencer
programmed thatthat
contains the conditions
implement for passing
the transition
from the preceding
control from one step to to
step theits
following stepstep.
successor depending on operating mode.
(mode-dependent)
Sequencer endat the end of a linear sequencer or at the end of a path of an

A branch stop
Switches the sequencer
alternative off completely
branch terminates when this is The
the sequencer. reached. Restartis
sequencer only
notby
executed
selective activation of a step in this sequencer possible (e.g. initial step or using
cyclically..
step selection)
A branchcase:
Application stopone
always
time follows a transition
run-through, e.g. start-up/rundown program
The sequencer can only be restarted by the parameter INIT_SQ
Jump to ais step

A jump the change from a transition to any step ( For or backward)
(Forward or backward)
use case: cyclic processing, loop machine
Application case: cyclical processing, machine loop
Figure 81 Basic elements for sequence structures

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“Upstream continuous operations”
The programming of the “prior continuous operations” is only permissible for special
functions, e.g. continuously animate status of all transitions. Otherwise agreement by the
Daimler contact person is necessary.
Figure 82 Example: always animate status of all transitions
This logic section is not shown on the visual display in expert mode.
“Downstream continuous operations”
The programming of “downstream continuous operations” requires explicit approval from the
Daimler contact person.
This logic section is not displayed on the visual display in the expert mode.

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3.3.12. Steps
Graphically, a step consists of a rectangular symbol with the designation of a step name. A
step contains x (0-n) actions (command outputs) with their locks and monitors.
Steps that follow each other are connected graphically by transitions.
In one step, only the monitors with the global monitoring time – which can be parameterized
by the visual display and the actions in the action list are programmed.
For the programming of the monitoring, three basic elements are available in FUP:
AND box Signal query and linking
OR box Signal query and linking
CMP box Comparison of values of multiple formats
In addition, the following extensions are available for the signal query and the logical linking:
Bin.Eingang Binary input for extension of the AND/OR box
Bin.Eingang neg. Negate binary input to AND/OR box
Branching Parallel branching structures with AND, OR, CMP
This basic element can be set up so it is linear or parallel, interconnected and differently
connected. In this case, max. 32 signals and/or binary results of a comparison box per logic
section are possible.
For programming the actions in the action list, preferably the binary operations are used.
These can be called directly in the object properties of an action – with operator prompting.
The number of actions for one step is limited to max. 100 actions because of the system. If
there are contradictory actions, the highest priority (lowest) action will be executed.
For the numbering of the steps, the integrated numbering mechanism is used so that this
column is numbered in ascending order while simultaneous branches with this numbering
are rated with a higher priority internally.
No locks can be programmed in the steps. The basic specifications, rules and
instructions must be complied with.
The more detailed action instructions, e.g. arithmetic, must only be used with
approval of the Daimler partner.
The programming will be done in LAD in Tuscaloosa. The basic application is

switchable between FUP and LAD for that reason.
Runtime control

Golbal Time with the
FGDB adjustable
Stepp no max 999

Step no max 24 Step Name extension
Characters Max 2 x 24(+1) Characters
2 prio optional 1 Prio
Transition no max 999 Action variable in FDGB

Tranisition-Name max 24 Characters Designation + commentin in DGBD
Figure 83 Example step with adjustable global run time monitoring

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3.3.13. Transition
A transition consists of – because of the S7-GRAPH system – max. 32 stepping conditions
that have to be fulfilled in order to activate the next step according to the operating mode.
Each stepping condition is defined by query of a signal or comparison of two values. A
stepping condition (WSB) consists of a signal query. In this case, either an external signal
(e.g., input E 1.0) and/or an internal signal (e.g. bit memory M 2.0) or the result of an
arithmetic function is queried.
Basic rule for the programming under consideration of diagnosis:

first sensors, then actuators, then internal operands/functions
Example waiting time

0,2 sec
* Action

example waiting time 200 ms
Figure 84 Example of step with fixed global waiting time = transition
3.3.13.1. Waiting time

The time value for S7-GRAPH start up immediately with the activation of the step, whereby
no timer is used but rather the system function Time_TICK(SFC64). By a comparative query
in the transition, stepping to the next step is prevented. If a start of the waiting time is
desired, e.g. after first reaching the target position, this is implemented in the next step.
Global waiting time

A global waiting time is incorporated in the sequencer only if necessary since this makes the
sequence longer for the system. The waiting time can be helpful in order to make up for
possible transient processes or simply to be able to implement actions without sensors (only
time-controlled).
If necessary, the direct query in the transitions is used, whereby for diagnostic reasons the
comparison box is incorporated at the end of the logic. Alternative solutions, e.g. using so-
called pseudo-actions that will also prevent the sequencing in the transition must be avoided.
Example global waiting time
* Actionx

example global waiting time
Figure 85 Example of step with adjustable global waiting time = transition

A global waiting time that applies to all steps of the sequencer can be set in the FGDB of
each

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data module access point. This can be performed, from the simplest visual display device to
the control system.
In the application case, this is blocked per access level.
If this is not desired, the value of the programmable controller program can be set so it is
fixed. In this way, all access mechanisms are blocked.
Local waiting time

In this case, the same requirements apply as for the global waiting time. Only the addressing
is different: per step, an individual comparison value is executed that is like IEC target value,
e.g. “T#100ms” for 100 milliseconds.
The programming and the incorporation into S7-GRAPH are performed according to the
same rules as for the global waiting time.
3.3.13.2. Monitoring time
Global monitoring time

Each step whose sequence is to be monitored will be activated with the default global
monitoring time of two minutes so that in an emergency, e.g. a gap during the monitoring due
to action modules during a system shutdown, an error occurs at the latest after two minutes
and a display and logging occurs in the alarm archive/control system with reference to the
possible cause of the system shutdown.
The run time monitoring is taken from the sample sequencer and adapted if necessary.
Inrespectively
addition to this higher-level time monitoring, run times for monitoring the
triggered function are implemented decentrally in each function
group. The setting of a local monitoring time especially tuned to one step is
generally not required and should be avoided.
* Actionx / Waiting y
Figure 86 Example step with adjustable global monitoring time

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Local monitoring time
If a special monitoring time applies for a specific step, this can be set using corresponding
parameterizing at the CMP box.
In this case, the same requirements apply as for the global waiting time. Only the addressing
is different: per step, an individual comparison value that is to be executed as IEC time value
like “T#45s” for 45 seconds is executed.
The programming and the incorporation in S7-GRAPH is performed according to the same
rules as for the global waiting time.
3.3.14. Immediate error

Using the data bit DIX138.4, it is possible to trigger an immediate error. The default for the
data bit is logic 1; for an immediate error, it is set to logic 0 by the user.
3.3.15. Connection to action modules
The action variables will be used as a start release for the action modules (FG
modules of the automatic range of the system to be controlled).
To lock the outputs with other function groups, at the FGFCs the parameters
FAusV and/or FAusR are connected. These serve then as crash locks (system
protection).
Figure 87 Release of the outputs for following function groups FC
The release of the controlling is basically programmed in the networks before the
call of the FGFCs in FUP, no matter with or without sequence usage.
Only the signal for the start of the motion in automatic is formed by the guide
sequence S7-GRAPH and is used as a start release at FGFC. If only one action
variable is used, parameters are set for this directly at the FGFC.
If several action variables are used, these are handed off to the FGFC by means
of transfer signals.

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Figure 88 Starting release on the function group FC
3.3.16. Alternative branching = EXOR sequences within one sequencer

Graphical branching elements are available for alternative sequences.
In this case, these are alternative branches that graphically represent a simple straight line to
the right. For simplification, these branching elements are offered by the tool as symbols for
fast incorporation and/or placement in the sequencer structure.
An alternative branching is used, e.g. for type differentiation and thus alternative processing
in the sequence process of the system.
The first transitions of an alternative branch are designated as opening transitions since this
term also includes the functionality. In this case, the step sequence basic system provides
that in the limit case, if all opening transitions are fulfilled at the same time, only one of x
opening transitions is sequenced and thus the correct exclusive OR functionality of the
alternative branch is ensured.
The programming is limited to the stepping conditions in the transitions for the system
sequence. The functionally correct processing is ensured by the basic system S7-GRAPH.
The number of branches must be limited to a total of max. 16

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Opening alternative branch
Application case: type differentiation, etc.
Only one branch can be active during “secured switching
behavior.”
The processing occurs from top to bottom and from left to
right.
Closing alternative branch

The corresponding branch is also closed for the processing
again to the left.
The processing occurs from top to bottom and from right to
left.
Alternatively, closing can occur via a jump.
Application case: graphical intersections
Priority sequence in limit case: all Tx fulfilled simultaneously

1st priority nth priority
Figure 89 Alternative branching in sequence sequences
For the opening transitions, the differentiation criteria for the alternative
sequence must be programmed.
Note: An empty transition is always a fulfilled transition with all the
consequences for the sequence.
3.3.17. Simultaneous branching = AND sequences within one sequence
The use of simultaneous branches must be agreed on with the control

technology project manager at Daimler AG.
A simultaneous branching is used for parallel processing of procedures that will be started
and ended synchronously. It represents the simplified synchronization of several linear
sequences that are graphically represented contiguously and also synchronized using the
graphical structuring. This includes the synchronous starting of the simultaneous branches at
the so-called opening steps and the synchronous ending of the simultaneous branches at the
so-called closing steps.
In this way, programming is simpler for the user and is limited to the essential, and also the
cycle and memory space performance is improved in comparison to individual linear
sequence steps.
The number of branches must be limited to a total of max. 16

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Opening simultaneous branch
Synchronization of all participating steps after the opening
branch in the same PLC cycle
In the further sequence, each branch is processed
independently.
Sequencing of all branches possible in the same PLC cycle
Initial steps are also called opening steps
Closing simultaneous branch

Synchronization during the combination, i.e. all branches wait
for each other until all steps are active before the closing
branch. Only then will closing take place simultaneously on
the left branch using the following transition.
The last step is also called the closing step.
Important: Last step = blank waiting step
(waiting for other simultaneous branches)
Figure 90 Simultaneous branching in sequencers
Another simultaneous branch is the graphical combination of another linear

sequence with synchronized start and end caused by the basic system of S7-
GRAPH.
The last steps before simultaneous combination are designed as empty waiting
steps for the synchronization of the adjacent branches.
3.3.18. Sequence representation in operation on the visual display
Prerequisite: All S7-GRAPH sequences of a module container are present,

exported in a gr7 file (same name as awl file) in the same directory. To do this,
the S7-GRAPH export tool is very helpful for the PC/EBF configuration
(considerably simplifies the incorporation of the S7-GRAPH sequences into the
visual display with Wonderware InTouch and integra-SIS tool)
Both the S7-GRAPH export tool and its description can be found in Volume III 26.
Control Technology / 12. Supporting Tools.
Work preparation for the correct visual display connection

All current S7 project data are available, exported into the directory
“integra/Project/AWL”:

Symbols
<Anlagenname>.sdf [<System name>]

HW configuration
<Anlagenname>.cfg

Modules
<Anlagenname>.awl

S7-GRAPH FBs
<Anlagenname>.gr7

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The sequence representation on the visual display is divided into two basic windows:
Sequence list List of all available sequence sequences of a programmable
controller program with display of the global sequence data like
max. step number, current step number per current
simultaneous branch, animation of the sequence using color
code
(see below) in line representation
Sequence details Graphical structure of the selected sequence from the
swquence overview list with operational functionalities
“SmartSyn” Guided step selection, only active in setup
“Initschritt” Resetting of the sequence to the initial step(s)
(basic setting)
The color code for the animation of the sequence:
Red = Error
Green = Automatic + no error
Yellow = Setup + no error
Gray = No operating mode active + no error
Blue = Marking of last active steps
and/or for “SmartSyn”
marking of the step number found
In the sequence list view, all sequences can be initialized mutually using one button (logged
into access level)
Sequence - FG-Name(max16 C. in FGDB

Coment - FG-Comment (max 40 Char.) in FGDB
Figure 91 Representation of the sequence list

Using the selection in the sequence list, the sequence details for one sequence are now
selectable.
In this way, the sequence graphic – divided into two partial windows – is opened.
Herein it is possible to operate the important functions like initialization and SmartSyn, as
well as enlarging the display (Zoom+: each click = +10 %) and/or reducing it (Zoom-:
each click = –10%) or adjusting it automatically (adjusted to partial window).

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Sequencename_ FG-Coment in FGDB
max 40 characters
1 Prio: S-Name extension max 2+24(+1)

characters
2 Prio S-Name max 24 characters
1 Prio T-Name max 24 characters
(+1:1 empty characters for line break)
default S-T-name hidden
Figure 92 Display of sequence detail = sequence graphic

The more detailed display in expert mode is based on the expert mode for STEP7 program
sections, whereby the syntax like N (non-saving) from S7-GRAPH was used. The display is
executed in FUP, whereby the status information is animated. This can lead the user, for
example, through the program location and the missing signal(s) and their operating
equipment codes to the possible error cause in the system.

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Example experts mode for a graph 7 FUP
animation for the transition condition
Figure 93 Expert mode for transition

In expert mode, the sequence name, sequence comments, transition number and transition
name are displayed for the transition in the header bar. In the center window section, the
stepping conditions (selectable absolutely/symbolically) in FUP are displayed with activated
animation mode (color in FUP graphic and additionally numerical status). In the lower
window section, the symbol list excerpt (matching the logic) is displayed/faded out.

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Example experts mode for a graph 7 step
FUP animation for the control and animation
for the action
Figure 94 Expert mode for step

In the expert mode for one step, in principle the same information is displayed as during the
transition. In this case – as for the S7-GRAPH programming – several logic sections can also
be displayed (max.2: action list and monitoring). If a logic section is not programmed in S7-
GRAPH, this blank logic section will not be shown on the visual display.
Other display and operating functionalities are stored in the detail windows of the FG. These
are selectable, e.g. using the FG label from the system view.
In it, other functions can be operated (prerequisite: log into necessary access level)
“SmartSyn”
as in the sequence overview
Monitoring time must not and/or must be acknowledged,
i.e. it is not accepted until the transition is fulfilled
Specified value for global waiting and monitoring times
Step sequence will move to step N
In addition, important information of the FGFCs like e.g. KeinStop, release of the inputs and
outputs and the origin references to the called FGFCs in the programmable controller
program are displayed in the Information tab.

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Figure 95 FG S7-GRAPH sequence organization

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3.3.19. SmartSync (guided step selection)
A synchronization of the step sequences to a specific step is no longer required in the new
step sequence programming since manual motions in setup operation no longer adjusts the
sequence. Manual motions are implemented locally in the associated function group module,
not within the sequence step. The synchronization of the new sequences thus comprises the
display of executable steps.
The step that is momentarily active, i.e. the step in which the step sequence is located, is
displayed. After a manual intervention, a SmartSync can now be performed, which displays
all the steps that can be executed at this time.
„SmartSync“ only activ in manual mode

Preselection executable steps T x -1 and T n = not true
Sequence 1 before Sequence 1 after
SmartSync
1. Mark - Display activ Stepp
automatcially a - Display executable steps
executable - Sequence stays in active step
step until the user select a new step
2. Steered
activation of the
right step( only a
marked stepp is
possible)
Figure 96 “SmartSync”
The display of executable steps is preselected according to the above criterion, and the two-
step operator prompting is supported for convenient step selection.
After the synchronization, the sequencer remains in the last active step until a new step is
selected.
The user now has the option to set the sequence in the marked step – with
support by the dialog – and/or to leave the sequence in the last active step.

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3.4. Special Cases
3.4.1. Stations
Execution occurs using the module description FC19 (FG_STATION; see Volume III /
Chapter 26. Control Technology\10. Software Library\01 Documentation\21. Doc S7 Basic
Software (BS)).
For more detailed error diagnosis and better local assignment of function groups, the console
areas are assigned to stations in mechanization systems.
The station module does not form a separate operating mode, rather it only collects status
alarms from the assigned function groups and forms group alarms from them.
The function groups are called from the station FB.
Figure 97 Inclusion of a station

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3.4.2. Function group expansion
If the area provided for this in the data module is not adequate for the display of error alarms
or warnings, the function module FC 16 “FG_DUMMY” is provided for the expansion of the
function group.
The expansion function group must be given a different identification than the main function
group. In the example, for expansion of the function group 000EK_001, a function group
000EK_001_H02 has been created.
Execution occurs using the module description FC16 (for FG_DUMMY, see Volume III /
Chapter 26. Control Technology\10. Software Libraries\01. Documentation\21. Doc S7 Basic
Software (BS)).
Figure 98 FC call of expanded function group

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3.4.3. Mechanization special functions
The function group FC4040_FG_SOFU-VAR_KP32 is used for management of the following
special functions in mechanization systems (bodyshop).
The following functions are integrated:
Stop at (after) cycle end
Maintenance position
System stop
Run empty
Cooling water suction
Ghost operation
Breaktest (KRC4)
The block can be called per plant area (safety area) or hierarchically superior.
Further user instructions can be found in the module documentation for FC4040 “FG_SOFU-
VAR_KP32“.”
The used special operational functions has to edited before calling the FC4040.
Figure 99 Calling FC22 mechanization special function

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3.4.4. Motion control screen
For the operation of the system using motion control screens on the unit operating field
(EBF), the function module FC13 “BEWUNGSBILD” [MOTION CONTROL SCREEN] must
be called. The call of the motion control screen function module occurs in console area FB.
For each EBF, a call of the FC13 is necessary.
Figure 100 Calling FC13 motion control screen

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3.4.5 Interfaces to third-party systems
The function group is used to display the status of the third-party system on the visual
display.
For each interface to a third-party system, FC49 must be called. On the input parameters,
the corresponding signals that are reported by the third-party system by way of the I/O
coupler (standard section) must be parameterized.
Figure 101 Call of FC49 interface to third-party system

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4. F Programming
The basic application is provided with default F password integra. The F password must be
modified for acceptance.
4.1. F Program Structure

The call of the safety program occurs with the FC1600 as "F_CALL" in the OB35 (OB36 for
CPU416F).In the FC1600, the FC1601 “F_PROGRAM” is called as the sequence group. The
FC1601 is used as a jumping point for all other modules of the safety program.
The standardizing provides for only one F call in a programmable controller. The
F call must always occur via FC1600.
Figure 102 Structure of the safety program

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4.1.1. Specifications for the programmer
Only safety-oriented modules (F-FB) released for integra must be used and
loaded. All data modules (instance DB and user DB) are specified and/or have to
be generated in the number ranges provided for them.
The procedure for the F programming of the HW-Konfig can be found in the
document 000_B3.26.03_PRL_HWKonfig_PROFINET_Vxx.xx.pdf.
The specification from the SIEMENS manuals must be complied with,

“Decentralized peripheral system ET200S fail-safe module,” and
“S7 F – Safety technology in SIMATIC S7”
The specification regarding the assignment of F modules to F templates from the

table “Zuordnung_ F-Templates_Vxx.xx-xls” found on the VE server are subject
to mandatory compliance
(VE Chapter: 26. Control Technology\10. SW Libraries\01. Documentation\34. Doc
S7 Fail Safe Software (F-SAFE))
Mandatory compliance is required for the following specifications

Preliminary links are programmed in the networks before the FB call.
No BIT MEMORY may be used.

DBX from the associated DB 25xx are used as auxiliary signals.
An example DB25xx specification is included in Chapter 4.1.2.
As auxiliary signals, only
“Safe zero” DB3276.DBX 36.3 and
“Safe one” DB 3276.DBX 36.4 may be used.
All networks and comment lines in the FCs must be adapted.

In the comment field of the first network of an FC, a Table of Contents must be
incorporated for the network comments of the respective FC (see Fig. 110)
All programmed elements must be provided with symbol names and symbol
comments.
The addresses in the basic application are “dummy addresses.”
The DBs of the emergency elements are numbered in ascending sequence and
designated according to “VE, B3.26.02.00_PRL_Software_SPS_Teil2_V0x.00”
Chapter 4.3.3 “Setup of emergency OFF and error alarm texts.”
The DBs 3276 to 3291 should only be considered a hardware example in the basic
application and will automatically be generated by the HW configuration of the
programmable controller.
During the programming with the F/FBs, the correct HW assignment must be ensured
(QBAD, ACK_REI, ACK_REQ).
If safe inputs and outputs are not used in the program, these must be deactivated in
the HW configurator.

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4.1.2. F program/suggestion for DB distribution according to basic
application
Data modules – Dbxy
DB 2500 to DB2549: Reserved for bit memory ranges of the user program
Type No. Name Family Symbols Comment/Explanation
DB 2500 F_DB F_SAFE F_DB_IFC Data module as bit memory range
(preliminary links) for data of the entire
system
DB 2501 F_DATA F_SAFE F_DATA_0xxSB_0nn Data module as bit memory range
to to (preliminary links) for data of safety
2531 F_DATA_0xxSB_0nn ranges 1 to 31 (serial number according
to HW plan)
DB 2532 F_DATA F_SAFE F-DATA_GESAMT Data module as bit memory range
(preliminary links) for data of the safety
functions that are assigned to the
general SB (FC1700, FC1800)
DB 2533 (Instance DB) System Application-specific User instance data modules (e.g. for
to generated application-specific safe timer cells)
2549
DB 2550 to DB2559: Reserved for sending and receiving data of the adjacent systems (system limits)
Type No. Name Family Symbols Comment/Explanation
DB 2550 F_DATA F_SAFE F_DB_xxxANL001 Global DB for safe HW I/O signals from/to
to to third-party systems 1 to 9 (xxx = system
2559 F_DB_xxxANL009 number, e.g. 133)
DB 2560 to DB2579: Reserved as I-DB for calls of FB1524 F_RCVDP (system-internal between programmable
controllers)
DB 2560 (Instance DB) System SEDB_RECV_xxx Instance DB for FB1524 F_RCVDP (safe
to generated coupling, xxx = programmable controller
2579 name within the system)
DB 2580 to DB2599: Reserved as I-DB for calls of FB1523 F_SENDDP
DB 2580 (Instance DB) System SEDB_SEND_xxx Instance DB for FB1523 F_SENDDP (safe
to generated coupling, xxx = programmable controller
2599 name within the system)
DB 2600 to DB2999: Reserved as I-DB for calls of user modules
DB 2600 (Instance DB) System SEDB_xxx Open user instance DB for the application
to user generated program (xxx = safety element
2999 abbreviation).
For visual display structuring of the safety
OCX, the input range recording begins, for
example, with DB2600 and the output
range shutoff, for example, with DB2700.
DB 3000: Reserved as I-DB for call FB1591 F_ACK_GL
DB 3000 (Instance DB) System F_ACK_GLDB Instance DB for FB1591 F_ACK_GL
generated (global reintegration of HW modules)
DB 3001 to DB3275: Reserve
DB 3276 to DB4095: Reserved for system-side generated DBs (automatic generation)
Table 7 Parameter “F program/DB classification suggestion”

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The DB classification is a suggestion that is useful in the integra basic application. If the
integra basic application (OB100/FC95 parameterizing) will be used unchanged as a basis,
the user must include the DB classification for DBs 2560 to 2999 according to the table. The
same is true for the DB range of the automatically generated DBs 3276 to 4906 and/or for
the reserved instance DBs
In DB3276 “F_GLOBDB,” the signals
“Safe VKE 0” DB 3276.DBX 36.3 and/or
“Safe VKE 1” DB 3276.DBX 36.4 are specified by the system.

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4.1.3. Call of the safety program in the OB35
Figure 103 OB35 call of the F_CALL
In addition to the call of F_CALL for the safety program, in OB35 (OB36 for CPU416F), still other
functions are implemented:
• Cycle time measurement for the safety program
• Counting of the OB1 interruptions by the F program
• Provision of “life bit” and “synchronization bit”
start-up.
The call interval for the OB35 (OB36 for CPU416F) must be adapted during the initial
The time value of the interval must be set so that the OB1 cycle is interrupted
maximum one time by the OB35 (OB36 for CPU416F). This means that the call interval
of the OB35 (OB36 for CPU416F) must be somewhat greater than the entire program
running time from OB1 and OB35 (OB36 for CPU416F) together.
Execution time OB35 = run time OB1 + run time OB35 + reserve (min. 10%)
The consequence of calling OB35 is that the total running time of the OB1 is not consistent,
depending on whether the OB1 is interrupted by the safety program or not.

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4.1.4. F_CALL FC1600
In OB35, FC1600 is called as F_CALL. In F_CALL, the FC1601 is specified as F sequence
group.
The settings are taken over from the basic project.
Figure 104 F_CALL

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4.1.5. Sequence group FC1601
The FC1601 is used for programming basic functions and as a jumping point for other
modules. The FC1601 is, so to say, the “OB1 of the safety program.”
In the comment field of the first network, a Table of Contents is set up regarding all the
following network functions.
The following functions are implemented in FC1601:
• Provision of non-safe signals from the standard program
• Global reintegration of fail-safe modules after “control voltage on”
• Call of the safety-oriented general input recording (FC1700)
• Call of the safety-oriented protection-range-oriented input recording (FC1701 - 1731)
• Call of the safety-oriented formation of group variables (FC1800)
• Call of the safety-oriented output shutoff
(FC1801 - FC1831)
• Call of the safe communication with third-party systems via I/O coupler
4.1.5.1. Example call of a safe RCV communication to the third-party programmable
controller
If a safe communication to a third-party system via I/O coupler is desired, the module
FB1524 “F_RCVDP” must be called to receive the safe data in the second network of the
FC1601. In the example, four hardware input signals of a third-party system are transferred
to a safety DB.
Figure 105 Safe communication via I/O coupler with FB1524

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4.1.5.2. Function of the signal “Safety ALIVE”
The signal “Safety alive” is used to check whether the safety program is being processed. If
this bit is no longer toggled, an error alarm is sent.
Figure 106 Sequence group FC1601 (the jump destination list of the safety program)

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4.1.5.3. Preparation of signals from the non-safe program section
In the network representations, signals are programmed that will be handed over from the
non-safe program section into the F program for safe further processing.
Figure 107 Preparation of routing signals from the non-safe program section
Network 4:
If an automatic emergency OFF acknowledgement to the fail-safe software modules is
desired when the control voltage is switched on, the signal
"Control voltage on” (“F_DB_IFC_000”.K1E) at the input parameters “AuSt” of the fail-safe
function modules must be parameterized.
Network 5:
The edge evaluation of F-K1E is available for automatic emergency OFF acknowledgement
for fail-safe software modules that do not have any internal edge evaluation on the
acknowledgement parameter (e.g. FB1628).
Network 6:
For the automatic reintegration of F modules, the signal “F-QUIT” (“F_DB_IFC”.Quit) that is
available temporally before the signal “Control voltage on” for formation of the trigger signal
is used for the reintegration by FB1591.

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Network 7:
Formation of blink cycles for the further processing in the F program section.
The blink cycles are used to control the lamps and will generally be specified in the
corresponding FB parameters.
Figure 108 Preparation for safety-oriented blink cycles
4.1.5.4. Preparation of additional safety-oriented signals for the F program
If“conveyor
in addition to the signals already programmed, other non-safe signals (e.g.
running” for monitoring a muting function) are needed in the safety
program; these are also programmed in FC1601 in networks to be set up
separately.
For this purpose, the data bits from DB2500 are used. (If necessary, DB2500 can
be lengthened).

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4.1.5.5. Global reintegration after HW module errors of F modules
Mode of operation
The fail-safe Siemens standard module F_ACK_GL (FB1591/in Siemens original FB219)
generates an acknowledgement for simultaneous reintegration of all F peripherals/channels
of the F peripherals of an F sequence group after communication errors and/or F
peripheral/channel errors.
For the reintegration, a user acknowledgement with positive edge is required at the input
ACK_REI_GLOB. The acknowledgement occurs analogously to the user acknowledgement
using the variable ACK_REI of the F peripheral DB but acts simultaneously on all F
peripherals of the F sequence group in which the F application module is called.
By the use of the F standard module F_ACK_GL, it is not necessary for the user to provide a
user acknowledgement with the variable ACK_REI of the F peripheral DB individually for
each F peripheral of the F sequence group.
Use in the basic application with call in FC1601

The global reintegration of F modules is always called before the actual input recording
(e.g.: FB1701) and connected with the instance DB “DB3000 F_ACK_GLDB.”
In order to achieve a one-time automatic global reintegration for F modules after control
voltage ON, the FB1591 is called in the basic application and the parameter
“ACK_REI_GLOB” is linked indirectly with the signal “F-QUIT.”
In addition, the parameter will be connected indirectly with the emergency OFF
acknowledgement button of the EBF in order to be able to perform a manual regeneration of
all F modules from the EBF.
In the application, the system programming can supplement the manual trigger by linking
additional acknowledgement buttons depending on the application case.
Figure 109 Call of the F_ACK_GL “FB1591” (FB219)

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4.1.5.6. Input recording, group alarm variable and output connection
The safety program for input recording for safety elements that have general validity and
cannot be directly assigned to any protected area will be called in FC1700.
The safety program for input recording for safety elements that can be assigned directly to
protected areas will be called in FC 1701 to FC1732.
FC1800 is used for system-specific formation of safe group alarm variables of the various
protected areas from the area of input recording.
The group alarm variables form the application-specific releases of the subsequent modules.
The program for controlling the safe outputs is called in FC1801 to FC1832.
Figure 110 Input recording, group alarm variable and output shutoff

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4.1.5.7. Example call of a safe SEND communication to the third-party
programmable controller
If a safe communication via I/O coupler to a third-party system is desired, the module
FB1523 “F_SENDDP” for sending the safe data must always be called in the last network of
the FC1601. In the example, the group alarm “emergency stop” and “emergency stop
acknowledgement” will be transferred to the third-party system via hardware outputs.
Figure 111 Safe communication via I/O coupler with FB1523

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4.2. Safety Program
During programming of the safety program, a differentiation is made between input recording
and output shutoff.
The input recording of the safety elements that cannot be assigned directly to any protected
area will be programmed in FC1700.
In FC1700, the formation of the bit memory for controlling the display LED “VI maintenance
switch lock active” occurs and is implemented in the console area call module.
The input recording of the safety elements that can be assigned directly to a protected area
can be programmed, for example, like emergency OFF, light grid, protective doors, etc. in the
modules FC1701 to FC1732.
The safe group variable formation of e.g. protected areas, rip lines, emergency stop areas
for subsequent controlling of safe outputs can occur application-specifically in FC1800,
depending on the requirement.
For the programming of the safe outputs, e.g. feedback circuit with K0C fuse, robot, safe
drives, etc., the protected area-specific modules FC1801 to FC1832 are available.
The distribution of the safety elements to the various FCs depends on the system
configuration.
Example:
• If a system can reasonably be divided into different safety areas, the division looks as
follows:
• General safety elements FC1700

Safety area 1 FC1701 / FC1801
Safety area 2 FC1702 / FC1802
Group variable formation for all safety areas FC1800

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4.2.1. Input recording FC1700, FC1701 – FC1732
The input recording of the safety elements is programmed in FC1700 and FC1701 to
FC1732. For this purpose, various function modules are available in the F library. Preliminary
couplings that may be necessary, e.g. acknowledgement signals, occur before the FB call
and they will be parameterized with the use of data bits on the FB.
The numbers of the instance DBs for safety elements start at DB2600 and are numbered in
ascending sequence.
Allgemeingültige
General
Safety-Elements
Sicherheitselemente
FC1700
Read Safety
Eingangserfassung der
Sicherheitselemente
Elements
SEDB
E- StopTaster
Not-Aus button
BR - E-Stop-button
Nt
Not-Aus
-Aus Taster DB2600
Schutzbereich
Safety-Area 31 31 FB1602
SEDB
FC1731 BR – VI-Switch
VI-Schalter
VI-3St
VI-3posSchalter
Switch
DB2601
Eingangserfassung
Read-safety der FB1612
Sicherheitselemente
Sicherheitselemente
Elements Schutzbereich
Safety-Area 3 3
Emergencyt
Not-Aus
-Aus Taster FC1701
Schutzbereich
Safety-Area 2 2
FC1701
Schutzbereich
Safety-Area
Sicherheitselemente 1 1
Schutztür
FC1701
Sicherheitselemente
StopTaster
NtE--Aus
Not-Aus button
SEDB
Not-Aus
Read Taster
Eingangserfassung
safety der DB2602
Pendelklappe Sicherheitselemente
Elements
Axis-range-controle FB1602
Not-Aus Taster
Schutztür SEDB
Emergency-stop-b.
Not-Aus Taster Schutztür mit
Safety-door +VI-Switch
VI-Schlt.
Muting-Lichtgitter
Schutztür DB2603
FB1603
Pendelklappe
Trittmatte
Safety-mat Schutztür
Safety-door SEDB
Pendelklappe Achsbereichsüberw..
Axis-range-control
Muting-Lichtgitter
DB2604
FB1601
Achsbereichüberwachung
Axis range control
Muting-Lichtgitter SEDB
Trittmatte Muting-Lichtgitter
Muting-Light-curtin
Muting-Lichtgitter
Muting-Light-curtin DB2605
FB1615
Trittmatte
SEDB
Trittmatte
Safety-mat Trittmatte
Safety-mat
DB2606
FB1602
Pendelklappe
Swing door SEDB
Pendelklappe
Swing door
DB2607
FB1602
Figure 112 Call structure of the input-side safety elements (sensors)

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4.2.1.1. FC1700 “Formation of acknowledgement signal types for safety elements”
The input recording of the safety elements that cannot be assigned directly to a
protected area can be programmed in FC1700.
In this network, the user-specific formation of an acknowledgement signal occurs that is
formed by a collection of local acknowledgement buttons in the system.
This signal can be used user-specifically for acknowledgement to SE modules (e.g. FB1602)
in the parameter “RSET.”
Figure 113 “Local acknowledgement signal”

In this network, the user-specific formation of an acknowledgement signal occurs that
implements a linking of local acknowledgement buttons and acknowledgement signals that
come from a third-party system (programmable controller).
This signal can be used user-specifically both for local and non-system-specific
acknowledgement of SE modules (e.g. FB1602) (an acknowledgement in the third-party
system thus also acknowledges a third-party safety element of the system).
Figure 114 “Local acknowledgement signal including acknowledgement of third-party

systems”
In this network, the user-specific formation of an acknowledgement signal occurs that
represents both a linking of local acknowledgement buttons and acknowledgement signals of
a third-party system as well as a one-time acknowledgement after the system is switched off.
This signal can be used user-specifically for local, non-system-specific acknowledgement
and for acknowledgement after network ON signal (both an acknowledgement in the third-
party system and the switching on of the system involved would thus acknowledge a safety
element).

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systems and network ON”
4.2.1.2. Input recording, emergency OFF for KP32F on EBF
Figure 116 Example input recording of an emergency OFF

For recording further safety elements in the plant the and –Logic has to be completed
withfurther ENBL-signals
Figure 117 Example editing group fault emergency Stop
According to the shown network “group fault emergency stop” the user has to
generate for each safety area a group fault flag , which contains all emergency
buttons, all BS-elements, and the maintenance (VI) switches- of the area.

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The control of the KP32K LED “Emergency Stop Red” has to be realized in FB110 (panel
zone block)

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4.2.1.3. Input recording, VI maintenance switch for PP17-I on EBF
For the VI maintenance switch on the PP17-I/EBF, the FB1611 is programmed with the type
36. In this application, the module supplies the following signals via its OUT parameters:
Unlocked VI maintenance switch no zone release

Panel zone locked VI maintenance switch release, panel zone
Plant zone locked VI maintenance switch release, plant zone
Figure 118 Call of FB1611 VI maintenance switch

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The network for controlling the KP32F LED “VI maintenance switch interlock active RED” is
realized in the FB110 (panel zone block) via the bit of the parameter “ANZ” of the FB1611.
Figure 119 Call of FB110 KP32F-LED VI-maintenance switch interlock active RED
For showing the status of the maintenance switch panel-or plant wide via the KP32F-VI-LED
the preceding “and-logic-gate has to be completed as described.
Using interlocks e.g. Buhl-defined connections, the group flags of the safety areas
or plant area (all locks of the SB active) has to control the VI-LED according to the
maintenance switch positions.
If there is no central interlocking (ZV) in use the input signals at the “and-logic-
gate” can be eliminated.
The signal “all locks of the SB active” must be formed with the use of locks, e.g.
Buhl-defined connections. The group signal must contain all locks of the protected
area and must be assigned in the corresponding protected area FC (e.g. FC1801).
The signal “all locks of the system active” must be assigned user-specifically in
the program (FC1800). The group signal must thus include all locks of the system.
VI_ANZ (FB1611 LED-parameter)

Display on KP32F
Add here the group flag maintenance switch
„all locks of the SB active” (panel area) interlockings active RED
Figure 120 Control of the KP32F-LED “VI-maintenance interlockings active RED

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4.2.2. Output shutoff FC1801 – FC1832 / group alarms FC1800
FC1800 is used for application-specific and system-specific formation of safe group alarm
variables for the various protected areas from the area of input recording (sensors).
The group alarm variables can be used system-specifically for shutoff of safety elements in
the output shutoff of the safety areas (starting from FC1801) or can be used as alarm
variables that are not specific to the programmable controller area. For the formation of the
group variables, for protected area 1 the DB2501 is used starting from the address
“RES_00.” For the formation of the group signals for other protected areas, the
corresponding successive data modules are used. (If group variables of this type are not
required in the project, the network is erased in the application with the call of FC1800).
The controlling of the safe outputs occurs in FC1801 to FC1832. For this purpose, various
function modules are available. Necessary preliminary links occur before the FB call, and
parameters will be set with the use of data bits on the FB. The instance DBs of the safety
elements are continuously numbered and start at DB2700 and will be continuously numbered
in ascending sequence.
Figure 121 Call structure of the output-side safety elements (actuators)

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As an example, the load controlling and/or shutoff of a scratch embosser will be shown as an
example.
The call of the FB1620 (load on/off) should occur in the output shutoff of the respective
protected area (FC1801 – FC1832).
During the formation of the on/off switching signal” the following signals have to be
considered in the creation logic:
- Group bit memory, complete emergency stop of the system
- Group bit memory, user protection of the respective protected area
- Switch setting, VI switch, console
- Control voltage ON
The switch-on signal then will be parametrized on the parameter “ON” in FB1620.
With the parameter “K1” of the FB1620, the corresponding power contactor of the scratch
embosser is triggered on/off. The input signal of the contactor alarm is parameterized on the
input parameter “RFK” and thus the correct switching of the contactor is monitored by the
software.
Adocumentation
detailed description of the modules and their connection can be found in the
for the respective function module.

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4.2.3. Connection of the safety modules
The linking of the FB input parameters occurs, in each case, before the FB call. If the same
parameter is required for various FBs (e.g., acknowledgement signal), it only needs to be
created once. If emergency stop signals for different protected areas act on one shutoff, the
group signal is formed in FC1800.
(The following illustrations should be understood as concept examples and adapted to the
application)
Schutzbereich 1 Schutzbereichzusammenfassung
Schutzbereich
Eingangserfassung 1 Sammelvariablen
z.B. FC 1701 z.B. FC 1800
>=
DB2501 DBX
“NA_ENBL_xx“
& DB2532 DBX
“SM_NA_000SB_001_NOT“
&
Schutztür mit ZH
DB2501 DBX
Sch utztür -Quitt. “BS_ENBL_xx“
Schutzbereich 2
Eingangserfassung
z.B. FC1702
DB2502
DBX“NA_ENBL_xx“
Figure 122 Example stepping interconnection of the input recording – safety modules

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Figure 123 Example interconnection of the output shutoff safety modules

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No preliminary links are permitted at the FB parameters. Preliminary links must be
programmed in separate networks before the FB call and with the use of the data bits
from DB2501 – DB2532 routed to the FB inputs.
This applies analogously for the output parameters of the FBs. If several operands will
be linked with one FB output, this must occur using data bits in a separate network
after the FB call.
For connecting the safety modules, the data bits of the data modules DB2501 to DB2532 are
available (so to say, the “bit memories” of the safety program).
The DB 2532 is prepared in the basic application. In DB2532, areas are provided for the
most important FB parameters, divided into “emergency OFF,” “operator protection” and
“other functions.” Each operand used in the program must be provided with symbol and
comment in the data module.
Figure 124 Example of user protection signal – symbol and comment in DB2532
The structure of the DB2532 on the basic application is used only for rough orientation
and must be adapted by the user according to the system configuration and expanded
if necessary.
Inmosttheimportant
integra standard fail-safe library, the DB2501 is provided with the areas for the
FB parameters as an application-specific copying format for the creation
of additional protected areas.

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4.2.4. Safe interface to third-party systems
4.2.4.1. Interface to the third-party system PROFISAFE to PNOZ
Function:
Emergency stop switch of System A was actuated and forwarded to System B.
• In System A, everything is safely shut down according to specification (shutoff matrix).

• In System B, according to risk evaluation, only adjacent roller conveyors, console areas
or the entire system will be safely shut down.
Acknowledgement of the emergency stop switch:

System A:
• With emergency stop switch unlocked and acknowledged, the emergency stop signal
interfaces in System B must be reset again. System B must not be acknowledged.
System B:
• If only the adjacent roller conveyors of System B were shut off (risk evaluation), these
start up again according to their programmed sequence without acknowledgement*.
• If an entire console area/system was switched off, the operating mode “automatic” in
System B is deleted. System B can/must be restarted.
Basic information:
• In the system in which emergency OFF was triggered, it must also be acknowledged.
• If a motion that could cause hazards will be initiated due to the unacknowledged start-
up, this must also be acknowledged in this system. (Restart lock using e.g. FB1602,
etc.)
• If a photoelectric barrier (safety area separation) between two systems is triggered, this
photoelectric barrier must be acknowledged on site with a view into the areas and after
that each system must be started again on its own.
Safe systems coupling PROFISAFE to PNOZ

Using a +/- safe output, the voltage supply of the PNOZ device of the adjacent system will
be shut off without feedback.
Figure 125 Systems PROFISAFE to PNOZ

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4.2.4.2. Interface to the third-party system PROFISAFE via DP/DP coupler
The safe communication between two controls occurs via the DP/DP coupler with the
modules FB1523 and FB1524 for sending and receiving the data.
The safe communication between the two controls must always be set up in both directions,
i.e. for each interface, the FB1523 (F_SENDDP) and the FB1524 (F_RCVDP) must be
called.
Care must be taken that the FB1524 (F_RCVDP) is always called in the first network of the
FC1601. As instance DBs for the calls of the FB1524, the data modules DB2560 to DB2579
are used.
The FB1523 (F_SENDDP) must always be called in the last network of the FC1601. As
instance DBs for the calls of the FB1523, the data modules DB2580 to DB2599 are used.
With one communication, 16 safe binary signals and two safe integer values can be
transferred in both directions. If this is not adequate, several safe connections can also be
set up between two controls. This occurs by expansion of the HW configuration and multiple
calls of the FB1523 and FB1524.
Figure 126 System interfaces, safety technology DP/DP coupler
The configuration for PROFIBUS DP with the DP/DP coupler for the safe
communication is described in the Project Planning Guideline
“000_B3.26.03_PRL_HWKonfig_PROFIBUS.”

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During the programming of the safe interface with the send
(FB1523_SE_SENDDP) and receive (FB1524_SE_RCVDP) modules, the points
from the respective module description absolutely must be complied with.
[VE, B3. 26.10. 01.34. Document S7 Fail-Safe Software (F-SAFE)]
No functions in the other programmable controller may be triggered directly from

a different programmable controller.

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4.2.4.3. Interface to third-party system PROFISAFE via PN/PN coupler
The safe communication between two controls occurs using the PN/PN coupler with the
modules FB1523 and FB1524 for sending and receiving the data.
The safe communication between two controls must always be set up in both directions, i.e.
for each interface, the FB1523 (F_SENDDP) and the FB1524 (F_RCVDP) must be called
once each.
It must be ensured that the FB1524 (F_RCVDP) is always called in the first network of the
FC1601. As instance DBs for the calls of the FB1524, the data modules DB2560 to DB2579
are used.
The FB1523 (F_SENDDP) must always be called in the last network of the FC1601. As
instance DBs for the calls of the FB1523, the data modules DB2580 to DB2599 are used.
With one communication, 16 safe binary signals and two safe integer values can be
transferred in both directions. If this is not adequate, more safe connections can also be set
up between two controls. This occurs by expansion of the HW configuration and multiple
calling of the FB1523 and FB1524.
Figure 127 System interfaces for safety technology PN/PN coupler
The configuration for PROFINET IO with the PN/PN coupler for safe
communication is described in the Project Planning Guideline
“000_B3.26.03_PRL_HWKonfig_PROFINET.”

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During the programming of the safe interface with the send
(FB1523_SE_SENDDP) and receive (FB1524_SE_RCVDP) modules, the points
from the respective module description absolutely must be complied with.
[VE, B3. 26.10. 01.34. Document S7 Fail-Safe Software (F-SAFE)]
No functions in the programmable controller may be triggered directly from

function groups in the different programmable controller.

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4.2.5. Emergency OFF signals to the third-party system
For the third-party system, the release signals (ENBL output of the FB) of one or several
safety elements will be reported.
In addition to the signal for safe communication, the emergency OFF must also still be
available in the standard interface. However, this does not occur in the F program but in the
standard section together with the other interface signals.
Figure 128 Emergency OFF signals to the third-party system

An error of the safe communication via the I/O coupler will be entered in the instance DB of
FB1523, and from there reporting will be forwarded.

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4.2.6. Emergency OFF signals from the third-party system
The safe signals from the third-party system will be linked in the FCs with the ENBL signals
of the safety elements for output shutoff. For the emergency OFF of the third-party system,
no function module will be called for a safety element. This means that the emergency OFF
from the third-party system does not need to be acknowledged in the system itself, but only
in the third-party system. The emergency OFF signal from the third-party system must be
linked, additionally in the non-safe user program to the parameter “NotAus_Fremd” of the
function group “FG_IFC-Fremd” (FC49) for reporting and visual display purposes.
Signals from the third-party system that lead to load shutoff in the incoming system are
displayed visually in this system by means of FB1635 with the corresponding color changes
and event entries for diagnostic purposes.
Figure 129 Emergency OFF signals from the third-party system

An error of the safe communication via the I/O coupler will be entered in the instance DB of
FB1524, and from there the alarm will be forwarded.

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4.2.7. Parameterizing for the function modules
A detailed description of the FB parameters can be found in the respective documentation of
the function modules from the F library.
In particular, the specification of the correct type of safety element (parameter TYP) must be
ensured. In this way, it is ensured that in the visual display the correct detail window will be
assigned to the safety element.
All inputs of the function modules are parameterized. For the fixed parameterizing of FB
inputs with VKE = 0 or VKE = 1, the bit memories M2.0 and M2.1 from the standard program
must not be used.
For VKE0 and VKE1 in the F program, the safe data bits are used from the data module
DB3276 “F_GLOBDB.”
Figure 130 VKE0 and VKE1 for the F program

Unused output parameters of the function modules, e.g. display lights, will not be
programmed and remain unconnected!

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4.3. Alarm structure of the safety program
Each FB call of a safety element makes available an emergency OFF alarm and an error
alarm. These two pieces of information are stored at a defined location in the instance DB of
each safety element (DB2600 – DB2999).
SIS Safety - OCX

Eintrag in Alarmzeile VISU Übersicht Detail
Not-Aus Meldung Störmeldung
nichtsicheres F-Programm
Programm FC1701
FC 34 DB 95 FB 1600
DB 1134...1138 DB 2601
DB 2601 Status
Typ 1
FC1801
DB 2701 DB2501
Ausgangsparameter
Typ 22 zur Ansteuerung des
sicheren Ausgang
(direkt sicheres
FC 96 Ausgangs-Peripherie-
DB 1140...1148 Signal)
FB 1623 FB 1623
DB 2702
DB 2701 DB 2702
Eingangsparameter Typ 22
„KeinStop“ des
Funktionsgruppen-FC
FC 202 FC 202
DB 501 DB 502
FC82 FC82
FB215
Figure 131 Alarm structure of the F program

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4.3.1. Safety element emergency OFF alarm
An emergency OFF alarm is present if a safety element has triggered correctly and no error
has occurred in the process. This is the case, for example, if an emergency OFF switch was
operated and both contacts have opened within the permissible discrepancy time. In the
instance DB of the corresponding safety element, the bit Farbe_ROT [Color_RED] is set in
the byte for color coding.
The FC96 (call in FB53) searches through all available instance DBs of the safety elements
for this data bit. If the data bit has the status = 1, in the function groups and/or expansion DB
of the function group emergency OFF (DB1134 – DB1138), the associated emergency OFF
alarm is set. With this alarm, the entry occurs in the interrupt line.
The assignment of emergency OFF alarm and instance DB of the safety element can be
seen from the comments of the emergency OFF DBs.
symbolic name of
the Instanz-DB of
the Safety-Elements
Figure 132 Example of DB1134 emergency OFF
Asafety
few FBs have an input parameter Diag_UEB. If this input has the status = 1 and the
element is triggered, in the instance DB of the safety element the bit Farbe_ROT
is not set, rather the bit Farbe_GELB [Color_YELLOW] is set. The consequence of
this is that no entry from the FC96 occurs in the emergency OFF FGDB (and thus also
not in the interrupt line).

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4.3.2. Safety element error alarm
An error alarm is present if an error has occurred in the safety element. This can either be an
error that was created by the function module, e.g. discrepancy monitoring, one-channel
controlling, etc. or an error alarm of the connected hardware (e.g., DI module passivation).
In the instance DB of the associated safety element, in this case the two bits Farbe_ROT
and STOERUNG [ERROR] will be set.
The FC96 (call in FB53) searches through all available instance DBs of the safety elements
for the data bit STOERUNG. If this data bit has the status = 1 in the function group or
expansion DB of the function group “safety element error” (DB1140 – DB1147), the
associated error alarm will be set.
The assignment of error bit and number of the instance DB by the safety element can be
seen from the comments of the data modules.
In addition, an error is also reported by the FBs of the safety elements by the FB1523 and
FB1524 (safe communication via I/O coupler) and entered in the DB1140 – DB1147.
symbolic name of
the instanz-DB of the
safety-element
Figure 133 Example of DB1140 safety element error
Ifcana hardware error occurs (e.g. passivation of an F_DI module), several error alarms
occur at the same time since several FBs of safety elements access inputs of the
same HW module.

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4.3.3. Structure of emergency OFF and error alarm texts
The texts for emergency OFF alarms are stored in the comments of DB1134 – DB1138; the
error alarms of the safety elements are stored in DB1140 – DB1147.
For automatic generation of these texts, the Excel tool FGDB_Not-Aus_F- SE_Vxx.xls is
available.
The symbol table with the symbols and the comments of the safety element instance DBs
(DB2560 – DB2999) serve as the basis. The comment texts are formed by the macro within
the Excel tool. To do this, comment texts and symbol designations from the symbol table are
supplemented with static words and copied to the table sheet Symbol DB fertig [Symbol DB
finished]. After that, the AWL sources for the DB1134 – DB1137 and DB1140 – DB1147 will
be generated with these generated comments that the user has to import and compile in his
or her project.
Comment texts for the emergency OFF and error alarms should not be modified manually
later in the DBs 1134-1138 and/or DBs 1140-1147.
If modified texts are necessary, these must be modified in the symbol table and the
associated DBs 1134-1138 and/or DBs 1140-1147 must be generated again with the use of
the Excel tool and imported into the project.
Exception: Emergency OFF alarm texts will be supplemented, for example, with location
information that cannot be included in the error alarm text; this must be done using manual
text after programming in the corresponding DB.
Itcorrespond
is necessary for the symbols and comments from the instance DBs to
precisely to the following convention (including comma):
Symbol Kommentar
SEDB_001BR_010-FN2 NET001=001BR_010-KF021.5, Emergency Stop
SEDB_001WAS001-SF1 NET001=001WAS001-FN029.2, VI-plant
SEDB_010RB_100 NET001=010RB_100-KF080.1, Robot
designation of the device Device

Functiongroup name of the safety
designation has to be separated with a comma + space
element
Fixed entry Fixed entry

SEDB_ NET001=
Figure 134 Symbols and comments of instance DBs of the safety elements
The emergency OFF and error texts generated from this look like the following:
Emergency OFF:
001BR_010-FN2 Emergency OFF (Text for the emergency off button at the EBF)
001WAS001-SF1 maintenance switch plant (Text for the maintenance switch)
010SB_010_PMEF1 PME-F (Text for a PME-F module)
Error:
Element 001BR_010-FN2 NET001=001BR_010-KF021.5 error
Element 001WAS001-SF1 NET001=001WAS001-FN029.2 error
Element 010SB_010-PMEF1 NET001=001EK_111-KF024.1 error
Figure 135 Example emergency OFF and error texts of the safety elements

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Further examples for emergency OFF/shutoff alarms:
Input safety elements:

Symbols: Comments:
SEDB_001BR_010-FN2 NET001=001BR_010-KF021.5, Operating comp. emerg. off
SEDB_001WAS001-SF1 NET001=001WAS001-FN029.2, maintenance switch plant
SEDB_010RB_100 NET001=010RB_100-KF080.1, Robot
SEDB_010STU_001 NET001=010STU_001-FN040.2, emergency stop door
Output- or switch off safety instance datablocks:

SEDB_010SB_010-PMEF1 NET001_001EK_111-KF024.1, PME-F
1. 2. 3. 4.
1. Function group (if a classification identification is required, this is separated using a
“minus” sign/see –FN2)
In the case of a PME-F, following the function group designation there is the module
designation with sequential module number.
2. fixed entry NET001

3. RUPLAN designation (-FG – module number)
4. separated by a comma + 1 blank space the name (description) of the safety element
follows

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4.4. Interface to the standard (non-safe) program
The following illustration shows the connection between safe and non-safe programs. Non-
safe signals that are queried in the F program are already described in the chapter Sequence
Group FC1601.
The signals from the safety program that are queried in the non-safe program are described
as follows:
The release outputs (ENBL) of the safety modules are placed on data bits of the safety area-
specific DBs (DB2501-2549). These data bits are available both in the safe and in the non-
safe program sections for logical further processing.
InSafetheinput
non-safe program section, safe input signals must not be queried directly.
signals are basically evaluated using safety FBs (e.g. FB1600). In this way,
both their visual display and the correct reintegration of the safe input module is
ensured.
If safe input signals whose correct reintegration is ensured are needed for queries in
the non-safe program section, these safe input signals are routed in the safe program
section to bit memories and/or data bits of the safety area DBs.
DB2501…2549
Figure 136 Interface between non-safe and F program (example: MS-Lenze 16-bit
architecture)

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4.4.1. Release signal “KeinStop”
If a drive is switched off either using hardware or by a safe stop of the F program, the
function module of the drive must be locked in the non-safe section in order to prevent run
time errors and other errors.
This occurs on all (drive) FCs with the input parameter KeinStop. This parameter must have
one signal if the drive is switched on using hardware (e.g. K0C contactor) and/or is released
with a safe output (e.g. Lenze FU or motor starter).
4.4.1.1. With the use of FB1620, FB1622
For this purpose, the safe output signal that triggers the safe drive (FB1620 – parameter: K1;
FB1622 – parameter: EN_STO) is programmed to the parameter KeinStop directly without
preliminary linking. This has the advantage that the parameter KeinStop can be
programmed directly without preliminary linking and always corresponds exactly to the actual
status of the drive and can be diagnosed using the Simatic reference function.
S7-Anwenderprogramm
FB111 Aufruf Antriebs-FC
S7-Anwender-Failsafe-Programm
FC1801 Aufruf Motorstarter-FB
Figure 137 Parameter “KeinStop” on function group FC (RF)/FB1622 (motor starter)

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4.4.1.2. With the use of FB1623/FB1624
During shutoff by FB1623/FB1624, the safe feedback “ST_STO” must be used by the drive in
the connection of the input parameter “KeinStop” in the standard program. In addition to the
feedback “ST_STO” from the drive, the signal “Ereig_HW_passiviert” and
“Ereig_HW_Fehler” must be programmed according to the following illustration!
The processing of the drive remains active by this network until the drive reports the signal
“ST_STO” = 1 (drive stops).
With the signal query “Ereig_HW_passiviert” and “Ereig_HW_Fehler,” in the case of an error
a “Kein_stop” will be triggered in the function modules.
Figure 138 Parameter “KeinStop” on function group FB with FB1623/1624

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5. Exporting Simatic sources for Integra
With the Integra S7 export tool, the source files are created from the S7 project and made
available to the visual display system.
A detailed description can be found on the Visual Enterprise Server in Vol. III Chapter 26 in
Document 000_B3.26.12.01_PRL_Unterstuetzende_Werkzeuge_Vxx.xx.pdf in the chapter
“Integra Step7 Export-Tool“.
Modules from the F program cannot be generated as sources and also cannot be
exported.

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Index of Abbreviations, Glossary
integra Daimler AG automation standard
DB Data module
FB Function module
FG Function group
FGFC Function group module
FGDB Function group data module
IDB Instance data module
IE Industrial Ethernet
SIS Standard Interpreter System
ISI generator Integrated Software Interface generator
SE Safety Element
I/O coupler PROFIBUS: DP/DP coupler
PROFINET: PN/PN coupler
Index of Illustrations
Figure 1 Change language to english (South Africa) .......................................................13
Figure 2 Name of variables in the FGDB .........................................................................14
Figure 3 Change language to english (South Africa) .......................................................15
Figure 4 Setting the operand field width ..........................................................................16
Figure 5 setting the PG/PC interface ...............................................................................16
Figure 6 Basic application S7 319F-3PN/DP ...................................................................17
Figure 7 project adjustments within the hardware configuration.......................................18
Figure 8 Setting for Comment Management ....................................................................18
Figure 9 Hardware configuration S7 319F-3PN/DP .........................................................19
Figure 10 Properties S7 319F-3PN/DP, General .............................................................20
Figure 11 Properties S7 319F-3PN/DP, Start-up .............................................................20
Figure 12 Properties S7 319F-3PN/DP, Synchronous cycle interrupts ............................21
Figure 13 Properties S7 319F-3PN/DP, Cycle/clock memory ..........................................22
Figure 14 Properties S7 319F-3PN/DP, Retentive memory .............................................22
Figure 15 Properties S7 319F-3PN/DP, Interrupts ...........................................................23
Figure 16 Properties S7 319F-3PN/DP, Time-of-day interrupts .......................................23
Figure 17 Properties S7 319F-3PN/DP, Cyclic interrupts ................................................24
Figure 18 Properties S7 319F-3PN/DP, Diagnostics/Clock..............................................24
Figure 19 Properties S7 319F-3PN/DP, Protection ..........................................................25
Figure 20 Properties S7 319F-3PN/DP, Communication .................................................26
Figure 21 Properties S7 319F-3PN/DP, F parameters.....................................................26
Figure 22 Properties S7 319F-3PN/DP, Webserver deactivated......................................27
Figure 23 Properties of PN-IO, General...........................................................................29
Figure 24 Properties of PN-IO, Addresses ......................................................................30
Figure 25 Properties of PN-IO, PROFINET .....................................................................30
Figure 26 Properties of PN-IO – Synchronization ............................................................31
Figure 27 Properties of Media Redundancy ....................................................................31
Figure 28 Properties of PN-IO, Time-of-day synchronization ...........................................32

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Figure 29 Properties of PN-IO-System, General ..............................................................33
Figure 30 Symbols for function modules..........................................................................38
Figure 31 Symbols for data modules ...............................................................................39
Figure 32 Module overview of basic applications .............................................................42
Figure 33 Module call FG_CPU-DIAGNOSE ...................................................................43
Figure 34 Module call FG_Schrank .................................................................................44
Figure 35 calling of FC4027 depending on the number of main switches and the power
supply concept .....................................................................................................................45
Figure 36 Preliminary links for “FG_PN-DIAGNOSE” in FB54 .........................................49
Figure 37 Module call of the “FG_PN-DIAGNOSE” in FB54 ............................................50
Figure 38 Module call FG_SICH_VI ................................................................................52
Figure 39 Call of Control stand coupling module with FB44.............................................54
Figure 40 DB_TCON_Para_RW_ISOonTCP / connection block OUCW1+OUCW2 ........55
Figure 41 OC Wizard.......................................................................................................56
Figure 42 Module call FG_DFI-COM (FC38) ...................................................................57
Figure 43 Module call FG_WTS ......................................................................................57
Figure 44 Routing binary signals for F program ...............................................................58
Figure 45 Entry of error alarms for the safety elements ...................................................59
Figure 46 Entry of error alarms for the safety elements ...................................................60
Figure 47 Console area: call example for the console function group .............................62
Figure 48 Console area: call example of VI switch indicator light....................................63
Figure 49 Functional group calls in the console area .......................................................63
Figure 50 FT: “U_FEin” of the “Switching On level” edited with VKE = 1 .........................66
Figure 51 FT: “U_FEin” during node failure (e.g. of drives) ..............................................66
Figure 52 FT: “ZP_Freigabe_Eingänge” of a function group during node failure (e.g. drive)
.............................................................................................................................................66
Figure 53 ME: “U_FEin” of the “Switching On level” edited with VKE = 1.........................67
Figure 54 ME: “U_FEin” of an FG during field bus errors of drives and valve terminal .....67
Figure 55 VT: “U_FEin” of the “Switching On level” edited with VKE = 1 .........................68
Figure 56 VT: “U_FEin” of the area level during field bus error of the ET200 ...................69
Figure 57 VT: “U_FEin” of the function group level during node failure e.g. ET200
terminals ..............................................................................................................................69
Figure 58 Additional errors, power main switches 230V and fuse openings.....................70
Figure 59 Creating additional general functions...............................................................71
Figure 60 Routing general additional errors .....................................................................71
Figure 61 Example comments for additional errors in the FGDB .....................................72
Figure 62 Example of routing additional warnings ...........................................................72
Figure 63 Routing auxiliary initiators ................................................................................73
Figure 64 Routing auxiliary alarm ....................................................................................74
Figure 65 Routing externally logged alarms.....................................................................75
Figure 66 Connect additional parameters ........................................................................76
Figure 67 Overview of sequencer organization................................................................77
Figure 68 Module structure of the FG S7-GRAPH sequencer organization .....................79
Figure 69 Options for incorporation of the FG S7-GRAPH sequencer organization .........80

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Figure 70 Example of calling the function group “FG-S7G sequencer” ............................81
Figure 71 Example call of S7-GRAPH sequencer ...........................................................83
Figure 72 Example status display and viewing modes in S7-GRAPH ..............................84
Figure 73 Application settings, General ...........................................................................86
Figure 74 Application settings, Editor ..............................................................................87
Figure 75 Application settings, Compiling/Storage...........................................................88
Figure 76 Application settings, Alarms.............................................................................88
Figure 77 Application settings, Printing............................................................................89
Figure 78 Module settings, Compile/Store .......................................................................90
Figure 79 Module settings, Alarms ..................................................................................91
Figure 80 Module settings, Process Diagnosis ................................................................91
Figure 81 Basic elements for sequence structures ..........................................................94
Figure 82 Example: always animate status of all transitions ............................................95
Figure 83 Example step with adjustable global run time monitoring.................................96
Figure 84 Example of step with fixed global waiting time = transition...............................97
Figure 85 Example of step with adjustable global waiting time = transition ......................97
Figure 86 Example step with adjustable global monitoring time .......................................98
Figure 87 Release of the outputs for following function groups FC ..................................99
Figure 88 Starting release on the function group FC .....................................................100
Figure 89 Alternative branching in sequence sequences ...............................................101
Figure 90 Simultaneous branching in sequencers .........................................................102
Figure 91 Representation of the sequence list...............................................................103
Figure 92 Display of sequence detail = sequence graphic .............................................104
Figure 93 Expert mode for transition .............................................................................105
Figure 94 Expert mode for step .....................................................................................106
Figure 95 FG S7-GRAPH sequence organization..........................................................107
Figure 96 “SmartSync” ..................................................................................................108
Figure 97 Inclusion of a station ......................................................................................109
Figure 98 FC call of expanded function group ...............................................................110
Figure 99 Calling FC22 mechanization special function ................................................111
Figure 100 Calling FC13 motion control screen .............................................................112
Figure 101 Call of FC49 interface to third-party system .................................................113
Figure 102 Structure of the safety program ...................................................................114
Figure 103 OB35 call of the F_CALL .............................................................................118
Figure 104 F_CALL .......................................................................................................119
Figure 105 Safe communication via I/O coupler with FB1524 ........................................120
Figure 106 Sequence group FC1601 (the jump destination list of the safety program) ..121
Figure 107 Preparation of routing signals from the non-safe program section ...............122
Figure 108 Preparation for safety-oriented blink cycles .................................................123
Figure 109 Call of the F_ACK_GL “FB1591” (FB219)....................................................124
Figure 110 Input recording, group alarm variable and output shutoff .............................125
Figure 111 Safe communication via I/O coupler with FB1523 ........................................126
Figure 112 Call structure of the input-side safety elements (sensors) ............................128

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Figure 113 “Local acknowledgement signal”..................................................................129
systems” .............................................................................................................................129
systems and network ON” ..................................................................................................130
Figure 116 Example input recording of an emergency OFF...........................................130
Figure 117 Example editing group fault emergency Stop ..............................................130
Figure 118 Call of FB1611 VI maintenance switch ........................................................132
Figure 119 Call of FB110 KP32F-LED VI-maintenance switch interlock active RED......133
Figure 120 Control of the KP32F-LED “VI-maintenance interlockings active RED .........133
Figure 121 Call structure of the output-side safety elements (actuators) .......................134
Figure 122 Example stepping interconnection of the input recording – safety modules .136
Figure 123 Example interconnection of the output shutoff safety modules .....................137
Figure 124 Example of user protection signal – symbol and comment in DB2532 .........138
Figure 125 Systems PROFISAFE to PNOZ ...................................................................139
Figure 126 System interfaces, safety technology DP/DP coupler ..................................140
Figure 127 System interfaces for safety technology PN/PN coupler ..............................142
Figure 128 Emergency OFF signals to the third-party system .......................................144
Figure 129 Emergency OFF signals from the third-party system ...................................145
Figure 130 VKE0 and VKE1 for the F program ..............................................................146
Figure 131 Alarm structure of the F program .................................................................147
Figure 132 Example of DB1134 emergency OFF ..........................................................148
Figure 133 Example of DB1140 safety element error ....................................................149
Figure 134 Symbols and comments of instance DBs of the safety elements .................150
Figure 135 Example emergency OFF and error texts of the safety elements.................150
Figure 136 Interface between non-safe and F program (example: MS-Lenze 16-bit
architecture) .......................................................................................................................152
Figure 137 Parameter “KeinStop” on function group FC (RF)/FB1622 (motor starter) ...153
Figure 138 Parameter “KeinStop” on function group FB with FB1623/1624 ...................154
Index of Tables
Table 1 Abbreviation for symbols for DB .........................................................................39
Table 2 Abbreviations for symbols for bit memories ........................................................40
Table 3 Conveyor technology field bus node error and associated shutoff level ..............65
Table 4 Mechanization field bus node error and associated shutoff level ........................67
Table 5 Process technology field bus node error and associated shutoff level ................68
Table 6 Parameter “FG_S7G_Kette” ...............................................................................82
Table 7 Parameter “F program/DB classification suggestion” ........................................116

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000 B3.026.02.00 GL-EN Software PLC Part2 CPU319F V50.00

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Peter Stocker (Fa. APM) i.A. PWT/ VAS

Phone: +49 (0)7031-90-81372

Transmission Only with written permission of Daimler AG

Author Peter Stocker (Fa. APM) i.A. PWT/ VAS 2011-12-12

Checked for content by H.P. Müller, FP/ SNT 2011-12-12

Klaus Haigis, PWT/ VAS 2011-12-12

Responsible for document Wolfgang Kochs, FP/ SNT

The original documents can be viewed by arrangement with the person

This document was generated in collaboration with:

Contact persons in the plant:

Project: Daimler AG, Standard integra

No. = Serial number P. = Page number V. = Version of change (document version)

Project: Daimler AG, Standard integra

Document Identification ......................................................................................................... 2

Typographical Conventions ................................................................................................... 2

Update Service ...................................................................................................................... 3

Update journal ....................................................................................................................... 3

Contents of this Document .................................................................................................... 8

1. Setting Up a New Project with integra .......................................................................... 9

1.1. Prerequisites .......................................................................................................... 9

1.2. Project language english .......................................................................................13

1.3. Settings on the Programming Device ....................................................................16

1.4. Entering the Application Creation ..........................................................................17

1.5. Hardware Configuration Adaptations S7-300 ........................................................18

2. Software Structure ......................................................................................................34

2.1. From the System Structure to the Software Structure ...........................................34

2.2. Number Ranges of the Modules ............................................................................34

2.3. Allocation in the User Area ....................................................................................35

2.4. Structure of the Symbols .......................................................................................36

Project: Daimler AG, Standard integra

3. Software Project Planning with integra ........................................................................41

3.1. Basic Application Software Packages ...................................................................42

3.2. System-specific Program Area ..............................................................................63

3.3. Guide Sequencer with S7-GRAPH ........................................................................77

Project: Daimler AG, Standard integra

3.4. Special Cases .....................................................................................................109

4.1. F Program Structure............................................................................................114

4.2. Safety Program ...................................................................................................127

Project: Daimler AG, Standard integra

4.3. Alarm structure of the safety program .................................................................147

4.4. Interface to the standard (non-safe) program ......................................................152

5. Exporting Simatic sources for Integra ........................................................................155

Index of Abbreviations, Glossary ........................................................................................156

Index of Illustrations ...........................................................................................................156

Index of Tables ...................................................................................................................159

Project: Daimler AG, Standard integra

In the event of a contradiction in the project engineering guidelines or tender specifications,

Contents of this Document

Project: Daimler AG, Standard integra

a) The following software packages must be used

b) integra software packages

Basic application S7-319F-3PN/DP: intP5_0x

Standard modules library: intL5_0x

Application examples APPL_PN5

Muster programs iRB_PN5

(intP5_0x, iRB_PN5, iMO_PN5, IFT_PN5) (intL5_0x, intF5_0x) (APPL_PN5)

Project: Daimler AG, Standard integra

The application templates is to

Project: Daimler AG, Standard integra

Project: Daimler AG, Standard integra

Is an example from a device exists, then

C2) HW updates – files for PROFINET

1.2.1. Creating Project in English language

1.3.1. Symbolic address operand field width

1.3.2. Set PG/PC interface

1.4.1. SIMATIC Manager View: S7 319F-3PN/DP

The programmable controller name must also be used in the VISU.

1.5.1. Adaptations for the S7-project

1.5.2. Setting for Comment Management

Detailed explanations on the subject of naming/designation systems are