Diagnostic options in

TIA environment
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Agenda

1. Introduction
2. Why is diagnostic important?
3. Diagnostic according to development chain
4. Use cases / Live demo
5. How can mistakes be avoid?
6. TIA Portal V16 overview

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Diagnostic
Introduction
Everything at glance and fast reaction

Diagnostic is the perfect solution for determine the

Network

Diagnostic
cause and location of any failure in a technical system. Hardware
Software
Process
...

Webinar‘s Goals
• To know all the diagnostic options available in TIA environment
• Structured approach to project analysis
• Tipps und tricks for error avoidance
• Overview of TIA V16

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Why is diagnostic important?
Why is diagnostic important?
Error tracking

Failures in a plant can have many causes:

• Wire break
• Short circuit
• Component failure
• Programming Errors
• Mechanical Impact(ex. accident with forklift truck)
• …

The primary goal in the event of an error is a fast

localization in order to avoid production downtime.

Especially with sporadic errors the search can

? be very time-consuming

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 Why is diagnostic important?
Advantages and Benefits
High availability of systems due to efficient diagnostic concept

Plant
• Increase productivity
… through fast error detection and troubleshooting

• Costs savings
… having fewer downtimes and production losses

Engineering
• Quality improvement … through a development enviroment that enables error diagnostic

• Time savings during

… through effective diagnostic tools
commissioning and maintenance

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Diagnostic according to development chain
Diagnostic
Best practices during development chain

Planning Installation Engineering Commissioning Operation Service

Electricians

Programmers

Commissioning team

Operators/ service personal

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Diagnostic
Best Practices for electricians
Everything at glance and fast reaction

Goals
• Diagnostics without engineering software and PLC
• Diagnostics of PROFINET networks and devices
• Diagnosis of I/O wiring of decentralized peripheral
devices

Requirements
• Diagnostics for logging system events
• Diagnostics for monitoring regular events

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Diagnostic
Best Practices for programmers
Everything at glance and fast reaction
Program
Goals
• Diagnostic on the engineering software
• Evaluation of diagnostic in the program
• Diagnostics on error events
• Reaction of events within the program

Interrupt OBs
Requirements

Instructions
• Special functions for diagnostic events
• General diagnostic for special events

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Diagnostic
Best practices for service personal
Everything at glance and fast reaction

Goals
• Diagnostics on engineering software
• Diagnostics without software. Ex. Webserver, HMI,…
• Diagnostic of pending or past errors
• Easy and fast implementation

Requirements
• An integrated diagnostic concept for all error messages
• Structured diagnostic concept for fast fault detection to reduce
downtimes
• Detailed text messages

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Diagnostic
Best practices for operators and maintenance
Everything at glance and fast reaction

Goals
• Fast diagnostic of pending or past errors without errors without
engineering software
• Diagnostic through devices ex. HMI

Requirements
• An integrated diagnostic concept for all error messages
• Structured diagnostic concept for fast fault detection to reduce
downtimes
• Detailed text messages

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Use cases and live demos
Diagnose
Use case description
DigiDemo machine
Initial Situation
The DigiDemo machine serves as a demonstration platform for
digitization applications. To enable the Siemens regions to
demonstrate the digitization cases to their customers
worldwide, it was decided to produce a new one.

Process
• Mechanic: Build the machine
• Electrician: wire the machine according to the diagram
• Programmer: Project Planning & Development
• Commissioner: Commissioning of the machine
• Operator: Operation of the machine
• Service: Troubleshooting

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Diagnostic
Use case description
DigiDemo machine

Goal What diagnostic

Each of the previous groups of the development options exist ?
chain is looking for a way to diagnose errors so they
can quickly identified and corrected them to save
time and effort.

The mechanic has finished the construction of the

machine, so it can be wired.

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Diagnostic options
in TIA enviroment
When can be used which one?

Topology View System diagnose PLC Display Hardware-Diagnose

LEDs
Network View
Device View Breakpoints
Webserver HMI
Process Diagnostic
Communication Diagnostic
TIA Portal-Online Network Diagnostic
ProDiag functions Trace PRONETA
Script-Diagnose
Diagnose in the Application Examples in SIOS
Instructions
Program Error-OBs Force Table
Channel-Diagnostic
Alarm Class DiagnoseBuffer User Defined Alarms
SIMATIC Automation Tool
Alarm Groups Watch Tables
Software-Diagnose

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Use cases

Live demo
Use case 1: Wiring error
Use case 2: Incorrect wiring
Use case 3: Programming error
Use case 4: Alarming in program
Use case 5: Firmware update
Use case 6: Configuration error
Use case 7: Process failures
Use case 8: Sporadic failures
Diagnostic
Use case description and tools selection

Electrician Use Case: Wiring error.

The electrician has connected all devices of Digidemo machine according
to the topology sent by engineering. The electrician checks with
PRONETA if the wiring is correct.

ET200SP can not be found in the network!

Reason: cable defective, ...!

How the failures can be diagnosed?

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Diagnostic
PRONETA- Network Analysis!

PRONETA,
• the PROFINET Network analyzer is a free tool
• Provides a quick overview of the devices connected to PROFINET

Network Analysis
… PROFINET is automatically scanned and PRONETA
shows, compares, exports and imports the topology
overview.

Without PLC and engineering system

… check the multiple use of IP addresses and PN names
easily, quickly and at an early stage

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Diagnostic
Cabel test
Diagnostic in the hardware

Diagnostic on LEDs
• Most SIMATIC modules (ex. Decentralized periphery) have
LEDs through which basic diagnostics can be performed.
• Diagnostic via LEDs provides operating information status of
the device about internal/external errors.
• LEDs could help to localize an error.

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Diagnostic
Use case description and tools selection

Electrician Use Case: Hardware failure on a ET200SP

Before the electrician starts with the signal wiring, He must check the IO
of all the ET200SP, he suddenly finds
a channel of a ET200SP is not working!
Commissioning
Engineer Reason: Hardware Failure...!

How the failures can be diagnosed?

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Diagnostic
PRONETA- IO-Signals check and record!

PRONETA
• It is a PROFINET network analyzer is a free tool
• IO checking and documentation of IO wiring for
decentralized peripherals

IO-Check
… during installation without engineering system
… document the test results quickly and easily

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Diagnostic
Use case description and tools selection

Programmer
Use Case: Programming error
The engineer has finished the program, now he has to test it with
PLCSIM Advanced in order to deliver it to the Commissioning engineer.
The programmer realized that as soon as he download the project,
the PLC changes to STOP and can no longer be set to RUN.
An error message „Cycle time has been exceeded“ is displayed in the
diagnostic buffer in the TIA Portal.

Reason: recursive blocks calls, logic errors...!

How the failures can be diagnosed?

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Diagnostic
Program diagnostic
Program diagnostic

Within TIA Portal different Diagnostic functions can

be found:

• Online Diagnostic > Diagnostic Buffer

• Online Diagnostic > CPU Cycle Time
• Program Info > Module Calls
• Program status
• Breakpoints
• Offline/Online – Device Comparison

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Diagnostic
Use case description and tools selection

Programmer Use case: Detect event and generate message

The engineer has used system functions and error OBs in the user
program so that the operator can quickly recognize and correct events.
He has programmed monitoring with Program_Alarm and parameterized
the failures with ProDiag and messages are generated according with the
current faults.

How the programming failures can be diagnosed?

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Diagnostic
Reacting to errors and generating messages within the program

Call functions
Block inside OB‘s

Diagnosedaten
3

senden
1

Monitor
Code Program Operands

Detect errors
2

Programming Parametrizing
Program_Alarm with ProDiag

4
Reacting with 2 User message
the program

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Diagnostic
Use case description and tools selection

Comissioning Use Case: Firmware discrepancy

Engineer The DigiDemo is mechanically and electrically ready and the programmer
has send the project, so the commissioning engineer on site can start up
the software commissioning, but when is trying to download an error
appears because.
The firmware of the project and the real PLC are different!

Reason: Differences between hardware that has been configured in TIA

Portal and the real one.

How the failures can be diagnosed?

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Diagnostic
Possibilities to update the firmware
Diagnostic with TIA Portal

• TIA Portal > Online Diagnostic> Functions>

Firmware Update

• PLC-Memory Card

• SIMATIC Automation Tool

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Diagnostic
Use case description and tools selection

Electri cian
Use Case: Configuration error
After the firmware update, the commissioning enginner could load the
project into the PLC:
Die ET200SP is not reachable but the leds are blinking!
Commissioning Possible reason: PN Name is missing, wrong modules...!
Engineer
How the failures can be diagnosed?

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Diagnostic
Program test
Program diagnostic

Available options for Online Diagnostic with TIA

Portal:

• Topology, device and network view

• Symbolic status display of the IO-Station
• Diagnostic with LED directly in the module

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Diagnostic
Use case description and tools selection

Operator
Use Case: Process failures
The operator of the machine has remote access to the machine, however
can not start the DigiDemo machine or find the cause!

Possible reason: Conditions not fulfilled...!

How the failures can be diagnosed?

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Diagnostic
Alarm view
HMI visualization
System diagnostic
Display messages from the diagnostic buffer of all integrated connections

Alarm view
Display current alarms during runtime

ProDiag-View
Display of the current status of the configured monitoring systems

Graph view
In case of any failure graph view display the step in which the chain is stock, the
previous, the next one and the criteria analysis

Criteria analysis view

Display of the erroneous operands who caused a failure in the user program

PLC-Code- view
Monitoring of the program displaying the current values of the variables
(LAD, FBD,GRAPH)

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Diagnostic
Use case description and tools selection

Service Use Case: Sporadic errors

The customer finds sporadic errors when positioning a piece at the
conveyor

Possible reason: Positioning error ...!

How the failures can be diagnosed?

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Engineering
Trace
Sporadic errors analyzed by trace
Recording of signals from the current program of the PLC at a
defined interval over a certain period of time.

Recording the signals

• can be started manually or with a trigger condition
• is displayed graphically and can be easily evaluated
• is stored and activated on the device
• can be permanently stored as a measurement in the TIA
Portal.

Completed measurements can be viewed via the PLC

webserver.

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How can mistakes be avoid?
How can mistakes be avoid?
Tipps and tricks
Plant identification system
Avoid time-consuming searches for the failed device by
clearly identifying systems, devices and functions.

Use a plant identification system for uniform and

systematic identification of machines and plants.
X1 Designation of the entire plant

Ex.:= XX.YY - Z.zz X2 Number of the entire system

1234 567 Y3 Name of the main component

Y4 Name of the subgroup within the main component
Z5 Number of the device or module according to the device list
zz (6,7) Serial number of the device, the assembly within the subgroup of
the main component

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How can mistakes be avoid?
Tipps und tricks
Risk analysis
Avoid system downtime by coupling all devices to a key unit,
since a failure of the unit means a complete failure of the
system.

Perform a risk analysis in advance to calculate the cost

of failure and plan your plant based on the results

Plant Priority low high

risk assessment
Hardware Investment *
low high

*high-availability PLC, ring topology, …

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How can mistakes be avoid?
Tipps und tricks
Programming Guideline
Avoid typos, clerical errors and program errors User-programm
in engineering

Use the programming guide line helps to

• create easily readable and understandable program code
• support program code in the diagnosis of program errors
• To ensure easy maintenance and simplified further development
BS

Use the Style guide Checker to detect errors in time and to optimize
your user program before commissioning!

Advantages
• Increased system availability through avoidance of PLC stops
• Time and cost savings
• Less susceptibility to errors

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How can mistakes be avoid?
Tipps und tricks
More Tipps

Avoid message chaos Classify messages by priority and urgency using alarm
classes and groups.

Prevent generate a lot of reports Use ProDiag for generate structured alarm messages

Ensure that the systems synchronize with each other Use the same timestamp for all systems
when using third-party systems.

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TIA Portal – www.siemens.de/tia-portal –
Further information can be found here!
SIMATIC Automation Tool https://support.industry.siemens.com/cs/ww/de/view/98161300
PRONETA http://www.siemens.de/proneta
Programmind StyleGuideLine https://support.industry.siemens.com/cs/ww/de/view/90885040
Diagnostic overview with https://support.industry.siemens.com/cs/ww/de/view/109752283
SIMATIC S7-1200/1500
Diagnostic by SIMATIC und https://support.industry.siemens.com/cs/ww/de/view/21566216
SCALANCE
System Diagnostic with https://support.industry.siemens.com/cs/ww/de/view/68011497
S7-1500
Tutorial Center “Diagnostic” https://cache.industry.siemens.com/dl/dl-
media/707/106656707/att_961750/v3/106656707_TIA_Portal_-
_Tutorial_Center_web/start.htm#!/de/5143

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Thanks for your attention!

SIMATIC System Support

DI FA S SUP

Phone: +49 911 895-4646

E-Mail: simatic.industry@siemens.com

Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features w hich may
not alw ays specifically reflect those described, or w hich may undergo modification in the course of further development of the products. The requested
performance features are binding only w hen they are expressly agreed upon in the concluded contract.
All product designations, product names, etc. may contain trademarks or other rights of Siemens AG, its affiliated companies or third parties.
Their unauthorized use may infringe the rights of the respective owner.

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