2 HW SW Comm PDF Free

Hardware and Software Commissioning
SIMATIC S7 Date: 02.12.2005

SITRAIN Training for
Automation and Drives
Siemens AG 2005. All rights reserved. File: SERV2_02E.1
Contents Page
Objectives .......................................................................................................................................... 2
Commissioning Checklist ............................................................................................................... 3
LEDs on the S7-300™ Power Supply ............................................................................................. 4
LEDs on the S7-300™ CPU ............................................................................................................ 5
LEDs on Digital Modules ................................................................................................................. 6
LEDs on the S7-400™ Power Supply ............................................................................................ 7
LEDs on the S7-400™ CPU ............................................................................................................. 8
Performing a Memory Reset and Warm Restart .............................................................................. 9
Hardware Configuration and Parameter Assignment ....................................................................... 10
Inserting a Station .......................................................................................................................... 11
Starting the HW Config Editor ........................................................................................................... 12
Generating a Hardware Setpoint Configuration ................................................................................. 13
CPU Properties: Cycle/Clock Memory ........................................................................................... 14
Saving the HW Setpoint Configuration and Downloading it in Module ............................................. 15
Uploading the Actual HW Configuration into the PG/PC ................................................................... 16
Module Address Overview ............................................................................................................... 17
HW Config: Edit Symbolic Names, Monitor / Modify Variables ...................................................... 18
Monitoring and Modifying Variables ................................................................................................. 19
Saving the Variable Table ............................................................................................................... 20
Opening a Variable Table and Establishing a Connection to the CPU ............................................. 21
Modifying Outputs in the Stop State ................................................................................................ 22
Exercise 1: Performing a CPU Memory Reset and Warm Restart ...................................................... 23
Exercise 2: Retrieving a Project and Save As .................................................................................... 24
Exercise 3: Adapting the Setpoint Configuration ................................................................................. 25
Exercise Preparation: Attaching the Fault Simulation Connector ..................................................... 26
Exercise 4: Testing the Sensor‘s Wiring on the Conveyor Model ....................................................... 27
Exercise 5: Testing the Actuator‘s Wiring on the Conveyor Model .................................................. 28
Exercise 6: Checking the Interface of the TP170B.............................................................................. 29
Exercise 7: Downloading a ProTool Project ........................................................................................ 30
Exercise 8: Downloading the Program ................................................................................................ 31
Exercise 9: Function Test of the Conveyor Model............................................................................... 32
SITRAIN Training for ST-SERV2

Automation and Drives Page 1 Hardware and Software Commissioning
Objectives
Upon completion of this chapter the participant will ...

... know the meanings of the LEDs on the S7 modules
... be able to perform a CPU memory reset
... with the "Monitor/Modify Variables" tool...
• ...be able to create and save a variable table
• ...be able to check the wiring of the sensors
• ...be able to check the wiring of the actuators


Commissioning Checklist
• Perform a CPU memory reset.
• Carry out a CPU warm restart.
• Check the LEDs on the modules.
• Start the SIMATIC Manager.
• Download the hardware configuration
• Check inputs using the Monitor/Modify Variable tool.
• Check outputs using the Monitor/Modify Variable tool.

Checklist The checklist shows the individual preparatory steps for commissioning the
hardware. If you do not want to use the default setting, it may be necessary to
assign parameters to the modules before you check the inputs and outputs.
The individual steps are described in more detail on the following pages.

LEDs on the S7-300™ Power Supply
LED "DC24V" State Reaction of the Power Supply
Continuous On 24 V available 24 V available
Output circuit is overloaded:

• Voltage dip,
• up to 130% (dynamic)
voltage recovery when
Flashing overload no longer exists
• up to 130% (static) • up to 130% (static)

voltage depression,
reduces the service life
Voltage interruption, automatic

Off Short circuit in output circuit recovery when short circuit
eliminated
Overvoltage or undervoltage on the Overvoltage can cause destruction.

Off primary side With undervoltage, automatic
(permissible range: 187V to 264 interruption.
VAC)

LED The power supply has a diagnostic LED "DC24V" on the front side of the
module. Use this LED to determine the state of the power supply.

LEDs on the S7-300 CPU

Status Displays SF = System Fault: group error, programming error or fault from a
( LEDs ) diagnostics-capable module
BATF = Battery fault: battery is empty or is not present
DC 5V = 5V supply voltage present.
FRCE = Lights up when a forcing is active.
RUN = Flashes when the CPU starts up and
is steady on in the RUN mode.
STOP = Is steady on in the STOP mode,
Flashes slowly when a memory reset is requested and
flashes quickly when a memory reset is carried out.
SF DP = System Fault DP: group error in the Distributed Peripherals
is steady on when there is a fault in the distributed peripherals
BUSF (BF) = Bus fault, is steady on when there is an interrupted cable, for
example.
Flashes when there is a station failure, for example

LEDs on Digital Modules
S7-300 S7-400
Status LEDs for every individual channel
Signal state
at the terminals
• Signal state
at the terminals
(for digital inputs)
• Internal state,
before the opto-
coupler
(for digital
outputs)

Status LEDs There are LEDs for diagnostics purposes for every input and output channel on
the module. These LEDs can be helpful in locating program errors.
The LEDs indicate:
• the process state for digital inputs
• the process state for S7-300 digital outputs
• the internal state before the optocoupler for S7-400 digital outputs.

LEDs on the S7-400 Power Supply
"INTF" -> internal

fault "BAF" ->
battery fault
"BATT1F"-> Battery 1 empty or missing
"BATT2F"-> Battery 2 empty or
missing
"DC 5V" -> 5 V OK
"DC 24V"-> 24 V OK
"FMR" Acknowl. switch (Fault Message Reset)
On/Off switch
(Standby)
Battery
compartment
Selection switch for battery monitoring

"BATT INDIC"
"VOLTAGE" selector
3-pin power
connection

Power Supply The power supply (PS) supplies the internal 5V voltage for the modules.
Automatic adjustment is made for line frequencies from 48 to 64 Hz.
LED "INTF" Lights up in the event of internal faults, such as

• Short circuit or overload at 5V/24V
• Standby switch on "0" and impermissible external supply
• Battery fault
LED "BAF" Battery fault. Lights up if the battery voltage on the backplane bus is too low.
Example: No batteries present or battery failure and there is no external power
supply available.
LED "BATT1F/ Lights up in the case of battery reversal, if no battery is present, or the battery
BATT2F" is half discharged. The BATT.INDIC switch for battery monitoring is set to the
1BATT position (for one battery), the 2BATT position (for 2 batteries) or OFF (no
battery monitoring).
LED "DC 5V/DC 24V" Is lit when the 5V/24V DC output voltage is within the tolerance limits and
flashes to indicate voltage recovery after a short circuit or overload.
"FMR" Ackn.Switch Acknowledgement switch for acknowledging and resetting a fault message
when the fault has been eliminated.
ON/OFF Switch Switches the output voltage (5/24 VDC) to 0V and switches off the LEDs by
(Standby) interrupting the control current circuit. (The power supply is then in standby
mode because the primary line voltage cannot be switched off.)

LEDs on the S7-400 CPU
INTF INTF
EXTF EXTF
BUS1F BUS1F
FRCE BUS2F
FRCE
CPU with one interface CPU with two interfaces

Fault LEDs CPUs have fault LEDs that provide first information about an occurred error or
that give the CPU status:
LED "INTF" Indicates an internal fault (error in the user program ).
LED "EXTF" Indicates an external fault (fault in an I/O module).
LED “BUS1F" Indicates a bus fault of the MPI/DP interface.
LED “BUS2F" Indicates a bus fault of the DP interface.
LED "FRCE" Indicates that inputs/outputs are forced.

Performing a Memory Reset and a Warm Restart
RUN-P
RUN RUN
1. Set the mode selector switch to STOP STOP
MRES
STOP
MRES
RUN-P
2. Hold the mode selector switch in the MRES position until RUN
RUN
the STOP LED has flashed twice slowly. STOP
Release the mode selector switch so that it returns to MRES
STOP
the STOP position.
MRES
RUN-P within 1 sec

RUN 3. Turn the mode selector switch to the MRES position once
RUN
more until the STOP LED begins to flash quickly. STOP
STOP
Release the mode selector switch so that it returns to MRES
the STOP position.
MRES
RUN-P
RUN RUN
4. Set the mode selector switch to the RUN-P (RUN)
STOP
position ! (A warm restart is carried out in the transition MRES
STOP from STOP to RUN/RUN-P)
MRES

Memory Reset When a memory reset is performed on an S7 CPU, the following happens:
• all CPU user data as well as the entire load and work memory are cleared
• the CPU interrupts all connections to other communications partners
• the CPU parameters and all modules are set to default values
• in the case that a memory card is used, the CPU copies the relevant portion
of the stored program needed for execution into the internal RAM
Warm Restart During a warm restart, the process images and the non-retentive data are
deleted. A new cycle begins after the process image input tables (PII) are read
in.

Hardware Configuration and Parameter Assignment
Configuration Assignment of racks, blocks and distributed

I/O in the Hardware Configuration tool.
You can select the components from a
hardware catalog.
Parameter assignment Parameter assignments such as retentive

areas, scan cycle time, and set-up of
analog input cards
Setpoint configuration Planned hardware configuration and

parameter assignment.
Actual configuration Actual configuration and parameter assignment

of existing hardware.

HW Configuration The modules are supplied from the factory with preset parameters. If these
default settings are OK, a hardware configuration is not necessary.
A configuration is necessary:
• if you want to modify preset parameters or addresses of a module (such as
to enable the hardware interrupt of a module)
• if you want to configure communication connections
• with stations that have distributed peripherals (PROFIBUS-DP)
• with S7-400™ stations that have several CPUs (multicomputing) or
expansion racks
• with fault-tolerant programmable logic controllers (option package).
Setpoint When you configure a system, a setpoint configuration is created. It contains a

Configuration hardware station with the planned modules and the associated parameters. The
PLC system is assembled according to the setpoint configuration. During
commissioning, the setpoint configuration is downloaded to the CPU.
Actual Configuration In an assembled system, the actual existing configuration and parameter
assignment of the modules can be uploaded from the CPU. This creates a new
HW station in the project.
A configuration upload is necessary, for example, if the project structure does not exist locally at the PG.
After the actual configuration is read out, you can set parameters and add part
numbers.
Notes With the S7-400™, the CPU can be assigned parameters in such a way, that
when there are differences between the setpoint configuration and the actual
configuration, the CPU startup is interrupted.
To call the HW Config tool, there must be a hardware station in the SIMATIC®
Manager.

Inserting a Station

Insert Station
You insert a new station in the current project by selecting the menu options
Insert -> Station -> SIMATIC® 300 Station or SIMATIC® 400 Station.
You can then change the name that is automatically given to this station -
"SIMATIC® 300 (1)" - to one of your choice.

Starting the HW Configuration Editor

HW Config This tool helps you configure, assign parameters to and diagnose the hardware.
Starting HW Config To start the HW Config tool:

• select a hardware station in the SIMATIC® Manager and choose the
Edit --> Open Object menu or
• double-click the hardware object.
"Hardware This is a window in the "HW Config“ application you use for inserting
Configuration" components from the "Hardware Catalog" window.
The title bar of this window contains the name of the project and the station
name.
"Hardware Catalog" To open the catalog:

• select the View -> Catalog menu or
• click the icon in the toolbar.
If “Standard” is selected as the catalog profile, all racks, modules and interface
modules are available in the "Hardware Catalog" window.
You can create your own catalog profiles containing frequently used elements
by selecting the menu options Options -> Edit Catalog Profiles.
You can add Profibus Slaves that do not exist in the catalog later on. To add
slaves, you use GSE files that are provided by the manufacturer of the slave
device. The GSE file contains a description of the device. To include the slave in
the hardware catalog, use the Options -> Install New GSE Files menu and then
Options -> Update Catalog. You will find the new devices in the catalog under
Profibus, additional field devices.

Generating a Hardware Setpoint Configuration

Generating a This means specifying how the modules are to be arranged in the rack. This
Setpoint configuration, specified by you, is referred to as the setpoint configuration.
Configuration
Rack For example, you open a SIMATIC® 300 station in the Hardware Catalog.
Opening the "RACK-300" folder shows the icon for a DIN rail. You can insert this
in the "Hardware Configuration" window by double-clicking on it (or using drag &
drop).
Two rack component lists then appear in the two-part window: a plain list in the
top part and a detailed view with order numbers, MPI addresses and I/O
addresses in the bottom part.
Power Supply If a load current power supply is required double click or use drag & drop to
insert the appropriate "PS-300" module from the catalog in slot no.1 in the list.
CPU You select the CPU from the "CPU-300" folder, for example, and insert it in slot
no. 2.
Slot No. 3 Slot no. 3 is reserved as the logical address for an interface module (for multi-
tier configurations).
If this position is to be reserved in the actual configuration for the later
installation of an IM, you must insert a dummy module DM370 (DUMMY).
"Inserting" Modules From slot no. 4 onwards, you can insert a choice of up to 8 signal modules
(SM), communications processors (CP) or function modules (FM) from the
HardwareCatalog using drag & drop or with a double-click.
The slots on which the selected module can be inserted are automatically
highlighted in green.

CPU Properties: Cycle / Clock Memory
Double-click
Clock Memory Bit 7 6 5 4 3 2 1 0

Frequency (Hz) 0.5 0.62 1 1.25 2 2.5 5 10
Period (s) 2 1.6 1 0.8 0.5 0.4 0.2 0.1

Cycle • "Scan cycle monitoring time (ms):"

- If this time is exceeded, the CPU goes into the STOP mode.
Possible causes why this time is exceeded: communications
processes,
frequently from interrupt events, errors in the CPU program.
- If you have programmed an error OB 80, the scan cycle time is
doubled. After that, the CPU also goes into the STOP mode.
• "Cycle load from communication (%):"
- Communication (such as data transmission to another CPU through
MPI or test functions the PG/PC triggered) is restricted to the specified
percentage of the current scan cycle time.
- Restricting the cycle load can slow down communication between the
CPU and PG.
- Example: Restricting communication to 20% results in a maximum
communication load of 20ms for a scan cycle time of 100ms.
Size of the With the CPU 318-2 and several S7-400™ CPUs, you can specify the size of
Process Image the process image (in bytes). The process image area always begins with input
and output byte 0.
Clock Memory Clock memories are bit memories that change their binary value periodically
(pulse-to-pause ratio 1:1).
Each bit in the clock memory byte is assigned a particular period/frequency.
Example of a flashing light with a flashing frequency of 2Hz :

Saving the HW Setpoint Configuration and Downloading it in Module
Download
(only when CPU
is in STOP mode)

Save You select the Station->Save menu to save the current configuration in the
current project (without generating system data blocks).
Save and Compile When you select the Station->Save and Compile menu or click the
icon in the toolbar, the configuration and parameter assignment data are
also saved in system data blocks.
Consistency Check You select the Station -> Consistency Check menu to check whether it is
possible to generate configuration data from the entries made.
Download in Module You select the PLC -> Download menu or click the icon in the toolbar to
download the selected configuration to the PLC.
The PLC must be in "STOP" mode!
System Data Blocks The system data blocks (SDBs) are generated and modified when you configure
the hardware and compile the hardware configuration. SDBs contain
configuration data and module parameters. When a system data block is
downloaded, it is stored in the CPU‘s work memory.
This makes it easier to replace modules, because the parameter assignment
data is downloaded to the new module from the system data blocks on startup.
In the programming device, the system data blocks are saved under: Project \
Station \ CPU \ S7_program \ Blocks \ System_data.
You double-click the System data briefcase icon to see the list of
system data blocks.
If you use a memory card as Flash EPROM, you should save the SDBs there as
well. That way, the configuration is not lost if you operate without battery backup
and there is a power failure.

Uploading the Actual HW Configuration to the PG/PC

Introduction A configuration is necessary only in the following cases:

• if you want to modify the basic module settings
• for stations with distributed I/O
• for S7-400™ with several CPUs or with expansion racks
You can read out the actual configuration from the CPU and look at the set
parameters in an existing system.
Actual Configuration During startup, the CPU generates an actual configuration. That is, the CPU
saves the arrangement of the modules and allocates the addresses in
accordance with a fixed algorithm. If no parameters have been assigned, the
default parameters defined at the factory are used.
The system stores this actual configuration in system data blocks.
Uploading to PG/PC There are two ways of uploading the actual configuration to the PG/PC:
1. In the SIMATIC® Manager:
select the PLC -> Upload Station menu.
2. In the HW Config tool:
select the PLC -> Upload menu or click the icon.
Storage on PG/PC The actual configuration read from the hardware is inserted as a new station in
the selected project on the PG/PC.
Note When you read out the actual configuration, the order numbers of the modules
cannot be completely identified. For this reason, you should check the
configuration. If required, insert the exact module type of the existing modules.
To do so, choose the module, and then select the Options -> Specify Module
menu.

Module Address Overview
“Address Overview”

Address Views the I/O addresses of the station configured.

Overview Select: View -> Address Overview …
Abbreviations:
R. Rack number
S. Slot number of the relevant module
DP Relevant only when Distributed Peripherals (I/O) are used
IF Interface module ID when programming the M7 system (in C++).

HW Config: Edit Symbolic Names, Monitor/Modify Variables
Once with right

Edit Symbolic Names You can directly access the symbol table from the "HW Config" tool. This allows
you to assign symbolic names to the inputs and outputs during hardware
configuration or at a later date when you can make suppliments or changes.
You open the symbol table with a right mouse click on the module. Select Edit Symbolic Names in the
follow-up box. A section of the symbol table with the relevant addresses is
then opened.
Monitor/Modify You can monitor or modify the addresses of the configured modules directly from
Variables the HW Config tool. The signals of the input modules can be "checked" and the
signals of the output modules can be "controlled" using the Monitor/Modify
(Variables) function.
Product Support Directly from the Internet, you can fetch information on modules or components
Information from the Product Support pages. As well, it is also possible to update HW Config
by incorporating individual components such as new CPUs or new DP devices
into the current STEP 7 version.
Requirements:
The PG/PC has an Internet connection, a browser for displaying Internet pages,
and the function is enabled in the HW Config Settings along with the
specification of the Internet address.
Note "Symbolic Addressing" and the editing of symbol tables is dealt with in depth in
the "Symbols" chapter. The Monitor / Modify Variables function is dealt with in
the "Troubleshooting" chapter.

Monitoring and Modifying Variables

Monitor You can monitor variables in two ways:

• The monitor values can be updated once when you select the Variable ->
Update Monitor Values menu option or click the icon.
• The monitor values can be updated every cycle when you select the
Variable -> Monitor menu option or click the icon.
Modify Procedure for modifying variables:

1. With the left mouse button, click the line in the “Modify Value” column for
the variable that you want to modify.
2. Enter the value in the correct form for the data type selected.
3a. To activate the modify values once, select the Variable -> Activate Modify
Values menu option or click the icon (or item 3b).
3b. To activate the modify values every cycle, select the Variable -> Modify
menu option or click the icon.
4. Use the "Monitor" function to confirm that the modify value has been
entered in the variable you selected.
Modify Value Valid You can make the "Modify value" entered in a table invalid by selecting that
value and clicking on the icon.
The now "invalid" value is displayed like a comment. You can make the modify
value "valid" again when you click on the icon again. Only valid modify
values can be activated.

Saving the Variable Table

Saving the You can use Table -> Save or Table -> Save as... to save a variable table.
Variable Table The first time a variable table is saved, the Save As... dialog window opens.
The Save as ... window allows the user to select the Blocks folder that the
variable table will be stored in.
You can give the variable table any name you choose. The name is inserted as
the symbolic name in the symbol table.
You can reuse saved variable tables for monitoring and modifying, making it
unnecessary to re-enter the variables.

Opening a Variable Table and Establishing a Connection to the CPU
Accessible CPUs
Configured
Directly CPU
connected
Station 11
Station (VAT Station 2 Station 3
CPU from
HW
Station
"Station
2")
PG

Area of Use You can double-click to reopen variable tables that are stored in a Blocks folder
of an S7 program at a later time for test purposes.
However, before you can activate the "Monitor" and "Modify" functions, an online
connection to a CPU has to be established.
Using the menu commands PLC -> Connect to . . . provides three connection
choices: Configured CPU, Direct CPU and Accessible CPU. There are toolbar
icons for connecting to the Configured CPU or Direct CPU.
Configured CPU If the variable table is stored in the Blocks folder of a hardware-dependent S7
program (assigned to a CPU in the project view), a connection to the station with
the MPI address is established. This station was also assigned to the higher-
level CPU with the help of the HW Config tool.
If the variable table is stored in the Blocks folder of a hardware-independent S7
program folder (assigned directly to the project root in the project view), the MPI
address of the hardware-independent S7 program can be established using the
Properties dialog of the program folder while in the online view of the SIMATIC®
Manager.
Direct CPU This menu command establishes an online connection between the active
variable table and the CPU to which the MPI cable from the PG/PC to the
programmable controller is connected. The PG can determine to which PLC it is
connected through the MPI cable.
Accessible CPU This menu command establishes an online connection between the active
variable table and a CPU that you select. If the user program is already linked to
a CPU, this menu command can be used to change the CPU.
Select a CPU to which you want to establish an online connection in the dialog
box. You can choose between configured and accessible CPUs.

Modifying Outputs in the Stop State

Function and The "Enable Peripheral Outputs" function can only be activated when the CPU is
Area of Use in the STOP state. It switches off the output disable of the peripheral outputs
(PQ). This enables you to modify the peripheral output when the CPU is in the
STOP mode.
The "Enable Peripheral Outputs" function is used mainly to check the wiring of
the peripheral outputs. It can, however, also be used to continue to control
actuators in the process, even though the CPU has gone into the STOP mode
because an error has occurred.
What To Do To enable the peripheral outputs, proceed as follows:
1. Open or edit a variable table (VAT) that contains the peripheral outputs that
you want to test or modify
(specify the peripheral outputs byte-by-byte, word-by-word or doubleword-
by- doubleword; you cannot modify individual output bits!)
2. Select the PLC -> Connect to… menu option to establish a connection to the
CPU you want
3. Switch the CPU to the STOP state
4. Enter the appropriate values for the peripheral outputs you want to modify in
the "Modify Value" column.
Examples: PQB 7 Modify Value: 2#01000011
PQW 2 W#16#0027
PQD 4 DW#16#0001
5. Use Variable -> Enable Peripheral Outputs to activate the modifying of the
outputs
6. Use Variable -> Activate Modify Values to modify the peripheral outputs.
7. To assign new modify values, enter these and then activate them with
Variable -> Activate Modify Values
Note Modifying or "Enable Peripheral Outputs" remains active until you deactivate it
using Variable -> Enable Peripheral Outputs or you press the ESC key. When
you change the operating mode of the CPU from STOP to RUN or STARTUP,
the Enable Peripheral Outputs is deactivated and a message appears.

Exercise 1: Performing a CPU Memory Reset and Warm Restart
Memory Re After Inserting a
set Function Manually From the PG Memory Card
- Mode selector - Mode selector - Mode selector in
in “STOP” in “RUN-P” position “STOP” position
position
- Hold mode selector - Menu options: - Insert Memory Card
in “MRES” position PLC -> Diagnostic/Setting (slow flashing of
Request until the “STOP” LED "STOP" LED indicates
-> Operating Mode -> Stop
flashes twice request for memory
Memory (slowly) reset)
- Menu options:
Reset - Release mode PLC -> Diagnostic/Setting
selector (returns -> Clear/Reset
automatically to the
“STOP” position)
- Switch the mode - Confirm memory reset - Switch the mode

selector quickly to the by clicking the “OK” selector quickly to the
"MRES" again and button (fast flashing of "MRES" position and
Perform
release (fast flashing of "STOP" LED release (fast flashing
"STOP" LED indicates memory reset of "STOP" LED
Memory
indicates memory reset being performed) indicates memory
Reset
being performed) reset being performed)
- Menu options:
- Switch mode selector PLC -> Diagnostic/Setting - Switch mode
Perform
to "RUN" or "RUN-P" selector
Warm Restart -> Operating Mode -> to "RUN" or "RUN-
position
P"
Warm Restart position
Task You are to perform a CPU memory reset and check whether the memory reset
was successful.
What to Do 1. Carry out the memory reset according to the steps in the slide above
2. Check the success of the memory reset (only if you have a CPU previous to
Oct. 2002. The memory reset was successful when only system blocks
(SDBs, SFCs, SFBs) are left in the CPU .
In the SIMATIC Manager -> switch to the Online View using
-> double-click on MPI=2 -> double-click on Blocks
Notes When the CPU memory is reset, all user data in the CPU are deleted.
To make sure that no “old” blocks are left in the CPU, a memory reset of the
CPU should be performed. The following takes place during a memory reset:
• All user data are deleted
(with the exception of the MPI parameter assignments).
• Hardware test and initialization
• If an Eprom memory card or a Micro Memory Card is installed, the CPU
copies the memory card contents back into the internal RAM after the
memory reset.
• If no memory card or Micro Memory Card is installed, the preset MPI address
is retained. If, however, a memory card is installed, the MPI address stored
on it is loaded.
• The contents of the diagnostic buffer (which can be displayed with the PG)
are retained

Exercise 2: Retrieving a Project and Save As

Task You are to retrieve a project and save it under the name "My_Project".
What to Do 1. Start the SIMATIC Manager

2. Delete the old project "My_Project" (should it exist):
File -> Delete -> User Projects -> select "My_Project" from the list ->
confirm
3. Retrieve the project “SERV2_A":
File -> Retrieve -> select "SERV2_A.ZIP" from the list ->
acknowledge with "OK" -> select "S7-Courses" from the list of target
directories -> acknowledge message with "YES"
4. Save the project under the name "My_Project"
File -> Save as... -> User projects -> enter "My_Project" as the name ->
confirm
Notes The project contains the program for the conveyor model as you edited it in the
previous course - ST-SERV1, a hardware station and a ProTool/Pro project for
the TP170B.

Exercise 3: Adapting the Setpoint Configuration

Task Since different training units and CPUs are used for the courses, the available
CPU has to be integrated into the setpoint configuration.
During the course, corrections to the hardware configuration also have to be
made.
Note If you have an S7-400 training unit, use the HW Station "S7-400".
What to Do 1. Start the "HW Conf" tool

2. Adapt the hardware configuration for the training unit
3. Exchange the CPU for correct one
4. Save and compile the configuration
5. Download the configuration into the CPU

Exercise Preparation: Attaching the Fault Simulation Connector
Fault simulation connector

Task In the following two exercises, you are to check the wiring of the sensors and
actuators of the conveyor model to the digital input and output modules.
The errors that you are to determine are simulated using a fault simulation
connector. This connector must first be attached to the conveyor model.
What to Do 1. Remove the 32-pin Sub-D plug on the conveyor model

2. Attach the fault simulation connector to the conveyor model
3. Attach the 32-pin Sub-D plug to the fault simulation connector

Exercise 4: Testing the Sensor‘s Wiring on the Conveyor Model

Task In this exercise, you are to check the wiring of the conveyor model‘s sensors to
the digital input modules according to the symbol table (see slide). You will
check the wiring of the actuators in the next exercise.
Note The errors that occur are simulated by the fault simulation unit that you just
attached. Your task is to determine the errors, not to eliminate them!
What to Do 1. Start the "Monitor/Modify Variable" function

SIMATIC® Manager -> PLC -> Monitor/Modify Variable
2. Enter the inputs shown in the slide into the variable table. Activate variable
monitoring using
Insert -> Range of Variables -> as of Address: I 4.0, Number: 8, Display

Format: BIN
3. To check the input wiring, press the sensors on the conveyor model one
after the other and observe whether the associated input states are
displayed on the screen
4. After you have completed the input wiring test, save the variable table under
the name "I/O Conveyor Model"
Table -> Save as... -> in the dialog, open the Blocks folder of the HW Station
"S7_300 _Station" -> enter the object name "I/O Conveyor Model" -> OK
5. Exit the Monitor / Modify Variable function
Result 1st. error: ................................................................................................

Possible Cause: ................................................................................................
2nd. error: ................................................................................................

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

.
Exercise 5: Testing the Actuator‘s Wiring on the Conveyor Model
Example:
Conveyor to the right

Task Now check the wiring of the conveyor model‘s actuators to the digital output
modules using the function "Enable Peripheral Outputs" .
What to Do 1. Open the "I/O Conveyor Model" variable table from the previous exercise
SIMATIC® Manager -> open the Blocks folder of the HW Station
"S7_300_Station" -> double-click on "I/O Conveyor Model"
2. Add the peripheral output byte PAB 0 Display format "binary" to the variable
table
3. Even if it isn‘t necessary here:
Establish a connection to the directly connected CPU
PLC -> Connect to -> Direct CPU
4. Activate the function "Enable Peripheral Outputs"
Variable -> Enable Peripheral Outputs
5. To test the output wiring, enter the state 1 for the respective output in the
column "Modify Value", activate it using and observe whether
the
associated actuator on the conveyor model is energized.

6. Exit the Monitor / Modify Variable function.
Result 1st. error: ................................................................................................

Possible cause: ................................................................................................
2nd. error: ................................................................................................

Possible cause: ................................................................................................
3rd. error: ................................................................................................

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

Exercise 6: Checking the Interface of the TP170B
Loader B6.0.2.16
Transfer
Start
Control
Panel
M OK X
P
I Panel is the only master on bus
Station Parameters
1
Address:
1s
Time-out:
Transfer Settings
OK X NetworkParameters
S7-Transfer Settings OK X
Channel Directories
Transmission Rate: 187,5
kbits\s
Channel 1: MPI
Serial:
Profibus Highest Station: 31
Remote Control
Enable Channel
Channel 2: Properties...
MPI Enable Channel
Remote Control Advanced

Task The interface of the TP170B is to be set up as in the slide, so that the
ProTool/Pro project can then be downloaded from the PG.
What to Do 1. Exit Runtime on the TP170B

2. Press the "Control Panel" button
3. Double-click on the "Transfer" icon
4. Define the settings as in the slide
5. With "OK", accept the settings until you get back to the "Control Panel"
6. Double-click on the "OP" icon
7. Press the "Save Registry" button
8. With "OK", accept the settings until you get back to the screen with the
"Transfer", "Start" and "Control Panel" buttons
9. Press the "Transfer" button. The TP 170B then waits for a connection from
the PG.

Exercise 7: Downloading a ProTool Project

Task You are to download the ProTool/Pro project to the TP170B.
What to Do 1. Open the ProTool/Pro project by double-clicking on the object

"TP170B_Colour"
2. Click on the "Download" icon
3. Acknowledge the messages that follow
4. Exit ProTool/Pro.

Exercise 8: Downloading the Program

Task The "Demo_1" S7 program contains the program for the conveyor model from
the previous course - ST-SERV1.
This program is to be downloaded and in the next exercise the function is to be
tested.
What to Do 1. Select the "Blocks" object from the "Demo_1" S7 program

2. Click on the icon
3. Acknowledge the message "Do you want to load the system data?" with
"No".
4. Switch on the conveyor model with S5 = ON
5. Connect the TP 170B and the PG to the MPI interface and the
ET 200S and the Micromaster to the Profibus interface
6. Carry out a warm restart on the CPU.

Exercise 9: Function Test of the Conveyor Model

System Function The conveyor model is to be operated through a screen on the TP170B as
follows.
System ON/OFF The system is switched on through the "System On" button and off through the
"System Off" button.
When the system is on, you can then set the manual mode or the automatic
mode.
Manual Mode The manual mode is selected with the "Auto/Manual" switch and is accepted
with the "Accept" button.
In manual mode, a part can be moved in the direction of the light barrier with
"Jog right" or in the other direction with "Jog left" as long as the appropriate
button is pressed.
Automatic Mode When the system is on, automatic mode can be selected with the "Auto/Manual"
switch and can be accepted with the "Accept" button.
In automatic mode, the parts are placed on the conveyor in front of the proximity
sensor "Ini1" or "Ini2". After acknowledging with the appropriate "S1" or "S2"
momentary-contact switch, the conveyor moves until the part has crossed the
light barrier. If the conveyor doesn‘t reach the light barrier within 6 seconds, the
conveyor stops and a fault is indicated on an LED on the simulator. This fault
can be acknowledged by pressing the momentary-contact switch I1.0
("T_Ackn_Fault).
The number of completed parts are counted as they cross the light barrier and
are displayed on the output field "Actual_Quantity". When the preset setpoint
quantity is reached, it is indicated on the LED "H4" on the conveyor model. Until
this is acknowledged with the momentary-contact switch "S4", no new transport
function can be started.


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Hardware and Software Commissioning

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

Upon completion of this chapter the participant will ...

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

• Perform a CPU memory reset.

• Carry out a CPU warm restart.

• Check the LEDs on the modules.

• Start the SIMATIC Manager.

• Download the hardware configuration

• Check inputs using the Monitor/Modify Variable tool.

• Check outputs using the Monitor/Modify Variable tool.

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

LED "DC24V" State Reaction of the Power Supply

Continuous On 24 V available 24 V available

Output circuit is overloaded:

• up to 130% (static) • up to 130% (static)

Voltage interruption, automatic

Overvoltage or undervoltage on the Overvoltage can cause destruction.

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

"INTF" -> internal

Selection switch for battery monitoring

SIMATIC S7 Date: 02.12.2005

LED "INTF" Lights up in the event of internal faults, such as

SITRAIN Training for ST-SERV2

CPU with one interface CPU with two interfaces

SIMATIC S7 Date: 02.12.2005

LED "INTF" Indicates an internal fault (error in the user program ).

LED "EXTF" Indicates an external fault (fault in an I/O module).

LED “BUS1F" Indicates a bus fault of the MPI/DP interface.

LED “BUS2F" Indicates a bus fault of the DP interface.

LED "FRCE" Indicates that inputs/outputs are forced.

SITRAIN Training for ST-SERV2

RUN-P within 1 sec

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

Configuration Assignment of racks, blocks and distributed

Parameter assignment Parameter assignments such as retentive

Setpoint configuration Planned hardware configuration and

Actual configuration Actual configuration and parameter assignment

SIMATIC S7 Date: 02.12.2005

Setpoint When you configure a system, a setpoint configuration is created. It contains a

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005

Starting HW Config To start the HW Config tool:

"Hardware Catalog" To open the catalog:

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005

SITRAIN Training for ST-SERV2

Clock Memory Bit 7 6 5 4 3 2 1 0

SIMATIC S7 Date: 02.12.2005

Cycle • "Scan cycle monitoring time (ms):"

SITRAIN Training for ST-SERV2

SIMATIC S7 Date: 02.12.2005