Tips and Tricks Slide Share

2011 Automation Summit
Orlando, FL
Navigating the world of automation

2011 Automation Summit
Title: Top Ten S7 Tips and Tricks
Track: NAPR
Topic: S7 PLCs
Presenter: Nick Shea
Company: DMC

Copyright © Siemens Industry, Inc. 2011. All rights reserved.
Page 2
DMC Company Profile
 Established in 1996, based in Chicago, IL

 Service Companies Nationally & Globally
 Siemens Solution Partner
Global Reach: Czech

Canada
Russia
Georgia
Mexico
China
India
Philippines
Rep.

Page 3
Bio
Nick Shea
Senior Project Engineer at DMC
Engineering Physics
(University of Kansas)
With DMC since 2006

Page 4
Top Ten S7 Tips and Tricks
 You already know the fundamentals of S7 PLC

programming…
 And the mistakes to avoid (thanks, Tim)
 Now, how do you develop, commission and

troubleshoot most efficiently?

Page 5
If you are an…
External Developer:
How do you work most efficiently to provide the highest

value for your customer while increasing project profitability?

Page 6
If you are an…
Internal Programmer:
How do you reduce start-up time for new equipment and

decrease production downtime while making modifications
or troubleshooting controls problems?

Page 7
Now… take your development to the next Level!

Page 8
Tips and Tricks for:
3.Rapid Diagnostics / Troubleshooting
5.Rapid Development
7.Advanced Tools

Page 9
Modular, Object-Oriented
Architecture with FBs and UDTs
#1

Modular, Object-Oriented Architecture with FBs
and UDTs
Best Practices for Controls Design – Generally Accepted
•Consistent Design and Documentation

●
Mechanical Design
●
Electrical Schematics
●
P&IDs
●
Software

and UDTs
Best Practices for Controls Design… also includes:
•PLC and HMI Projects

●
Naming conventions
●
Hardware architecture
•Modular Software Architecture

●
Function Blocks
●
UDTs

and UDTs
System Architecture

and UDTs
Program Architecture
(similar to system architecture!)

and UDTs
Example of High-Level Function Block:

and UDTs
Example of Device Level Function Block utilizing UDTs:

and UDTs
Variables encapsulated by udtHMI_VFD_Control

and UDTs
Variables encapsulated by udtErrors_VFD

and UDTs
Outputs Inputs
Start Start
Stop Stop
Motor Command Speed SP Speed SP Motor I/O

Function Block Engage Brake Engage Brake Function Block
Reset Error Reset Error

Acceleration Acceleration
Motor I/O
Motor Command Command Command Function
Function Block
Block
Start
Stop
Speed SP One variable is used
Engage Brake
Reset Error to pass multiple
Acceleration piecesCopyright
of information Navigating the world of automation
© Siemens Industry, Inc. 2011. All rights reserved.
Page 19
Monitoring Instances of Function
Blocks
#2

Monitoring Instances of Function Blocks
There are two PLC modes and they are toggled in the CPU Properties on the
“Protection” tab: Process Mode and Test Mode.
Default is Process mode.

Switch to Test Mode.
Download the hardware configuration.

Page 21
This option is also shown in the Debug -> Operation dropdown menu from the
Ladder Editor

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Right-click on the block and select “Monitor with Call-Up Path”
Process Mode Test Mode

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Note!
As you probably expect, this does slow down the CPU cycle time so this should
only be used when necessary and always leave the final system with
“Process Mode” checked.

Page 24
Report System Error
#3

Report System Error
Siemens Support Website
FAQ: How can you report S7 system errors in WinCC?
FAQ:
How can you have system error messages from a SIMATIC S7-300 / 400 displaye

Page 26
Report System Error
End Result:
No (0) programming required!

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Report System Error
10 easy steps: (website has screenshots and full instructions)
 Create S7 and HMI stations.

 Add languages. Set “English” as default
 Open the "Report System Error..." dialog in hardware configuration.
 Activate the entries. Choose the OB blocks that will generate messages
 Transfer blocks to the CPU. Download the generated blocks to the CPU.
 Add a connection to the CPU from the WinCC flexible project (if needed)
 Configure alarm settings. Activate Simatic SFM in the alarm procedure.
 Configure alarm viewer to include “S7 Alarms”
 Activate the check boxes in CPU Messages from Simatic Manager
 Start WinCC flexible and enjoy your diagnostic messages!

Page 28
RAM Disk
#4

RAM Disk
• When compiling an S7 project, many small files are read and written.
• RAM Disk is RAM that is used as a disk drive – via 3rd party software.
• RAM Disk is orders of magnitude faster than other forms of storage media.
• We’ve reduced >10 min compile times to <3 min.

Page 30
Auto-Generate Symbol Table
#5

The S7 PLC symbol table allows copy/paste directly from a spreadsheet such as
MS Excel.
•If possible, develop your IO list in a compatible format

•Alternatively, build a tool to convert it to a compatible format
•For example, thousands of IO can be added into the symbol list in a few
minutes.

Page 32

Page 33
Using Local Memory to Parse
Data
#6

Using Local Memory to Parse Data
Split data types into smaller pieces without using ST or SCL.
3. Assign a variable to TEMP memory.
10. Move data into the TEMP memory variable.

Page 35
Using Local Memory to Parse Data
Split data types into smaller pieces without using ST or SCL.
3. Access the TEMP or Local memory using the “L” prefix.

Page 36
Network Node Activating,
Deactivating, and Monitoring
#7

Network Node Activating, Deactivating, and
Monitoring
Dynamically activate and Deactivate

Profibus and Profinet Nodes
Using “D_ACT_DP” SFC12
Examples:
• Modular Machines
• Alternate Machine Configurations

Page 38
Network Node Activating, Deactivating, and
Monitoring
Monitoring Ethernet Nodes using “RDSYSST” SFC51

Page 39
Safety Programming
#8

Safety Programming
• Leverage Siemens safety blocks

Page 41
Safety Programming
• Safety program can be really simple or really complicated depending on the

application.
• Example of implementing simple E-Stop safety functionality:

Page 42
Safety Programming
• Always ON and OFF variables available inside “F_GLOBDB” datablock.

Page 43
Backup DB Data by Generating
Source
#9

Backup DB Data by Generating Source
A simple yet common problem when programming a Siemens Simatic S7-300

PLC is losing the data already stored in the PLC after downloading an updated
data block.

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In the normal case:
If you are simply adding items to the end of a flat data block (not adding items to
a user-defined type (udt) within the data block, for example) then to retain the
values of the data block follow these quick steps.
5.Go online with all of the blocks in Simatic Manager.

6.Copy the online version of the data block whose values you would like to retain
into your offline project.
7.Add the items to end of the data block.
8.Download - your values will be retained.

Page 46
A more complicated change to the data block such as adding items to a udt
used with the data block requires extra steps. Even if you have first saved a copy
of your online values prior to making the change, the values will be lost after you
save the change. Therefore, follow these extra steps.
3.Follow steps 1 and 2 above.

4.Open the datablock and Generate Source for the data block.
File -> Generate Source. This will save a version of your data block;
and the values in a file in the Sources folder.

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10. Make all changes that you need to the data block (not source code)
then Save and Close the data block.
11. Open the Source file you created and compile it. This will set all values in the
data block equal to the values you see in the Source file.
12. Download - your values have been retained.

Page 48
Keyboard Shortcuts
#10

Keyboard Shortcuts
Navigating / Searching
Cross Reference: Ctrl-Alt-Q
Find: Ctrl-F
Find Variables within a FC or FB: Ctrl-Shift-F (search forward)

or
Ctrl-Shift-B (search backward)
Jump to Network: Ctrl-E
Reference Data Interface: Ctrl-R
Open an FC or FB: Ctrl-Alt-O

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Keyboard Shortcuts
Development Shortcuts
New Empty Rung / Network: Ctrl-R
Normally open contact: F2

Normally closed contact: F3
Coil: F7
Empty Box: Alt-F9

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Keyboard Shortcuts
Monitoring / Diagnostics / Other Shortcuts
Monitor: Ctrl-F7
Module Information: Ctrl-D

Page 52
Keyboard Shortcuts
Monitoring / Diagnostics / Other Shortcuts
Operating Mode: Ctrl-I
Download: Ctrl-L

Page 53
Summary

Summary – Top Ten S7 Tips and Tricks
1. Modular, Object-Oriented Architecture with FBs and UDTs

2. Monitoring Instances of Function Blocks
3. Report System Error
4. RAM Disk
5. Auto-Generate Symbol Table
6. Network Node Activating, Deactivating, and Monitoring
7. Safety Programming Basics
8. Using Local Memory to Parse Data
9. Backup DB Data by Generating Source
10. Keyboard Shortcuts

Page 55
Thank You
Nick Shea
nick.shea@dmcinfo.com
www.dmcinfo.com

Page 56

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2011 Automation Summit

Navigating the world of automation

Navigating the world of automation

Title: Top Ten S7 Tips and Tricks

Presenter: Nick Shea

Navigating the world of automation

 Established in 1996, based in Chicago, IL

Global Reach: Czech

Navigating the world of automation

Senior Project Engineer at DMC

With DMC since 2006

Navigating the world of automation

 You already know the fundamentals of S7 PLC

 And the mistakes to avoid (thanks, Tim)

 Now, how do you develop, commission and

Navigating the world of automation

If you are an…

How do you work most efficiently to provide the highest

Navigating the world of automation

If you are an…

How do you reduce start-up time for new equipment and

Navigating the world of automation

Now… take your development to the next Level!

Navigating the world of automation

Tips and Tricks for:

3.Rapid Diagnostics / Troubleshooting

Navigating the world of automation

Navigating the world of automation

Best Practices for Controls Design – Generally Accepted

•Consistent Design and Documentation

Navigating the world of automation

Best Practices for Controls Design… also includes:

•PLC and HMI Projects

•Modular Software Architecture

Navigating the world of automation

Navigating the world of automation

Navigating the world of automation

Example of High-Level Function Block:

Navigating the world of automation

Example of Device Level Function Block utilizing UDTs:

Navigating the world of automation

Variables encapsulated by udtHMI_VFD_Control

Navigating the world of automation

Variables encapsulated by udtErrors_VFD

Navigating the world of automation

Motor Command Speed SP Speed SP Motor I/O

Reset Error Reset Error

Navigating the world of automation

Default is Process mode.

Navigating the world of automation

Navigating the world of automation

Right-click on the block and select “Monitor with Call-Up Path”

Process Mode Test Mode

Navigating the world of automation

Navigating the world of automation

Navigating the world of automation

Siemens Support Website

FAQ: How can you report S7 system errors in WinCC?

Navigating the world of automation

No (0) programming required!

Navigating the world of automation

10 easy steps: (website has screenshots and full instructions)

 Create S7 and HMI stations.

Navigating the world of automation