Training Document for Comprehensive Automation Solutions Totally Integrated Automation (T I A)

Training Document for Comprehensive Automation Solutions Totally Integrated Automation (T I A) MODULE T I A Training Document Page 1 of 66 Module

This document has been written by Siemens AG for training purposes for the project entitled "Siemens Automation Cooperates with Education (SCE)". Siemens AG accepts no responsibility for the correctness of the contents. Transmission, use or reproduction of this document is only permitted within public training and educational facilities. Exceptions require the prior written approval by Siemens AG (Mr. Michael Knust michael.knust@siemens.com). Offenders will be liable for damages. All rights, including the right to translate the document, are reserved, particularly if a patent is granted or utility model is registered. We would like to thank the following: Michael Dziallas Engineering, the teachers at vocational schools, and all others who helped to prepare this document. T I A Training Document Page 2 of 66 Module

T I A Training Document Page 3 of 66 Module

Page 1. Preface... 6 2. Notes on Using S7-GRAPH... 8 3. Installation of the Software S7-GRAPH... 8 4. Sequence Controls... 9 4.1 Timed Sequence Control... 9 4.2 Process-Dependent Sequence Control... 10 5. Possibilities of Presenting Motional Sequences and Signal States... 11 5.1 Description of the Control Task... 12 5.2 Notation in Chronological Sequence... 13 5.3 Table Form... 13 5.4 Shorthand... 13 5.5 Motional Diagrams... 14 5.6.1 Path-Step Diagram... 14 5.5.2 Path-Time Diagram... 14 6. Configuring the Cutting Apparatus... 15 6.1 Assignment of Signal Elements... 15 6.2 Assignment of Work Elements... 15 6.3 Function Chart according to DIN 40719 Part 6... 15 6.4 Function Chart for the Cutting Apparatus... 16 T I A Training Document Page 4 of 66 Module

Page 7. Generating an S7-GRAPH Program... 17 7.1 Starting the SIMATIC-Manager and Generating a New Project... 17 7.2 Inserting the SIMATIC 300 Station and Opening the Hardware Configuration... 18 7.3 Configuring the Hardware and Transferring it to the Automation Device... 19 7.4 Generating the Symbol Table and Entering the Symbols... 20 7.5 Inserting the S7-GRAPH Function Block... 21 7.6 Opening the S7-GRAPH and Entering the Step Sequence... 22 7.7 The principle of the Sequencer. 23 7.8 Active Step... 23 7.9 Elements of a Sequencer... 23 7.10 Generating the Sequencer according to the Function Chart... 24 7.11 Setting the Properties of the Organization Block OB1... 33 7.12 Editing OB1 and Loading Blocks to Module... 34 8. Test and Diagnostic Functions... 35 8.1 Monitoring the Step Sequence... 35 8.2 Monitoring/Manipulating Variables... 35 8.3 Controlling the Sequence... 36 8.4 Synchronization... 37 8.5 Diagnostic Functions... 39 9. Configuring the Cutting Apparatus with Supplementary Conditions... 41 9.1 Description of the Supplementary Conditions... 41 9.2 Assignment of Signal Elements... 42 9.3 Assignment of the Working Elements and Indicator Lights... 42 9.4 Inserting the Supplementary Conditions in the Control Program... 43 9.5 Hierarchy of the Supplementary Conditions... 43 T I A Training Document Page 5 of 66 Module

Page 10. Programming the Supplementary Conditions... 45 10.1 Open Symbol Table and Supplement Signals... 45 10.2 Generating a Function F for the Supplementary Conditions... 46 10.3 Open Function F and Input Networks... 47 10.4 Open Function Block FB1 and Make Changes... 50 10.5 Additional Actions and Events... 53 10.6 Setting the Block Properties... 55 10.7 Accept Block Settings and Save Function Block FB1... 56 10.8 Changing OB1... 57 10.9 Transferring the Program to the Module... 60 11. Parameters of S7-GRAPH FB... 61 11.1 Parameter Records of the FB... 61 11.2 Input Parameters of S7-GRAPH FB... 62 11.3 Output Parameters of S7-GRAPH FB... 65 The following symbols serve as a guide through the Module: Information Programming Notes T I A Training Document Page 6 of 66 Module

1. PREFACE In terms of its contents, Module is part of the teaching unit entitled 'Programming Languages. Fundamentals of STEP7 Programming 2 to 3 days Module A Additional Functions of STEP7Programming 2 to 3 days Module B Plant Simulation with SIMIT SCE 1 to 2 days Module G Programming Languages 2 to 3 days Module Industrial Fieldbus Systems 2 to3 days Module D Process Visualization 2 to3 days Module F Frequency Converter at SIMATIC S7 2 to 3 days Module H IT Comminication with SIMATIC S7 2 to 3 days Module E Learning Objective: In module, the reader learns how to program a step sequence control by using the graphic programming tool S7-GRAPH. The following steps, including a detailed example, are discussed. Installing the software Introducing types of sequential controls, and showing how to represent motional sequences, control states, signal flow and motional diagrams. Preparing a simple motional sequence, represented as path-step diagram. The associated sequence control is generated in STEP7-GRAPH as a step sequence program Using test and diagnostic functions, the principle of operation of the generated program is checked. By adding to the task definition supplementary conditions, the expanded functions of S7- GRAPH are shown. T I A Training Document Page 7 of 66 Module

Prerequisites: To successfully work through module, the following knowledge is assumed: Knowing how to handle Windows Fundamentals of PLC programming with STEP 7 (for example, Module A3 'Startup PLC Programming with STEP 7) Hardware and software required 1 PC, operating system Windows 2000 Professional starting with SP4/XP Professional starting with SP1/Server 2003 with 600MHz and 512RAM, free hard disk storage 650 to 900 MB, MS Internet Explorer 6.0 2 Software STEP7 V 5.4 3 Software S7-GRAPH V5.x 4 MPI interface for the PC (for example, PC adapter USB) 5 PLC SIMATIC S7-300 with at least one digital input and output module. The inputs have to be taken to a panel Sample configuration: - Power supply: PS 307 2A - CPU: CPU 314 (minimum requirement) - Digital inputs: DI 16xDC24V - Digital outputs: DO 16xDC24V/0.5 A 1 PC 2 STEP 7 4 PC Adapter USB 3 S7-GRAPH 5 SIMATIC S7-300 T I A Training Document Page 8 of 66 Module

2. NOTES ON USING S7-GRAPH With the programming language S7-GRAPH, the functional scope of STEP 7 is expanded by the capability to graphically program sequence controls. With S7-GRAPH, you will be able to program sequence controls clearly and quickly. The process is broken down into individual steps, and the sequence is represented graphically. The actions to be performed are specified in the single steps. The step enabling conditions for the respective next step (transitions) can be generated in the programming language LAD or FBD. The program language S7-GRAPH corresponds to the sequence language SFC "Sequential Function Chart, specified in the standard DIN EN 61131-3 (IEC 61131-3). When using S7-GRAPH, the following has to be noted: - A prerequisite is the software package STEP7 Professional Basic Version, or STEP7 Basic Software for Students (not STEP 7 Mini!) - The generated programs can be run on CPUs of the SIMATIC S7-300 and S7-400. - Because of the higher memory requirement of the programs, only CPUs starting with CPU 315 are used for industrial applications. - For training purposes, simple step sequences -like the example provided in this document- can be tested starting with CPU 313C/314/314-IFM. 3. INSTALLATION OF THE S7-GRAPH SOFTWARE S7-GRAPH is an option package for STEP 7; that is, it is assumed that STEP7 is installed on your computer (refer to Module A2 Installation of STEP 7 V5.x / Handling the Authorization). S7-GRAPH is shipped on a CD-ROM which includes a diskette. The diskette contains the license key (authorization) that has to be transferred to the PC. It makes using S7-GRAPH possible. It can be transferred back to the diskette to be used on another PC. Starting with STEP 7 Professional V5.3, this license can also be managed via a network. Regarding the topic Installation and Transfer of the Authorization, please refer also Module A2 Installation of STEP 7 V5.x/ Handling the Authorization. To install S7-GRAPH, do the following: 1. Place the CD of S7-GRAPH in the CD-ROM drive. 2. The setup program is now started automatically. If not, start it by double clicking on the file setup.exe. The setup program guides you through the entire installation of S7-GRAPH. To use S7-GRAPH, a license key (authorization) -that is, the right to utilization- is necessary on your computer. You have to transfer it from the authorization diskette to the computer. This happens at the end of the installation. There, the setup program asks you in a dialog box whether you want to execute the authorization. If you select 'Yes, you only have to insert the authorization diskette, and the authorization is transferred to your computer. T I A Training Document Page 9 of 66 Module

4. SEQUENCE CONTROLS A sequence control is a control with a positive step by step sequence: the step enable of one step to the programmed next step takes place depending on the step enabling condition. The step sequence can be programmed in a special way; for example, jumps, loops, branches. Sequence controls can be programmed with S7-GRAPH because the step by step sequence can be represented graphically very simply and quickly. There are two types of sequence controls: 4.1 Timed Sequence Controls In the case of timed sequence controls, the step enabling conditions are dependent only on time. To generate step enabling conditions, the following can be used, for example: timers, time counters, drum controllers or cam mats with constant speed. Program Mat Drive Motor Drive Motor Camshaft T I A Training Document Page 10 of 66 Module

4.2 Process-Dependent Controls In the case of process-dependent sequence controls, the step enabling conditions are solely dependent on signals of the controlled system. To generate the signals, signaling elements such as position switches, buttons, or sensors are used. These recorded signals can also be linked to timing functions. Limit Switch START Valve Cutting Apparatus When the start valve is operated, the cylinder of the cutting apparatus moves forward. After the frontal end position is reached, the position switch is operated, and the cylinder travels back autonomously. T I A Training Document Page 11 of 66 Module

5. REPRESENTATION POSSIBILITIES FOR MOTIONAL SEQUENCES AND SIGNAL STATES The interaction of working elements and control elements can be shown clearly by using suitable representation possibilities. Even if the task definitions are demanding, the relationships can be recognized quickly and reliably. In addition, the simple representation of motional sequences and control states allows for communication on a larger scale among the most diverse experts. Possible representations of motional sequences and signals states - Description of the control task The control sequence is described in the form of a text. - Notation in chronological sequence The motional sequence is described in brief lines. - Table The step by step sequence is entered in a table. - Shorthand Notation With a simplified description of the motions, the sequence can be explained quickly and simply.. - Motion diagram Using position step or position time diagrams, the motional sequence is represented graphically. Moreover, a better overview of the relationships is provided. - Function Chart A function chart is a process-oriented representation of the control task. The function chart replaces or supplements the verbal description, and represents the control task, clearly laid out, with its essential features and the respective applications. S7-GRAPH is a programming language that corresponds to the fundamentals of a function chart. The program example below explains the different possible representations. T I A Trainung Document Page 12 of 66 Module

5.1 Description of the Control Task A control for a cutting apparatus is to be designed. Through the interaction of a feeding unit and a cutting apparatus, rod material is to be cut. The feeding takes place with the feed cylinder (Cylinder B) which, during the forward and backward movement, also moves the pneumatic clamping device (Cylinder A). If the material is inserted against a limit stop, it is held by the clamp (Cylinder C). After that, the cutting process can start (Cylinder D), and at the same time, the clamping device (Cylinder A) can be opened. If the clamping device (Cylinder A) is opened, Cylinder B moves back to its initial position. When the cutting process is completed (Cylinder D), and when the feeding unit has reached the initial position, the clamp (Cylinder C) is opened and a new work operation can begin. The start is triggered by the start button being activated when all cylinders are in the rear end position. Cylinder C Clamp Cylinder D Cutting Cylinder A Clamping Device Cylinder B Feed Function T I A Trainung Document Page 13 of 66 Module

5.2 Notation in Chronological Sequence Cylinder A moves forward and closes the clamping device. Cylinder B moves forward and moves the material up to the fixed stop. Cylinder C moves forward and clamps the rod material into the cutting apparatus. Cylinder A moves back (the clamping device is open) and cylinder D moves forward (cutting). Cylinder B moves back (the feeding unit moves back) and cylinder D moves back. Cylinder C moves back and opens the clamping device. 5.3 Table Step Cylinder A Cylinder B Cylinder C Cylinder D 1 Forward - - - 2 - Forward - - 3 - - Forward - 4 Return - - Forward 5 - Return - Return 6 - - Return - 5.4 Shorthand Notation For the motional sequence, it is often insignificant what kind of task a motion performs. Thus, a motional sequence can be used for the most varied controls. In the case of extensive controls, the motional sequence should first be described in shorthand, since it provides a quick overview of the motions. In the shorthand version, the motions are assigned to characters. Character for the forward motion or the forward stroke of the cylinder: + Character for the backward motion or the return stroke of the cylinder: - For motors, M+ can be used for CW rotation, M- for CCW rotation, and M* for Stop. Parallel motions are written one above the other in shorthand notation. For our example, the shorthand notation looks like this: A- B- A+ B+ C+ D+ D- C- T I A Trainung Document Page 14 of 66 Module

5.5 Motion Diagram 5.5.1 Path-Step Diagram Here, the work flow of a work element is shown; namely, in dependence on the respective steps (step: state change of any unit), the distance traveled is entered. If there are several work elements present for one control, they are shown in the same manner, and drawn one below the other. The relationship is established through the steps. In the case of a path-step diagram, the distance of the step lines is always the same. In addition, the signal lines can be entered in the path-step diagram. For our program example, the path-step diagram looks like this. Element State 1 A S 1 2 3 4 5 6 7 = 1 Step line AND operation of two signals B C D 0 1 0 1 0 1 0 Status line Function line Signal line Limit switch 5.5.2 Path-Time Diagram The path-time diagram is essentially a path-step diagram where in addition, the time characteristics of the motion are indicated by means of a time bar. At the lower end of the diagram, the duration of a motion is displayed. The spacing of the step lines changes depending on the time needed. The number of steps and the type of motion remain unchanged. T I A Trainung Document Page 15 of 66 Module

6. CONFIGURING THE CUTTING APPARATUS To configure the cutting apparatus, a function chart is to be prepared according to the assignment of the signal elements and the work elements. 6.1 Assignment of the Signal Elements S0 Start button S1 a0 Position switch Cyl.A moved back S2 a1 Position switch Cyl.A moved forward S3 b0 Position switch Cyl.B moved back S4 b1 Position switch Cyl.B moved forward S5 c0 Position switch Cyl.C moved back S6 c1 Position switch Cyl.C moved forward S7 d0 Position switch Cyl.D moved back S8 d1 Position switch Cyl.D moved back 6.2 Assignment of the work elements Y1 Y2 Y3 Y4 Valve for Cylinder A move forward/back Valve for Cylinder B move forward/back Valve for Cylinder C move forward/back Valve for Cylinder D move forward/back 6.3 Function Chart according to DIN EN 61131-3 (IEC 61131-3) The function chart is a process-oriented representation of the control task, regardless of its implementation; for example, the operational equipment used. It facilitates the interaction of various technical fields, such as the machine building industry, pneumatics, hydraulics, process engineering, electrical engineering, electronics, etc.. A control task with its essential features is clearly presented in a rough structure (step field) and in a detailed structure (instruction field) with the details required for the respective application. Note Since in the case of the cutting apparatus, two separate work stations (feeding station and cutting apparatus) are involved, the function chart has to be prepared with a simultaneous branch. T I A Training Document Page 16 of 66 Module

6.4 Function Chart for a Cutting Apparatus according to DIN EN 61131-3 (IEC 61131-3) 1 Initial Step S0 Start S7 d0 Cyl.D returned S5 c0 Cyl.C returned S3 b0 Cyl.B returned S1 a0 Cyl A returned & 2 S Move forward Cylinder A S2 a1 3 S Move forward Cylinder B S4 b1 4 S Move forward Cylinder C S6 c1 R Cycl A back 5 6 S Cyl. D forw. S1 a0 S8 d1 R Cycl. B back 7 8 R Cyl. D back S3 b0 S7 d0 & 9 R Cyclinder C back T I A Training Document Page 17 of 66 Module

7. GENERATING AN S7-GRAPH PROGRAM A runnable S7-GRAPH is to be generated from the function chart. 7.1 Starting the SIMATIC Manager and Generating a New Project 1. Click on the symbol New 2. Enter project name 3. Click OK T I A Training Document Page 18 of 66 Module

7.2 Inserting the SIMATIC 300 Station and opening the hardware configuration 1. Highlight project name Cutting apparatus 2. Click on Insert 3. Select Station 4. Click on SIMATIC 300 Station 5. Select SIMATIC 300(1) 6. Double click on Hardware T I A Training Document Page 19 of 66 Module

7.3 Configuring the Hardware and Transferring it to the Automation Device 1. Enter hardware component 2. Save and compile 3. Load hardware to module 4. Close window Note The hardware configuration shown is an example. Hardware should be configured depending on the automation device used. T I A Training Document Page 20 of 66 Module

7.4 Generating a symbol table, and entering the symbols 1. Open directory tree and click on S7 Program(1) 2. Double click on Symbols 3. Enter symbol table 4. Save symbol table 5. Close window Note The addresses of the operands have to be adapted to the respective automation devices. T I A Training Document Page 21 of 66 Module

7.5 Inserting S7-GRAPH Function Block 1. Open directory tree and click on Blocks 2. Click on Insert 3. Select S7 Block. 4. Click on Function Block 5. Select GRAPH as programming language 6. Click OK T I A Training Document Page 22 of 66 Module

7.6 Opening S7-GRAPH and entering the step sequence 1. Click on Blocks 2. Double click on FB1 This opens the S7 GRAPH program Actions or command field Step field The first step of the sequencer is inserted in the block automatically. This step is marked as the initial step, and is active when the sequencer starts. Transition or step enabling condition Error messages and warnings T I A Training Document Page 23 of 66 Module

7.7 The Principle of the Step Sequence A step sequence consists of a series of steps that are activated in a specified sequence, depending on the step enabling condition. Processing a step sequence starts with an initial step or with several initial steps that are located anywhere in the sequencer. As long as the actions of a step are performed, this step is active. When executing several steps simultaneously, all these steps are active. A step is exited when all possibly pending disturbances are remedied or confirmed, and the transition following this step is completed. The next step that follows the completed transition becomes active. A jump to any step of this step sequence or another step sequence of the FB is located at the end of a step sequence. This allows for the cyclic transmission of the step sequence. A sequence end can be placed at the end of the step sequence. The sequence ends by reaching the sequence end. 7.8 Active Step An active step is a step whose actions are processed at the moment. The step becomes active If the conditions of the previous transition are met If it is defined as an initial step, and the step sequence was initialized or If it is called by an event-dependent action 7.9 Elements of a Step Sequence Step and transition Sim branching open Jump Sim branching closed Sequence end Alt branch open Insert step Alt branch closed T I A Training Document Page 24 of 66 Module

7.10 Generating the sequence control according to the function Chart 7.10.1 First Step 1. Double click on Block Comment and Step Name and make inputs 2. Click on Input of the transition 3. Insert And symbol 4. Attach Additional Inputs 5. Enter operands at And symbol T I A Training Document Page 25 of 66 Module

6. Click on Transition T1 7. Click on Step and Transition The second step has been inserted. T I A Training Document Page 26 of 66 Module

7.10.2 Second Step 1. Click on designation field and enter step designation 2. Insert Action 3. With a double click, enter the action to be performed or click on it with the right mouse key, and select Object Properties 4. Enter the transition Possible events Possible standard operations T I A Training Document Page 27 of 66 Module

7.10.3 Third and Fourth Step 1. Click on Transition T2 2. Click on Step and Transition twice to insert steps S3 and S4 3. Enter step designations and actions 4. Enter the transitions T I A Training Document Page 28 of 66 Module

The next steps are inserted with a branch. There are two types of branches Alternative Branch It is inserted after the selected step, and starts with a transition. The steps of an alternative branch are processed only when the transition is completed. The branch can be closed to the left of a transition, or be ended with a sequence end. Close alternative branch Insert sequence end Simultaneous Branch It is inserted after the selected transition, and starts with a step. The steps of a simultaneous branch have to be processed, since they are executed parallel to the basic steps. The branch has to be closed to the left of a step. Close simultaneous branch T I A Training Document Page 29 of 66 Module

7.10.4 Inserting a Branch To insert a branch, it is better to switch to the overview representation. To generate a simultaneous branch, the following has to be done: 1. Click on Transition T4 2. Insert Step and Transition (step S5 and transition T5 are inserted) 3. Click on Transition T4 4. Click on Sim Branch (step S6 is inserted) 5. Click on Transition T5 6. Insert Step and Transition (step S7 and transition T6 are inserted) 7. Click on Step S6. 8. Insert Step and Transition (Step S8 and transition T7 are inserted) 9. Click on Step S8 10. Click on Sim Branch closed 11. Click on Step S7 To enter the actions and transitions, switch again to the single page representation. T I A Training Document Page 30 of 66 Module

7.10.5 Entering actions and transitions of steps five to eight, and inserting the last step 1. Switch to single page representation 2. Enter actions 3. Enter transitions 4. Click on Transition T6 5. Insert Step with Transition T I A Training Document Page 31 of 66 Module

7.10.6 Processing the last step, and inserting the return jump to the first step 1. Enter step designation and action 2. Enter transition 3. Click on Transition T8 4. Insert jump. 5. Enter S1 at the jump label, or click Step S1, so that the jump destination is inserted. Initial state T I A Training Document Page 32 of 66 Module

7.10.7 Setting the Block Properties and Saving the Completed Block Prior to saving the block, the block settings should be changed. 1. Click on Options 2. Click on Block Settings 3. Set size of FB to Minimum 4. Set runnability to autonomously runnable so that the standard FCs are incorporated into the function block 5. Click on Synchronization 6. Click on OK 7. Save block 8. Close S7-GRAPH Note If there are still errors in the block, it cannot be saved. A faulty block can only be generated as source. When storing the block, an associated data block and SFC64 are generated. Both are copied to the directory Blocks. T I A Training Document Page 33 of 66 Module

7.11 Setting the Properties of the Organization Block, and Opening OB1 1. Click on Blocks 2. Double click on OB1 3. In the properties of the organization block, set the programming language FBD 4. Click on OK Note If OB1 should not open automatically after setting the properties, OB1 has to be double clicked once more in the directory Blocks. T I A Training Document Page 34 of 66 Module

7.12 Editing OB1 and loading blocks to the module 1. Change View to function chart FBD 2. Enter block title and network title 3. Click on the input field 4. Open Program Elements 5. Insert FB1 by double clicking 6. Enter block DB1 7. Save OB1 8. Close LAD/STL/FBD 9. Click on Blocks and load blocks to module After the blocks are transferred to the module, the program can be tested. T I A Training Document Page 35 of 66 Module