Welcome

Gearless Drives
PCS7 Training
June 2015

Introduction to the automation part

of the Siemens Gearless Drive system

For reference only / Copyright Siemens AG 2009-2015. All rights reserved

 Course Contents
Introduction

1. Process Control System Introduction

2. Gearless Drive Island Concept
3. Creating a PCS7 Project
4. S7 Program
5. Overview of OB, FC, FB and DB
6. S7 language STL LAD FDB
7. Structure for Gearless Drives
8. Plant View Island structure
9. Example GD CFC (Continuous Function Charts)
10. HW Configuration, Net Pro, Simocode, Analog Value
11. Compiling and download
12. WinCC

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 Course Contents
Introduction

13. Exercises
14. PCS7 Project archiving
15. S7 <-> DCS
16. Miscellaneous

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 PCS7 Overview

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 Process Control System Introduction

Overview of PCS 7

PCS 7 is a process control system that supports you during configuration

with numerous automatic functions so that you can create a project
quickly and conveniently.
When you have become an advanced user, you will also find that
PCS 7 provides a variety of options, with which you can create individual
and project-specific solutions tailored to your specific requirements.

Content of PCS 7

The project is created with the Engineering System, generally abbreviated

to ES. The ES consists of various applications.
All applications provide you with a graphic user interface for simple control
and clear display of your configuration data.

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 Process Control System Introduction

Content of PCS 7
SIMATIC Manager
the central application providing you with access to all other applications
that you use to create a PCS 7 project. The SIMATIC Manager is the
starting point for creating your entire project.

HW Config
configuration of the entire hardware of a system, for example CPUs,
power supply, communications processors.

CFC Editor
for creating CFC charts

PCS 7 OS with various editors

for creating the OS configuration

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 Process Control System Introduction

What is the SIMATIC Manager?

The SIMATIC Manager is the central application and in some ways the "core"
of PCS 7. This is your starting point from which you can open all other
applications in which you make the settings for your PCS 7 project.
The SIMATIC Manager and all other applications are "linked" to each other.
When you start the SIMATIC Manager, for example, you can also see all the
blocks you inserted in a CFC chart with the CFC editor. Another great
advantage of this linking becomes clear when you configure the operator
station. You can access all data you created in the SIMATIC Manager and the
other applications, for example, you can visualize a process tag from a CFC
chart quickly and simply during configuration of the OS. Due to its central
function within PCS 7, it is worth taking time to become familiar with the
structure and functions of the SIMATIC Manager.

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 Process Control System Introduction

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 Process Control System Introduction

Meaning of View in the SIMATIC MANAGER

The SIMATIC Manager provides you with three different views. One important
feature of these views is that the objects they contain exist only once in reality
but can be displayed and manipulated in the various views. Each view has
basically the same structure: In the left-hand pane you see the tree structure
and in the righthand pane the detail window. Each view has its own particular
advantages depending on the task in hand.

Component view this represents the physical memory location of the

individual objects, for example of the charts and blocks. In the Component
view, you can see immediately which blocks and charts belong to which PLC.

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 Process Control System Introduction

Plant view

This shows the hierarchical structure of your plant.

You can divide the plant into sections or units and can see
which charts and which process pictures belong to which plant section.

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 Process Control System Introduction

Process object view

this shows details of the individual objects of the plant view.
This is particularly suitable when you want to assign similar parameter values
to a large number of objects, add comments to them or interconnect them

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 GD Island Concept 1/2
Group overview part 1

Group = .A Interface with others. Main circuit breakers (for converter and excitation
transformers), DCS-Interface
Group = .B Power and control voltage, distribution and supervision
Group = .C Converter transformer supervision
Group = .D Spare
Group = .E Excitation transformer supervision
Group = .F Harmonic Filter (Option)
Group = .G Cycloconverter, supervision of protection equipment
Group = .H Cycloconverter cooling system with heat exchanger, pumps, monitoring equipment
Group = .J Excitation system including excitation cabinet, cooling fan, monitoring equipment
Group = .K Ring motor and monitoring, motor isolators, winding temp. monitoring,
air gap monitoring analog/digital
Group = .L Motor auxiliaries, motor cooling system and monitoring
Group = .M Motor space heating
Group = .N General monitoring, bearing temp monitoring, earth fault monitoring, emergency off
function, fire protection system, PLC-system functions, mill weight

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 GD Island Concept 2/2
Group overview part 2

Group = .M Motor space heating

Group = .N General monitoring, bearing temperature monitoring, earth fault monitoring,
emergency off
Group = .P MLCP and what is related to this panel (start siren, shutdown bell)
function, fire protection system, PLC-system functions
Group = .R Brake system. Panel, calipers, heater, accu pumps
Group = .S Low/high pressure lube system control and monitoring, rundown emergency system,
bearing oil pressure and flow monitoring
Group = .T External cooling system (option)
Group = .U Interface to Closed Loop Control, Closed Loop Control functions
Group = .V Spare
Group = .W Spare
Group = .X E-House air conditioning and heating, air flow and temp. monitoring
Group = .Z E-House lighting

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 GD Process Object View

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 Creating a PCS7 Project

Creating a PCS7 Project

The Project can be created on two ways:

New or New Project Wizard

With New a new Project can be

created manually.

Using the New Project wizard

it will be guided

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 Creating a PCS7 Project

Creating a PCS7 Project

Example: Multiproject
Project Name: New_P
Directory: Training

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 Creating a PCS7 Project

Create in Multiproject

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 Creating a PCS7 Project

Create in Multiproject a Project NEW_AS

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 Creating a PCS7 Project

Insert a Simatic 400 station

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 Creating a PCS7 Project

Select the Simatic Station and Insert the Hardware

According to the station

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 Creating a PCS7 Project

Example:

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 Creating a PCS7 Project

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 Creating a PCS7 Project

Create in Multiproject a Project NEW_OS

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 Creating a PCS7 Project

. Insert a OS

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 S7 Program

after Selection of S7 Program at first the folder Sources, Blocks and

symbols are displayed.

Sources: Folder for STL Source files

Blocks: Folder for OB, FC, FB, DB
Symbols: Folder for Symbolics

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 S7 Program

Adding of Folder for CFC Charts

Insert -> Technological Objects -> CFC

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 S7 Program

Adding of Blocks

Insert -> S7 Blocks

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 Overview of OB, FC, FB and DB

OBS

OB1 is processed cyclically by the CPU. The CPU reads line by line and
executes the program commands. When the CPU returns to the first
program line, it has completed exactly one cycle. The time required for this
is known as the scan cycle time.

Function (FC)

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 Overview of OB, FC, FB and DB

Example insert of FC1

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 Overview of OB, FC, FB and DB

Example insert of FC1

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 Overview of OB, FC, FB and DB

Example FB1

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 S7 Language STL LAD FBD

Choosing Ladder Logic, Statement List, or Function Block Diagram

With STEP 7, you create S7 programs in the standard languages Ladder

Logic (LAD), Statement List (STL), or Function Block Diagram (FBD). In
practice, and for this chapter too, you can select which language to use.

Statement List (STL)

Suitable for users from the world of computer technology, for example.

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 S7 Language STL LAD FBD

Choosing Ladder Logic, Statement List, or Function Block Diagram

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 Structure for Gearless Drives Flags
Allocation Flags <-> Mill Interlockings
For each group exists an area of flag bits with the same signification for
mill interlocking.
All these signals must have signal state high to enable operation of Mill Drive.
(Exception: Start permit only for starting the mill, during operation does not
matter).
M xyz.0 Emergency Off EO
M xyz.1 Gate Blocking GB
M xyz.2 Fast Stop FS
M xyz.3 Normal Stop NS
M xyz.4 Start Permit SP

The Mill is ready for operation, when all groups have Start Permit
(High signal = OK).

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 Structure for Gearless Drives Flags

Example
Flags used for island A

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 Block Structure for Gearless Drives Flags
Block Structure within a Group (Island)
Also a special structure of blocks is used in the PCS7-program for
each group, this structure is equal for all groups, in groups with few or
less functions only some of the blocks are used.
FCxy0 General (Mill interlocks)
FCxy1 Interlocks/Control (Island intern)
FCxy2 }
FCxy3 }
FCxy4 } => free available,
FCxy5 } e.g. for communication tasks
FCxy6 }
FCxy7 Operation Messages
FCxy8 Status
FCxy9 Single Fault Messages
xy - consecutive counting number, equal within one group, for one
group always a range of 10 blocks is reserved

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 Program Structure for Gearless Drives

For every Group a special area of Blocks (FC's, DB's) and Memory Bits is reserved.

Group = .A Functions FC700 - FC709 / Data Blocks DB700 - DB709

Memory Bytes MB 700 - MB 709
Group = .B Functions FC710 - FC719 / Data Blocks DB715 - DB719
Memory Bytes MB 710 - MB 719
Group = .C Functions FC720 - FC729 / Data Blocks DB720 - DB729
Memory Bytes MB 720 - MB 729
Group = .D Functions FC730 - FC739 / Data Blocks DB730 - DB739
Memory Bytes MB 730 - MB 739
Group = .E Functions FC740 - FC749 / Data Blocks DB740 - DB749
Memory Bytes MB 740 - MB 749
Group = .F Functions FC750 - FC759 / Data Blocks DB750 - DB759
Memory Bytes MB 750 - MB 759
Group = .G Functions FC760 - FC769 / Data Blocks DB760 - DB769
Memory Bytes MB 760 - MB 769
Group = .H Functions FC770 - FC779 / Data Blocks DB770 - DB779
Memory Bytes MB 770 - MB 779
Group = .J Functions FC780 - FC789 / Data Blocks DB780 - DB789
Memory Bytes MB 780 - MB 789
Group = .K Functions FC790 - FC799 / Data Blocks DB790 - DB799
Memory Bytes MB 790 - MB 799

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 Program Structure for Gearless Drives

Group = .L Functions FC800 - FC809 / Data Blocks DB800 - DB809

Memory Bytes MB 800 - MB 809
Group = .M Functions FC810 - FC819 / Data Blocks DB810 - DB819
Memory Bytes MB 810 - MB 819
Group = .N Functions FC820 - FC829 / Data Blocks DB820 - DB829
Memory Bytes MB 820 - MB 829
Group = .P Functions FC830 - FC839 / Data Blocks DB830 - DB839
Memory Bytes MB 830 - MB 839
Group = .R Functions FC840 - FC849 / Data Blocks DB840 - DB849
Memory Bytes MB 840 - MB 849
Group = .S Functions FC850 - FC859 / Data Blocks DB850 - DB859
Memory Bytes MB 850 - MB 859
Group = .T Functions FC860 - FC869 / Data Blocks DB860 - DB869
Memory Bytes MB 860 - MB 869
Group = .U Functions FC870 - FC879 / Data Blocks DB870 - DB879
Memory Bytes MB 870 - MB 879
Group = .V Functions FC880 - FC889 / Data Blocks DB880 - DB889
Memory Bytes MB 880 - MB 889
Group = .W Functions FC890 - FC899 / Data Blocks DB890 - DB899
Memory Bytes MB 890 - MB 899
Group = .X Functions FC900 - FC909 / Data Blocks DB900 - DB909
Memory Bytes MB 900 - MB 909
Group = .Z Functions FC910 - FC919 / Data Blocks DB910 - DB919
Memory Bytes MB 910 - MB 919
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 Block Structure for Gearless Drives

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 Block Structure for Gearless Drives

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 Block Structure for Gearless Drives

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 Block Structure for Gearless Drives

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 Block Structure for Gearless Drives

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 Block Structure for Gearless Drives

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 Plant View Island Structure

Internal Group Structure

Each group has the following components / CFC Charts:
(as maximum, some groups have less components,
depends of the technical function in a group).
Common functions xCOMMON
Drives xDRIVE
Analog Values xMEAS
Operation Messages xMESSAGE/xOPERATION
Single Fault Messages xMESSAGE/xSINGLEFAULT

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 Example GD CFC GROUP

Example Group H

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 Example GD CFC COMMON

Extract from HCOMMON

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 Example GD CFC COMMON

Group general interlock

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 Example GD CFC COMMON

Group Emergency off (Page 3)

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 Example GD CFC Drive

Example DRIVE

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 Example GD CFC Drive

Example DRIVE

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 Example GD CFC Drive

Example DRIVE

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 Example GD CFC Drive

Example DRIVE

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 Example GD CFC Drive

Example DRIVE

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 Example GD CFC Analog Value

Example Analog Value

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 Example GD CFC Messages

Example Messages

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 Example GD CFC Messages

Example Messages

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 Example GD CFC Messages

Example Messages

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 Example GD CFC Run Sequence

PCS7 Run Sequence

The Run Sequence of the PCS7 Program has the same structure,
sorted by groups:
H_COMMON General functions Group = .H
H_DRV Drives Group = .H
H_OP Operation Messages Group = .H
H_SF Single Fault Messages Group = .H

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 HW-Config 1/4

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 HW-Config 2/4

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 HW-Config 3/4

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 HW-Config 4/4

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 Netpro

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 Netpro

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 Simocode

A Simocode is connected to the PLC via Profibus DP.

The Relationship slave No / Periphery Address is listed.
Example:

Periphery Addr. Periphery

Designation Description English Slave-No. Motor Current Current Unit Diag. Addr.
PIW Addr. PQW

=.H01 Converter Cooling Pump 1 74 16,9 A 2,4 - 25A 4301 4301 16363
=.H02 Converter Cooling Pump 2 75 16,9 A 2,4 - 25A 4311 4311 16362

=.J01 Exitation Rectifier Fan 76 2,93 A 2,4 - 25A 4331 4331 16329

=.L11 Motor Cooler 1 Fan 1 23 20,85 A 10 - 100A 4021 4021 16360

=.L12 Motor Cooler 1 Fan 2 24 20,85 A 10 - 100A 4031 4031 16359
=.L21 Motor Cooler 2 Fan 1 33 20,85 A 10 - 100A 4041 4041 16358
=.L22 Motor Cooler 2 Fan 2 34 20,85 A 10 - 100A 4051 4051 16357
=.L31 Motor Cooler 3 Fan 1 43 20,85 A 10 - 100A 4061 4061 16356
=.L32 Motor Cooler 3 Fan 2 44 20,85 A 10 - 100A 4071 4071 16355
=.L41 Motor Cooler 4 Fan 1 53 20,85 A 10 - 100A 4081 4081 16354
=.L42 Motor Cooler 4 Fan 2 54 20,85 A 10 - 100A 4091 4091 16353

=.M01 Space Heater 22 33,03 A 10 - 100A 4101 4101 16352

=.R11 Brake Pump 1 45 16,3 A 2,4 - 25A 4111 4111 16351

=.R12 Brake Pump 2 46 16,3 A 2,4 - 25A 4001 4001 16350
=.R14 Brake System Tank Heater 58 0,55 A 0,3 - 3A 4241 4241 16341

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 Simocode

Example:

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 Simocode

Example: Drive H01: Profibus Address: 74 Input-Address 4301 Q-Address 4301

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 Simocode

Example: Drive H01: Profibus Address: 74 Input-Address 4301 Q-Address 4301

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 Analog Value

HW Analog Value

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 Analog Value

HW Analog Value

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 Analog Value

HW Analog Value

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 Analog Value

CFC Analog Value

(IW 1704)

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 Compile Charts as program

With the compile button the charts are compiled.

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 Compile Charts as program

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 Download

With the download button the program is transferred to the PLC.

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 Compile OS

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 Compile OS

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 Compile OS

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 Compile OS

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 Compile OS

The

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 Compiling

The

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 Compiling

Remarks:

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 WinCC

The WinCC Project is opened with right mouse click

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 WinCC

With the runtime Project is started.

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 WinCC Computer Properties

With the computer properties are displayed

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 WinCC Computer Properties

Computer properties: Startup

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 WinCC Computer Properties

Computer properties: Parameters

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 WinCC Computer Properties

Computer properties: Graphics Runtime

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 WinCC Computer Properties

Computer properties: Runtime

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 WinCC Tag Management

In the Tag Management the variables are allocated.

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 WinCC Tag Management

Example: Variables of a TCP IP connection

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 WinCC Graphics designer

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 WinCC Graphics designer

Example

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 WinCC Graphics designer

Open PDL

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 WinCC Graphics designer

Example Drive: Select symbol -> right mouse -> properties

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 WinCC Graphics designer

Example Analog Value: Select symbol -> right mouse -> properties

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 WinCC Graphics designer

Example Status : Select symbol -> right mouse -> properties

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 WinCC Graphics designer Dynamic Wizard

Select: View -> Toolbar

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 WinCC Graphics designer Dynamic Wizard

Analog value
Copy an existing symbol e.g. H03XT01

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 WinCC Graphics designer Dynamic Wizard

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 WinCC Graphics designer Dynamic Wizard

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 WinCC Graphics designer Dynamic Wizard

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 WinCC Graphics designer

Remarks

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 WinCC Alarm Logging

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 WinCC Archives

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 HMI GD Communication Overview
Brief introduction HMI-System

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 HMI Mill Status Overview
Brief introduction HMI-System

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 HMI Help
Brief introduction HMI-System

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 HMI Faceplate Analog Reading
Brief introduction HMI-System

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 HMI Faceplate Drive
Brief introduction HMI-System

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 HMI Group Info
Brief introduction HMI-System

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 HMI Predefined Trends
Brief introduction HMI-System

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 HMI Message System
Brief introduction HMI-System

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 WinCC Exit WinCC Explorer

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 Exercises New DRIVE

Hardware Modification

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 Exercises New DRIVE

Software Modification

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 Exercises New Analog Value

Hardware Modification

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 Exercises New Analog Value

Software Modification

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 Exercises New Message

CFC

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 Exercises New Message

FC

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 Assignments and Exercises

Exercise PLC/ HMI handling

for operational purposes
for maintenance / service purposes
for analysis / trouble shooting purposes

Exercises troubleshoooting

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 Assignments and Exercises

- Creation online trend group for operation monitoring

- Operation evaluation last day
- Check readiness of system for operation / troubleshoot problems
- Exercise HMI Handling
- Find last shutdowns of mill

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 PCS7 Project Archiving / Retrieving

Additional points for archiving / retrieving

First close all applications of the SIMATIC manager as CFC-Charts, Functions,
hardware configuration and so on, when everything is closed, closed the project.
As second step check, if any win-CC system or application is connected and stop
sharing, if necessary (description below)
Then try to start the archiving/retrieving.
If the systems still reclaims active functions, try the WinCC Reset function and
restart the simatic manager, before starting the archiving/retrieving function

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 PCS7 Project Archiving / Retrieving
Step 1 Step 2

Step 3 Step 4

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 SW Language Selection
Language selection is done with: Options - Manage Multilingual Texts - Change Language

After selection of Change language appears the selection mask to opt between English
and Spanish

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 SW Language Selection

Ex. For selection of all messages of one AS select 1 in the left window

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 SW Language Selection

Attention:

Change/add a text needs

to be done always twice,
in English and in Spanish!

For selection of single messages of one island select for ex. Only NSINGLE
(Note: much faster, if you want to change/add only some messages for one island)
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 S7->DCS Overview

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 S7->DCS Drive Status

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 S7->DCS Drive Status

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 S7->DCS Drive Status

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 S7->DCS Analog Values

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 S7->DCS Analog Values

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 S7->DCS Single Faults/Limits

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 S7->DCS Single Faults

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 S7->DCS Single Faults & Limits

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 S7->DCS Actual Signal Status

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 S7->DCS Actual Signal Status

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 S7->DCS First Fail Signal

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 S7->DCS First Fail Signal

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 S7->DCS Actual Values

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 S7->DCS Actual Values

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 S7->DCS Group Status

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 S7->DCS Group Status

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 DCS->S7

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 DCS->S7

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 DCS->S7

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 Addresses

Example

SAGMILL WIN CC Server / Engineering Station for SAG-Mill 1

PLC: SIMATIC S7 / CP443 - Ind. Ethernet 08.00.06.01.01.01 140.80.01.01

CLC: SINAMICS / Ctrl. Signals & Messages

HMI: WIN CC (CP1623) 08.00.06.01.01.04 140.80.01.04

LAN: PCS7-Station 140.80.01.05

DCS: TCP/IP communication 08.00.06.01.01.09 140.80.01.09

DCS: Modbus RTU communication (Option)
DCS: Modbus on TCP communication (Option) 140.80.01.09

SAGMILL1PR HP Color Laserjet Printer 140.80.01.10

SAGMILL1CLC LAN: CLC Engineering Notebook for SAG-Mill 140.80.01.02

SINAMICS SL150 Simotion D4x5 drive control IE2/NET 140.80.01.12

OP177 140.80.01.198

PDA1 Data Recorder for SAG-Mill 1 140.80.01.03

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 Settings for Compilation/ Download

Example

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 User DBs for HMI

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Thank you for your attention!

--

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