SICAR Workshop

Standardization framework for Automotive

Vertical - Auto USA / November 2020

siemens.com/automotive
Agenda

1 SICAR Introduction and Overview

2 Programming and Documentation

Day 1
3 Initialization / HMIs and Operation Mode Areas
Core PLC/HMI

4 Safety

5 Production Data

6 Diagnostics

Day 2
7 Tec Units and Device Interfaces
Library

8 Alarming

9 GRAPH Sequence
Siemens Automotive
We support customers to standardize

Higher MTBF and lower MTTR

Shorten commissioning Easy knowhow transfer

Certified suppliers
Clear installation
guidelines Reduced troubleshooting

Compact
Shorten ramp-up

cabinet
Pre-configured HMI screens Pre-validated Hardware and Software
Defined interfaces Common training program
Reusable
projects

Data integration granted Higher acceptance over the time

by the architecture

Easy maintenance Continuous improvements through learnings

Automotive automation standards

EDDI
APA
What is SICAR?
PLC and HMI framework for Customers without own standards

Smart application example -

A part of standardization

Clear framework – defined

“What & How”

Basic Set of “Building blocks”

Innovation based on
TIA
TIA Portal
SICAR
What is our approach? – Help to help themselves

Standardization framework based on SICAR Customer specific standardization based on SICAR

Customer specific application field’s solutions

Experience out of application field’s

Documen- Documen-
tation

Customer Application
tation System-/ System-/
Alarming + Alarming + Process
Basic HMI&PLC
Process

for HMI & PLC

with Examples

Digitalization
Online
Digitalization

Online diagnostic

UseCases
diagnostic
help

Library
help Library
Proven

for
for

Application PLC HMI Application

PLC HMI
project Functions Functions project
Functions Functions
PLC+HMI PLC+HMI

Expand functionalities Application platform

based on TIA Portal Versions “Give a man a fish and you based on TIA Portal
feed him for one day.
Teach him how to fish and you
feed him for a lifetime.”
SICAR
Standardization framework

Ranges of application Automotive industry + OEMs + 1st Tiers Library

Bodyshop Assembly without their own automation standard • PLC templates
→ Based on TIA Portal • HMI templates
• Drives application

Conveyor Battery
Integrated system
HW/SW platform functions
• System diagnostics
• Code viewer
STEP 7/WinCC Adv. IPC/Panels (LAD/FBD/GRAPH)
• Integrated
message system
• SiVArc – HMI
SINAMICS S7-151x F
Standardization framework screen generation

Basic application
Executable basic project Extendable Simple architecture
PLC + HMI = Start up Documentation
GRAP • Online help
H/ • STEP 7 (Project)
LAD/ • WinCC Adv. RT
FBD
SICAR
Coverage of an automation software standard

Customer
Customer specific Customer specific Customer specific Customer specific Tec Customer specific Customer specific Customer specific Responsibility
PLC program HMI screens Units Interfaces Alarms Documentation
application Customer specific
• Process specific • For non-Siemens • Process specific • Automation standard PLC + HMI application
• Application specific • Plant overview
• Tec Units products alarms and description
Customer specific standard @SICAR

FBs, FCs, DBs Station screens

• Faceplates (e.g. Robots..) messages • User instructions
• etc. • application description

Core Core Basic Interfaces for Alarm / Diagnostics Documentation

PLC Project HMI Project Tec Units Siemens products
• Global functions • Menu guided • Pos-Devices • Interfaces incl. State-, • Alarm viewer • Documentation
- Operation modes • Operation mode • Rollerbed Diag.- screens • ProDiag / Viewer - Tec Units
- Panels Managem. • Templates for • Lifter - RF 200/300 Ident • System diagnosis - Online HMI-RT Coverage of
• HMI - Interface • Valves - MV540 • Web Server - Online TIA STEP 7
faceplates
• On/Off device - G120D drive • Profinet Diagnostic SICAR platform
• GRAPH Startup • HMI Styles
• Safety Startup • … - Bool-Variables • SMC Diagnostic • German / English
SICAR

Executable basic
• Templates for Tec • E-stop / Euchner - User Operation • PLC Checksum
PLC + HMI application
Unit Doorsystem • Energy
- E-Meter (E2M)
- EEM
• Production data
- Counter, Shift-Cnt.
- Limits- & Cycle-Val.
- OEE/Trend
• Shift model
• G/S-Drive blocks

PLC HMI Tec Units AddOn Alarms / Diag. Documentation

Workshop Goal

• Create working SICAR project!

• Begin with seed project

• Create:
• 2 x HMI
• 2 x Op Mode Areas
• 2 x Tec Units
• Alarming using ProDiag
• GRAPH Sequence

Page 8
Requirements for SICAR
V4.0

• Software
TIA Portal V15.1 Upd4 and above
• STEP 7 Professional
• STEP 7 Safety
• WinCC Comfort
• ProDiag
• SINAMICS Startdrive

• Hardware
• S7-15xx PLC firmware V2.x
• TPxxxx Comfort Panel HMI 12” and above or IPC with
WinCC Runtime Advanced

• Hardware Simulation
• PLCSIM V15.1 or PLCSIM Advanced V2.0 and above
• WinCC Comfort simulator

• Additional Licenses
• ProDiag tag license for PLC (max. 5 licenses @ 250
supervisions/license)
• ProDiag RT license for Comfort or Advanced

Page 9
SICAR
Provided information
User documentation Getting started

Basic project with examples

Release notes

Where to get SICAR? [email protected]

Page 10
SICAR
Documentation
Alarms/ Documen-
PLC HMI Tec Units AddOn
Diag. tation

• User defined documentation TIA-Portal ES

Available in the TIA-Portal project. Mark and press >Shift+F1>

• User defined documentation on HMI RT

User defined documentation as a PDF file
Video’s

• Multilingual
Implemented languages are English and German
Additional languages can activated by user

Page 11
SICAR
Documentation

• In TIA Portal, press <Shift+F1> while selecting any block,

faceplate, screen, etc. to open its documentation
• Multilingual – select the proper Reference Language.
Documentation is provided in English and German but others can
be added
• The folder \UserFiles\UserDocumentation\en-US\ contains the
document Home.pdf which has links to all other documentation

Page 12
SICAR
Training / Support

Training - Customer Workshop Support

• Customer Workshop • Local SICAR experts

• Local SICAR expert or HQ • SICAR platform support by HQ
• Content : • SICAR tech support E-mail
Getting Started • Yammer (internal to Siemens)
Live Demo with TIA Portal + PLCSIMAdv + model
Q&A • WeChat (China)

• Special training offers case by case • Support offers case by case

Page 13
Tesla Software Template
Getting started

• Tesla software template – sent to line builder

• Tesla template programming conventions – see TS-0011193 Tesla

Siemens Controls Standard

• Tesla template documentation inside Portal project – added on top of

SICAR documentation

Page 14
Project Overview
PLC project structure

Page 16
Project Overview
Where does line builder put screens / logic?

• HMI
• ES project
• User folder

• RT project
• create button on top of 4 more in each Op Mode Area
• create button on top of 4 more in main screen
• create button in 4more pop area

• PLC
• User folder contains user library blocks
• 04_User contains calls to user logic (if not pertaining to
already created Op Mode Tec Unit)

Page 17
Project Overview
Where does Tesla line builder put screens / logic?

• See see TS-0011193 Tesla Siemens Controls Standard

sections 3.2, “Library Structure” and 3.3, “Folder Structure”

• Library

• Use existing structure – do not create vendor company

folder

• Project

• Use existing structure

• Use _Library, _LibrarySafety, and _MasterCopies to hold

library objects

• Use 03_OPMode to store Op Mode Area logic, grouped as

shown for blocks and tags

Page 18
SICAR Naming Conventions
For machine builder

• All naming based on Siemens

programming styleguide

Page 19
SICAR Naming Conventions
For machine builder

DIN EN 81346-1 DIN EN 81346-2

Page 20
Naming Conventions
What are Tesla naming conventions?

• See see TS-0011193 Tesla Siemens Controls Standard

sections 2.6, “Project Naming”; 2.7, “IO Naming”; and 3.4,
“Function Naming”

• Based on ePLAN

Page 21
Terminology
HMI
• Operation Mode: auto, manual, single step, etc.

• Operation Mode Area: logical area running in the same

operation mode (e.g. auto, manual), containing sequences
and devices

• Max. 24 (V4.0), 12 (V3.1)

• HMI/Panel

• HMI: touchscreen
Panel(s)
• Panel: pushbuttons, e.g. Key Panel, pushbuttons

• Max. 32 HMI+panels (V4.0); 8 HMI, 32 panels (V3.1)

• Tec Unit: drag-and-drop PLC FB, UDT, faceplates, screens

for non-vendor specific control (motions, valves, power
on/off) with built-in process diagnostics

Page 22
SICAR
Core PLC project
Alarms/ Documen-
PLC HMI Tec Units AddOn
Diag. tation

• Control ON/OFF
Centralized switch ON / OFF function of the control
• HMI
Management of HMI (IPC / Panels) and Push Button panels
Interface between HMI and PLC (max. 8 HMI)
• Operation mode management
Realize the management of operation modes
12 Operation Mode Areas
Each Operation Mode Area can change operation mode (AUTO, Manual) independently
• Safety: Startup blocks
Example template for E-Stop and F_OUT with feedback control
Example template for an Euchner gate entry device

Page 23
SICAR
Core HMI project
Alarms/ Documen-
PLC HMI Tec Units AddOn
Diag. tation

• Menu guidance

• Operation modes

• Pop-up screens technology

Legends
Operation
Auto / Manual/ Single step
Control ON/OFF
Security dialogs
…

• Overview screens

Page 24
Hands On: Overview of HMI with working simulation

Page 25
Basic Configuration
PLC

The system and clock memory byte are set in the CPU properties under the
corresponding context menu.

MB1 = Clock memory byte

MB2 = System memory byte

Page 26
Basic Configuration
PLC license enable (if used)

Page 27
Basic Configuration
Tesla PLC

• Already set in template project

• See TS-0011193 Tesla Siemens Controls Standard section 2.3,

“PLC Configuration”

• Safety password: safety

• Download password: tesla

• Display screen PIN: 123

• Enable F-activation

Page 28
Constants
Initialize system limits

Customer Responsibility

Modify constants
to lowest value
• Reduce scan load on
PLC
• Free memory of PLC

Page 29
Tesla User Constants
Initialize system limits

Customer Responsibility

Modify constants

• Set quantities

• Set DP-DP IDs (see

TS-0011193 Tesla
Siemens Controls
Standard section 5.4)

Page 30
Hands On: Setup PLC data from previous slides

Page 31
Overview of Cyclic OB
Calling of SICAR blocks

OB1

Page 32
Overview of Cyclic OB
Network 2: PLC initialization

OB1

Page 33
Global Info
Provides user signals

GlobalInfo: provides global signals for use throughout the

SICAR project – do not change

• Number of Operation Mode Areas

• Number of HMIs

• Clock and system byte

• Global safety info

Page 34
Control On/Off
Power on to cell

• The block supports the On/Off function from the HMI with the pop
up dialog or alternative using external pushbuttons.

• The feedback is time monitored, in case of a failure a ProDiag

message are activated.

1. Define Plant identifier as WString

2. Machine builder provides contactor feedback signal

indicating control on and Time On value signal must be
seen before expiring

3. Define remaining default values per example

Page 35
Hands On: Set up PLC init

Page 36
Overview of Cyclic OB
Network 3: Define Op Mode Areas and HMIs/Panels; Safety Decoupling

OB1

Page 37
Config of Op Mode Areas / HMIs
Reminder

Page 38
Config of HMIs
Create a call of PanelHMI for each HMI / Panel

1 5 8

3
9
7

2 10
6

Page 39
Config of HMIs
TypeOfPanelHMI -> constants

Page 40
Config of HMIs
Connect predefined parameters

Parameters are predefined

Page 41
Config of HMIs
User signals

• The following structures are available to the user for assigning signals and
reading the status.

• All other variables in the typePanelHMI structure are for internal use only.

"OpmodePanel".panelHMI[i].inExt. of data type typePanelIn OpmodePanel".panelHMI[i].outExt. of data type typePanelOut

Page 42
Config of Op Mode Areas
Creating new Op Mode Areas

• The block “Opmode" must be called and configured for each

Operation Mode Area used.

• The array index of the variable created at parameter

“structOpmode" must correspond to the number of the Operation
Mode Area (opmodeNo).

• The parameters “1stPanel…16thPanel" are used to assign

configured HMI/Panel to the Operation Mode Area. The number
is derived from the array index of the created variables.

Page 43
Config of Op Mode Areas
User logic above Opmode call
1

• eStop: E-stop values. False → Op Mode Area exits its Op

Mode (auto, manual, single step)
2

• safetyDoor: Safety door signals. False → Op Mode Area

exits its Op Mode if in auto or single step, but not manual

• basicStartCondition: Requirements to run the Op Mode.

False → Op Mode Area exits its Op Mode

Positions Reads inside opMode library block

• posImmediateStop: position to request immediate stop
1 2

• initalPos: position to request initial position (home)

• posStopEndOfCycle: position to request stop end of cycle

1 2

• posOpenDoor: position to request open safety door

• emptyFinish: feedback of request empty line 1

Page 44
Config of Op Mode Areas
User logic above Opmode call

• Alarm: Generates a fault if true. Tie to sequencer

faults, ProDiag states, any other causes of faults
related to the Op Mode Area

Page 45
Config of Op Mode Areas
Statuses readable after Opmode call

• Statuses set by Opmode FC

• For use throughout SICAR project

• opmodeArea, controlNoHMI

• <opMode>Active: auto, manual, single step

• Reset

• Special functions: requests for special modes, e.g. immediate

stop, initial position (home), etc.

Page 46
Config of Op Mode Areas
Statuses readable after Opmode call

• Special function: Additional Op Mode subcategory

• Stop: In auto, immediately stops the sequence in the current step

• End of Cycle: In auto, stops the sequence at the end of a cycle in

the home position

• Home position: In auto or manual, brings the cell back to the

home position

• Release Entry: Request entry using gate

• Single Step/Step +1: In manual mode, steps the sequence

through step by step

• Empty Line: In auto or manual, requests to empty the line

• Without part/Dry run: In auto, runs the cycle without a part

• See network 31 of Opmode FC and the Special Functions

documentation for more details

Page 47
Hands On: Insert second HMI and second Op Mode Area

Page 49
SICAR Safety
What is provided?

• Safety Acknowledge Instruction

• Alarming Function Block

• Provides ability to trigger ProDiag alarms inside

safety logic

• Text list associated with failsafe alarms

• Safety standard coupling

• Euchner Gate switch device / with HMI faceplate

Page 50
Safety Startup
Safety – standard program decoupling

• These data blocks serve as the data interface-DB to transfer data between
the standard and the safety program. This helps avoid direct accesses
between the standard and safety program.

• Data flow:
• standard (write) -> safety (read)
• standard (read) <- safety (write)

• These blocks must be adapted to application/user specific needs.

Standard Program Safety Program

Data Buffer

CallInterfaceStndTo
InterfaceStndToSafe MAIN_FFB
Safe

InstMAIN

InterfaceSafeToStnd

Page 51
Safety Tips
safety – F-Source and Destination addressing

https://support.industry.siemens.com/cs/us/en/view/109740240
Page 52
Hands On: Safety

Page 53
 Overview of Cyclic OB
Network 4: Operation Mode Areas

OB1

• Process logic
• Tec Units / Devices
• Sequences
• Empty in SICAR base
project

Page 54
Overview of Cyclic OB
Network 5: User blocks

OB1

• For anything that

doesn’t fit other
categories
• Empty in SICAR base
project

Page 55
Overview of Cyclic OB
Network 6: Production Data

OB1

Page 56
Production Data
Counter
TIP: To Reset counter,
ensure you click on
• With this block, counters can be realized via a simple user
interface and displayed on a HMI. The value range of the counter dataset to
counters is the data type “UInt“. enable reset

• Call ProdDataCounter for every DataSet required

2

• Program control of data set and counter to increment /

decrement / reset counter

Page 57
Production Data
Shift Counter

• With this block, counters can be realized via a simple user

interface and displayed on a HMI. The value range of the
counters is the data type “UInt“.

• Call ProdDataCounter for every DataSet required

2
• Program control of data set and counter to increment /
decrement / reset counter

Page 58
Production Data
Cycle Timer 3

• Timer displayed on HMI

• Target cycle time

• Current cycle time

• Average cycle time
• Cycle count

• Set user constant NO_OF_DATASETS_CYCLETIMER

• Leave pulse100ms, numberOfDataSets alone

2
• Set dataSet index in brackets 1

• Write to dataSet in network above

• run
• hold
• reset
• resetAverageAllExt

Page 59
Production Data
Limit Values

• numberConfigDataSets
• Maximum of 8 with 10 limit values
• dataSetNumber
• Dataset number of block call
• dataSet
• The parameter is predefined, only the number of
the dataset [1..8] needs to be assigned
• colorCodeSelectButton
• The color-code for the animation of the select
buttons (1..8). The parameter is predefined, on the
number of the dataset [1..8] needs to be assigned.

Do not use the structure with the index [0]. This

index exists only due to the zero-based
calculation of the WinCC RT!

Page 60
 Production Data
Shift Models

• dateAndTime
• The block needs the current date and time for
internal comparisons. The parameter is predefined
and does not need to be modified.
• remoteOnOff
• 0 : Remote Off – use time values in the instance DB
• 1 : Remote On – copy time values from a global DB
into the instance DB
• The time values in the static part of the instance
DB, in the structure “statDayTimesHMI”
• shiftmodelTimesRemote
• Assign a global DB to this parameter. These values
are then transferred to the instance DB.

Page 61
Production Data
Shift Counter + OEE + Trend

2
• OEE trends on HMI separated by shift
Shows target vs. actual performance per shift
• Set user constant NO_OF_DATASETS_SHIFTCOUNTER
• Set dataSetNumber and set dataSet index in brackets
• Tie target and expired times from shift model FB above to
shiftProdTimeTarget, shiftProdTimeExpired
• Leave numberOfDataSets alone
• Write to dataSet in network above
• countPartsCurrent
1
• countPartsCurrentOK

Page 62
Hands On: Production Data

Page 63
SICAR
Alarms & Diagnostics
Alarms/ Documen-
PLC HMI Tec Units AddOn
Diag. tation
1
1• PN Diagnostics (customized)
2
Diagnosis and visualization of PROFINet devices
2• PLC Diagnostics (customized) & SMC Diagnostic
Read and display Times, Ident & Maintenance data, SMC data, PLC-checksum of the PLC
3 3• System diagnostics (WinCC Control)
Overview about the available devices of the installation
4• WEB-Server (WinCC Control)
HTML-Browser provides information about the status of all Webserver based devices
4
(Identification, diagnosis buffer, device status, messages, communication data and
5 topology data)
• Alarming (customized)
Multilingual alarm block package. It is possible to create own alarm texts which can be
activated with a trigger bit and displayed in the WinCC alarm control.
5• Alarming (ProDiag)
6 6
Integrated Process Diagnostic based on ProDiag functionality
6• Code viewer
Integrated Code viewer for Process alarms and GRAPH

Page 64
Overview of Cyclic OB
Network 8: Diagnostics

OB1

Page 65
Diagnostics
Interface Signals Bool

• The block serves as a calling interface of the block

“InterfaceSignalsBool“. The block is designed as
function block in order to implement the block calls as
multi-instances.

• The block “InterfaceSignalsBool“ is called in multi-

instances in this block

Page 66
Diagnostics
PROFINET

• Set plantIdentifier

• Copy constants per right

• Alarm Masks (configurable)

Page 67
Diagnostics
PLC

• PLCDiag: reads PLC I&M data to display on HMI

• Check that localCommon and localPROFINETInterface are

tied to correct system constant

• PLCChecksum: reads in checksums of standard blocks, safety blocks,

and text lists to display on HMI and generates warning if changed

• Set plantIdentifier

• Set correct text list index

• SMCDiag: determines wear on SIMATIC Memory Card (SMC) and

generates warning if limit is met

• Set plantIdentifier

• Set correct text list index

Page 68
Diagnostics
PLC – Set language

• Flag toggles between SICAR languages

• Simply use TIA Portal’s built-in multilingual feature to set multilingual

project texts

Page 69
Diagnostics
Others

• PROFINET diagnostics

• Built-in WinCC control

• Web server viewer

• View PLC or device web

servers

• Video player

• PDF viewer

• View documentation or work

instructions on HMI or
network drive

Page 70
Hands On: Diagnostics

Page 71
Overview of Cyclic OB
Networks 9-12: Demo

• Optional examples OB1

Page 72
User Operation
Custom pushbuttons with feedback

• Located in
\_SICAR_MasterCopies_PLC\UserOperation\

• Set feedback, visibility, and enable in network above

UserOperation call

Page 73
Library
Overview

• Drag-and-drop components on top of core PLC and HMI

• Reusable “black box” components

Page 74
SICAR
Tec Units
Alarms/ Documen-
PLC HMI Tec Units AddOn
Diag. tation

• Device ON / OFF
Tec Unit to control the ON /OFF function of a device with feedback monitoring

• Lifter function
Tec Unit to control a lifting device with 2 speeds, 2 directions and 2 positions

• Positioning devices
Tec Unit to control a positioning device with 1 speed, 2 directions and 2 positions.
Tec Unit to control a positioning device with 2 speeds, 2 directions and 2 positions.
Tec Unit to control a positioning device with 2 speeds, 2 directions und 2 positions,
including part detection

• Roller bed block

Tec Unit to control a roller bed with 2 speeds, 1 direction and 1 position.

• Valve control
Tec Unit to control a valve with 1 cylinder.
Tec Unit to control a valve with up to 8 cylinders.

Page 75
SICAR
Interfaces
Alarms/ Documen-
PLC HMI Tec Units AddOn Diag. tation

1
2 1• Drive
Interface to control a SINAMICS G120 drive

2• Ident
Interface to control read / write functions of data from / to a tag (RF200/RF300),
3
4 read 1D/2D code with machine vision camera MV400/500

• Energy data & EEM

3 Interface to measure and display energy data via AI-EnergyMeter
4 Energy Efficiency Monitor

Page 76
Tec Units
What is a Tec Unit?
• Tec Unit: drag-and-drop PLC FB, UDT, faceplates, screens for non-
vendor specific control (motions, valves, power on/off) with built-in
process diagnostics

• Interface: driver connecting output of Tec Unit to a device (e.g.

G120, RF180C)

Page 77
Tec Units
Overview
• DevOnOff: Switch device on or off with feedback

• Lifter2S2D2P: Lifter with 2 speeds, 2 directions, 2 positions

• PosDevxSxDxP: Positioning device with x speeds, x directions, x positions. Pctrl

indicates part control, or part presence

• RB2S1D1P: Roller bed with 2 speeds, 1 direction, 1 position, including handover

• Valve1(To8)Pos: Valve unit with up to 8 cylinders

Page 78
Interfaces
Overview
• DriveG120: G120 drive with free telegram

• GS120_TELEGRx (SICAR Addon): S120 or G120 V/f, speed control,

and EPos using telegram 1 or 111

• EnergyMeter: up to 8 AI energy meters

• IdentMV: MV400/500 1D/2D barcode reader

• IdentRF: RF200/300 RFID system

Page 79
Tec Units
Integration
• Tec Unit documentation in user documentation

• Guidelines in SICAR_Tec Unit_HMI-Objects in user documentation

Page 80
Tec Units
Integration – FB, faceplate, manual moveline

Page 81
Tec Units
Integration – Diagnostic screen

Page 82
Hands on -> Configure positioning Tec Unit

Page 83
Tec Unit Alarms
What is ProDiag?

ProDiag – Error analysis within

the production process
USP
• Efficient diagnosis of process failures via the
standardized machine and plant diagnostics
Jump into
system ProDiag PLC code
Automatic
• “Integrated” – automated generation of code generation
monitoring data and visualization
• “fast and efficient troubleshooting” – Auto
Update
detailed information about error location,
cause, and correction Configure alarm Visualize
• “reactionless” – programming of monitoring
independent of application code

“PD” in block name designates block containing ProDiag functionality

Page 84
Tec Unit Alarms
ProDiag integrated into blocks
• Each instance of a block
programmed with ProDiag brings in
associated supervisions

• No need to customize alarm text

one-by-one – dynamically created
from a “recipe”
Program_Alarm
ProDiag

Page 85
Tec Unit Alarms
Comparison to Program_Alarm

• Using Program_Alarm, must define static

alarm text in a DB for each type of Tec Unit

• Only dynamic text included in alarms using

Program_Alarm Tec Units = plant identifier
Program_Alarm
ProDiag

Page 86
 Tec Unit Alarms
Comparison to Program_Alarm

Bit Alarm (HMI) Program_Alarm (PLC) ProDiag (PLC)

• Bit Messages must be copied • Centralized timestamp in the • Automatic Visualization of the
in every HMI-Program PLC Alarms
• If Changes are made the HMI • Diagnostics on PLC, • Changes during operation
must be reloaded Webserver and Display • Automatic Code-Generation
• Manual Assignment for PLC- • Strongly fluctuating cycle time • Centralized timestamp in the
Program (Bit assignment) for simultaneous appearing PLC
events
• Timestamp must be • Diagnostics on PLC,
synchronized manually • Increase Programming effort Webserver and Display
(depending on the number of
supervisions)

Integration

Page 87
Tec Unit Alarms
ProDiag block calls

• Calling a block with ProDiag

supervisions requires a ProDiag FB

• ProDiag FBs are auto-generated

system blocks – no need to program
the alarm logic yourself

• SICAR ProDiag FBs are located in

\_SICAR_ProDiag\

• ProDiag FBs have states that can be

queried in PLC program – use these to
easily put an Op Mode Area into the
alarm state

• This essentially acts as an alarm filter

in the PLC

Page 88
Tec Unit Alarms
ProDiag code viewer

• View faulted supervisions on HMI

• Easily correct faults by analyzing PLC

code

• Preconfigured SICAR screen – no

need to configure anything

Page 89
Hands on -> Configure positioning with ProDiag

Page 90
Alarming
Alarms with ProDiag

The blocks differ by

• Supervision type
• Operand – Op
• Error message – Me
• Alarm class
• Alarm
• Warn
• Info
• Number of alarms
• 8
• 16
• 32

Page 91
Alarming
Alarms with ProDiag - Implementation 1

1 Create PLC Alarm text list for each

call of Alarm block

2
Create entry in
Global_General_AlarmTextList
linking PLC alarm text list
2

3
Call the alarm block linking entry in 3

Global_General_AlarmtextList

Page 92
Alarming
Alarms without ProDiag – Program_Alarm

When alarming is required and ProDiag is not enabled in project, Alarm1To8

can be used.

Internally Program_Alarm instruction is used to generate an alarm based on

string text passed into block.

No language translation without multiple language DBs, higher cycle times

Page 93
Operator Prompt

The Operator prompt function offers the possibility of

displaying operator prompts via a popup.

Page 94
Tesla Alarming Concept

• Tesla alarming is based on ProDiag – see TS-0011193 Tesla Siemens Controls Standard
chapter 6, “Alarm Structures”

• “Design alarming for the end user – do not display alarms that do not directly help the end user
solve the problem.”

• Alarms follow the form “PLANT_IDENTIFIER” + “Alarm message”

• Only one alarm may be active at a time for a Tec Unit

• Alarms must follow documented hierarchy of importance/priority, and if two are triggered, only
the most important is shown

• Alarms must be classified into appropriate categories and subcategories

• Function blocks must be programmed so that they are compliant with the PLC code viewer HMI
control

• E.g. if an emergency stop button is pressed which causes a safety interlock on all the
corresponding equipment, the equipment must not alarm, only the emergency stop alarm must
be present. Additionally, if the hardware that is handling the emergency stop is not
communicating, then filter out the emergency stop alarm.

Page 95
Hands on -> Configure Alarms

Page 96
Sequence
GRAPH programming language
• GRAPH: Siemens graphical programming language for
creating linear and parallel sequencers broken down into
individual steps

• Available on S7-1500 and S7-300 processors (no license

required for TIA Portal)

• Has been certified according to IEC 61131-3 and

PLCopen Base Level since November 2001 (first
manufacturer to receive the PLCopen certificate)

• Programmers that use S7-GRAPH create their programs

strictly according to the international standard IEC 61131-
3, as Sequential Function Chart (SFC) is one of the five
languages defined

Page 97
Sequence
GRAPH programming language
• Quickly program sequential manufacturing process into a
“flow” of steps with branches and parallel operation

• Minimal programming effort and greater clarity through

graphic programming.

• Excellent legibility for maintenance personnel.

• Less time in the commissioning phase thanks to the

graphical programming interface.

• Minimal implementation effort because there are few

possibilities for errors when generating code.

• High availability of the machine through process

diagnostics functions (interlock and supervision).

• Fast error detection through PLC code display and criteria

analysis on the HMI.

Page 98
Sequence
Creating a sequence using GRAPH
• SICAR provides template FB for creating a new GRAPH sequence (Program
blocks\_SICAR_MasterCopies_PLC\Sequencer\StartUpSequence)

• GRAPHControl in GRAPH sequence’s permanent pre-instructions syncs SICAR Op

Modes with GRAPH modes (automatic, semi-automatic, manual)

StartUpSequence

Page 99
Sequence
HMI sequence viewer
• Can view status of sequences using HMI sequence
viewers using SICAR GRAPH overview popup

• Can view supervisions preventing steps from

progressing using preconfigured HMI code viewer

Page 100
Hands On: Insert GRAPH sequence

Page 101
Reference: Underbody line in body shop of JMC, China
installed by DEMC, China (line builder) based on SICAR@TIA Portal

Installed Hardware:
1x SIMATIC S7-1500F, CPU 1517F-PN/DP
2x SIMATIC HMI Comfort Panel TP1500
8x SINAMICS G120D (CU240)
7x SIMATIC ET 200SP (Failsafe)
2x SIMATIC PN/PN Koppler
1x SCALANCE X224

14x Kuka Robot KRC4

49x IP65 Turck-Module

Page 102
Reference: “Bush pressing“ Opel Kaiserslautern
Installed by FFT (line builder) based on SICAR@TIA Portal

Overview
Installed Hardware:
SIMATIC S7-1500F, CPU 1516F-PN/DP
SIMATIC HMI IPC277E 15“ Touch
SIMATIC HMI KP8F
SIMATIC ET 200SP (standard & failsafe)

2x Roboter Fanuc R-30iB (connect. via CP1604)

4x PROMESS Process devices (Profibus)
4x SMC valve cluster
1x Euchner MGB

Page 103
Questions

Page 104
Thank you for your attention!

SICAR Support Team

DI FA SO AUTO TECH
E-Mail: [email protected]