04 Diagnostic Maintenance

Diagnostics
Basic Workshop
Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

SIMATIC diagnostics
Increased plant availability
- IDEAL -
Plant with complete diagnostics
 Increased availability
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
Report System Error (build in S7-1500)
S7standard
S7 standard Trace Function (S7-1500 only) PROGRAM_ALARM
diagnostics
diagnostics Diagnostics using S7 Program Error OBs
Diagnostics via Programming Device System Status List
Diagnostics via LEDs + Controller Display

- ORIGIN -
Plant without diagnostics
SIMATIC diagnostics
- IDEAL -
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
Diagnostics
• Introduction 4
• Diagnostic LEDs
• Diagnostic in TIA-Portal
• Diagnostic in User Program
• Trace Editor
• Systemdiagnostic
• Web Diagnostic
• Summary

Diagnostics
In general
Supported S7-1500 diagnostic features:

 Analyze status LEDs directly at the device modules
 Set parameters of diagnostic events for CPU / interface module and device modules in
hardware catalog
 Reaction of errors in user program – Programming of error OBs / generation of program
alarms
 Diagnostic alarms for: circuit brake, wire brake, missing load voltage, exceeding limits
 Integrated system diagnostics

Diagnostics
Introduction
Possibilities Benefits Boundary conditions
LED Directly viewable diagnostics Local at hardware modules
PG/
Detailed diagnostic information Engineering software necessary
STEP 7
System diagnostics Predefined diagnostic information Set at hardware configuration
Diagnostic devices (CPU-Display / Same concept of displaying diagnostic

Connection to PLC is required
Webserver / HMI) information
Engineering required to read back

Trace Graphical Monitoring of Process Variables
the informations
User defined program FC

FB
Reaction to events in program code Additional programing work
Diagnostics
• Introduction 04
• Diagnostic LEDs 07
• Diagnostic in TIA-Portal
• Trace Editor
• Web Diagnostic
• Summary

Diagnostics with LEDs
Functional principle S7-1500 S7-1200 S7-300/400/WinAC
Operator’s level
Error detection
Detection of the…
-type
Controller’s level
-source
… of an error at modules
Error reaction
3rd Party
• Alarm view
-LED at modules
Field level
LEDs of CPU
1 2 3
1 STOP/RUN (two color LED: green/yellow)
2 ERROR (one color LED: red)
3 MAINT (one color LED: yellow)
6 4
4 X1 P1 R (two color LED: green/yellow)
5
X1 P2 R (two color LED: green/yellow)
5
X2 P1 (two color LED: green/yellow)

6
* LED-display of S7-1500 CPU (without front flap)

Status LEDs of CPU
LEDs Meaning
RUN / STOP Lights green CPU in operating mode RUN

(green/yellow)
Lights yellow CPU in operating mode STOP
Flashs yellow Internal operations in CPU (e.g. STARTUP, FW-Update)
Flashs green/yellow CPU in operating mode STARTUP
ERROR Flashs red Diagnostic event occurs

(red)
MAINT Lights yellow Maintenance-alarm of a module

(yellow)
Special cases All lights are flashing CPU - defect

Flash test
Interfaces - LEDs of CPU (LINK/RX/TX)
LINK/RX/TX-
Meaning
LED
No data is received / send at the PROFINET
LED off
interface.
An Ethernet connection is existing between
LED lights green PROFINT interface and a communication
partner
Interface is connected to a PROFINET
LED flash green
device
LED flash green Flash test is active
The PROFINET interface receives / transfers

LED flash yellow data from a communication partner in the
Ethernet network
Interface module
Diagnostics with status LEDs of LEDs Meaning

STARTUP module RUN / STOP Lights green Works correctly– in communication with
(green) IO controller
Flashes green IM deactivated/ not configured / STARTUP /

reset to factory settings
ERROR Flashes red Group errors and group error channels/ Set
(red) configuration unequal actual configuration /
invalid configurations/ Parameter
assignment error in module
MAINT Lights yellow Maintenance request– lose of
(yellow) synchronization / Maintenance-alarm of a
module
Special cases All LEDs light LED Test at STARTUP (0,25s)
All LEDs flash IM – defect/ flash test

S7-1500 Display
Overview Diagnostic Modules Settings

(Identification) (Alarm and Diagnostic Buffer) (Central and Decentralize) (IP-Address, Time, …)
Diagnostics
• Introduction 04
• Diagnostic in TIA-Portal 14
• Trace Editor
• Web Diagnostic
• Summary

SIMATIC diagnostics
- IDEAL -
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
Diagnostics via Programming Device
Module status: Diagnostic buffer
Offline <-> Online
Online Firmware
update
Editors
Online
Network view Topology view
Device view
subordinate defect
o.K.
Differences Online/Offline
Defect
only Online
Maintenance
only Offline
Diagnostics
• Introduction 04
• Diagnostic in User Program 18
• Trace Editor
• Web Diagnostic
• Summary

Diagnostics using S7 Program
Overview of error OBs (OB8x & OB12x)
Asynchronous errors • If the CPU operating system

OB80 Time error detects an asynchronous error, it
OB81 Power supply error calls the associated OB
OB82 Diagnostic interrupt • Due to their temporal occurrence, these errors cannot be
OB83 Insert/Remove module interrupt
assigned to the program sequence
OB84 CPU hardware fault
OB85 Program execution error
OB86 Rack failure
OB87 Communication error • Synchronous errors occur when processing an invalid
instruction
• In their temporal sequence, these errors can be assigned
directly to the program sequence
Synchronous errors
OB121 Programming error
OB122 I/O access error

Diagnostics with PROGRAM_ALARM S7-1500 S7-1200 S7-300/400/WinAC
How is it possible to create an alarm with an event in the user program?
Program with function block PROGRAM_ALARM

Alarm texts are send by program
Displayed as alarms
in CPU-display
User program
PROGRAM
FB
Local ALARM Displayed as alarms
Local
in HMI
Reaction to events
Displayed as alarms
in Webserver of PLC
PROGRAM_ALARM can only be used Webserver
within FBs
Configuration of the FB S7-1500 S7-1200 S7-300/400/WinAC
Multi-instance DB entry in the

interface
Additional values to the alarm

message up to 10 additional
values
Configure you message
In PLC Alarms Settings the

message can be customized
and integrated into the alarm
system of the S7-1500
Quality Information S7-1500 IO Cards
• To ensure the correct handling of the input values you have the possibility to activate the value
status (QI = Quality Information) in the properties of the module
• An additional bit will reserved for each channel in the process image. E.g. 2 Byte for a 16
channel input module
Quality Information ET200SP
Each Bit represents one slot

of the IO-Station.
32 Bit = 32 Slots which is the
maximum for a ET200SP.
This 4 Bytes can be used in

HMI for fault display.
Diagnostics
• Introduction 04
18
• Trace Editor 26
• Web Diagnostic
• Summary

SIMATIC diagnostics
- IDEAL -
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
Introduction
Definition S7-1500 S7-1200 S7-300/400/WinAC
General definition:
A trace is a chronological documentation of events. The point is: “What
happened when?”
TIA Portal:
In TIA Portal the Trace is a chronological recording of signals
(variables, parameter, etc.) out of the program that is operated in the
PLC. The recording is running through a specified time period and can
be graphically displayed.
Introduction
Use case Examples S7-1500 S7-1200 S7-300/400/WinAC
Sporadic faults
Analyze the trace
Problem solved
Record the
trace +
Plant
Adoption of program optimized
Commissioning or process
Trace Editor
Activation S7-1500 S7-1200 S7-300/400/WinAC
The trace–editor gets

opened in the work area
2x
Trace Editor
Areas
1 1 Function menu bar for trace

handling
2
2 Diagram with signal trends
3 3
Signal table
4
4
Trace handling
5 5
Configuration area via the properties
of the inspector window
Trace editor
Function menu bar and trend diagram
Selection of
Buttons to
recording to be
activate/deactivate
displayed in
recordings
trend diagram
Functions to edit and

analyze the trend
diagram
Legend for Display areas for

recorded signals recorded signals
Trace editor
Signal table
 Overview of the configured signals for the trace including the graphical representation
Signal is displayed in Color for the signals

the trend diagram in the recording
Available signals out

Axis values for the
of the trace
signals
configuration
Trace editor
Trace handling
The trace handling contains 3 parts:

 Trace configurations (in the project) 1
 Installed traces (in the PLC) 2
 Measurements (in the project) 3
1 2 3
 Configured traces in  Available traces in the CPU  Stored trace measurements in the
the project  State of these traces project
 Display of trace in trend diagram  Display of measurement in the trend
 max. number of traces in the PLC diagram
depends on PLC (CPU 1516 = max. 4  Start time of the measurement
traces)
Trace editor
Configuration menu in the inspector window
 The trace configuration is created in the inspector window including

1 general information, e.g. name of the configuration
2 relevant signals
3 recording conditions (sampling, trigger)
1
2
3
Configuration
Trigger – Trigger on tag
• With “Trigger on tag” additional settings have to be done
Trigger variable
Period of time before the

trigger, in which signals
are already recorded Trigger event (pos./neg.
edge, bit pattern, value,
etc.)
Pre-trigger is included in recording duration

Trace
Import/Export
Import Export
 Traces in “.ttrec” format can be imported  Traces stored in the project can be
into an existing project exported as files with “*.ttrec“ or “csv”
format
1 1
2
2
Remarks
Traces
 Only one recording can be displayed but all traces of a PLC can be recorded at the
same time
 If a running or completed trace in the PLC gets restarted by the trigger event the
current recording gets overwritten
 If a configuration was created or a trace was stored as a measurement the project
has to be saved to persist them in the project (no automatic saving)
 The trend diagram can be saved as an image (*.bmp) or can be copied to the
clipboard
Diagnostics
• Introduction 04
18
• Trace Editor 26
39
• Web Diagnostic
• Summary

SIMATIC diagnostics
- IDEAL -
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
With PG / STEP 7
Functional principle
Operator’s level
Error detection
Detection of the…
-type
Controller’s level
-source
-cause
… of an error with
PG / STEP 7
3rd Party
Field level
With PG / STEP 7
Details
CPU
S7 - user program CPU creates diagnostic

(FB PROGRAM_ALARM) event Module
Module creates
Operating system with Diagnostic event diagnostic event
diagnostic functionalities
Diagnostic buffer STEP 7 requests diagnostic

information from CPU
Display
System diagnostics S7-1500
Functional principle
HMI 5
5. Display of the alarms (for HMI devices
supporting the S7-1500 communication*)
4. HMI connects matching alarm texts to the
Alarm 4 diagnostic event
texts
CPU
2 3. The diagnostic function generates alarms and
3 casts them to HMI / CPU-Display / Webserver
2. Operating system analyses error information

and calls diagnostic function
Feld 1
1. Error in device is recognized and diagnostic

event is send to CPU
* MPx77, Basic Panels, Comfort Panels, Mobile 277, RT Adv., RT Prof. (no diagnostic viewer)
Diagnostic Event are based on PROFIBUS and PROFINET Standards,

independent from the IO-Vendor
Configuration in device view
System diagnostic is activated

at any time. It is possible to
configure alarm settings
Compile hardware configuration S7-1500 S7-1200 S7-300/400/WinAC
No blocks will be created during compiling

process because system diagnostics is
integrated into the operating system of the
PLC
No additional compilation required
saves resources
System diagnostics viewer at Comfort Panels / RT Advanced
Viewer is similar to the

Web Server view of S7
PLCs
CPU – Webserver
System diagnostics
viewer
System diagnostics window at Comfort Panels / RT Advanced
1
Move “System diagnostics window” to
global screen
Show the “System diagnostics window”

with the help of the “Diagnostics
Indicator”.
Use the button from the global library at
a template or a screen
3
Use the system function
“ShowSystemDiagnosticsWindow”
Benefits of integrated system diagnostics
 System diagnostics is part of the PLC’s operating

system
 The user program is not affected by system

diagnostics Benefits of integrated system diagnostics
Reduced engineering effort

 Integration of new modules via recompiling of
hardware configuration Error minimization
No need of additional resources
No additional compilation
Predefined alarm texts available in operating system
No extensive integration test necessary
PLCs- Displayed Displayed

Webserver as alarms in in HMI
CPU-display
Comparison of „S7-300  S7-1500“ system diagnostics
System diagnostics S7-300 System diagnostics S7-1500
Diagnostics and diagnostic alarms can independently be activated Active diagnostic results automatically in diagnostic alarms
Diagnostic alarm can be suppressed Diagnostic alarm can not be suppressed
Not loaded error-OB  CPU switches to STOP Not loaded error-OB  CPU stays in RUN
System diagnostics only in RUN supported System diagnostics is RUN and in STOP supported
Need of program blocks Diagnostic is integrated into PLC‘s operating system

Diagnostics
• Introduction 04
18
• Trace Editor 26
• Systemdiagnostic 39
• Web Diagnostic 50
• Summary

SIMATIC diagnostics
- IDEAL -
WebNavigator (WinCC)
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
Web Functionality
 Easy access to diagnostics data of the modules using standard office tools
 Supported commissioning and operation
 No engineering license is required for gathering diagnostics information's
 Access is possible with any web browser even from Smartphone, Tablet,…
 Increased plant availability
Enable Web Interface
Setup User with User rights
Convert User Defined Webpage into

DBs
Workflow User defined Webpage
1
Web-Application
Convert Web-Application
Call WebPages in into Datablocks
Web browser Create Webpage with any
4 editor 2
Call “WWW” in Startup OB
3
STEP 7
Project
DB100
Download in CPU DB99 Import in STEP 7-Projekt
Block Call in Startup OB
Web browser
Enter IP address
e.g.: 192.168.1.101 Ethernet

SCALANCE: Web Based Management (WBM)
using the SCALANCE X208 as an example
Enter IP address
e.g.: 192.168.1.111 Ethernet

SCALANCE: Web Based Management (WBM)
Port diagnostics
HMI panel: sm@rt Service
Remote control
Enter IP address
Smart Service
Ethernet
HMI panel: sm@rt Service
Remote control
Diagnostics
• Introduction 04
18
• Trace Editor 26
• Systemdiagnostic 39
• Web Diagnostic 50
• Summary
61

SIMATIC diagnostics
- IDEAL -
WebNavigator
Remotediagnostics
Remote diagnostics
WebServices
Systemdiagnostics
System diagnostics
S7standard
diagnostics

- ORIGIN -
Summary
 System Diagnostic will be generated automatically, no block call required.
 Seamless integration into HMI-Panel and SCADA System.
 Innovative Diagnostic View with Comfort Panels.
 Consistent Diagnostic in PLC-Display, Web-Server and HMI Alarm View.
 User defined Messages can be implemented with simple block calls bounded to the program.
 Trace function allows graphical recording of variables.
 No additional resources and compilation is required from the user

program.
 Free Features embedded in the system

Useful Links
Programming recommendations for S7-1200 and S7-1500 with STEP 7 (TIA Portal)
http://support.automation.siemens.com/WW/view/en/67582299
Programming guideline for S7-1200/1500 (also in PDF as customer workshop)

http://support.automation.siemens.com/WW/view/de/81318674
Migration:
Migration production plants– http://support.automation.siemens.com/WW/view/en/83558085
Migration PLC´s – http://support.automation.siemens.com/WW/view/en/83557459
Migration Vizualisation – http://support.automation.siemens.com/WW/view/en/76878921
Migration communication – http://support.automation.siemens.com/WW/view/en/83558087
Migration periphery – http://support.automation.siemens.com/WW/view/en/83558994
Let us know if there is anything
we can support you with!
For further information and support, please contact:
Mr. Tran Van Hieu
SITRAIN Manager – Digital Industry Academy
Siemens Vietnam
Email: tran-van.hieu@siemens.com
www.siemens.com.vn
www.facebook.com/Siemens.Vietnam
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04 Diagnostic Maintenance

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04 Diagnostic Maintenance

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Diagnostics

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Diagnostics via Programming Device System Status List

Diagnostics via LEDs + Controller Display

Diagnostics via Programming Device System Status List

Diagnostics via LEDs + Controller Display

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Supported S7-1500 diagnostic features:

 Integrated system diagnostics

Possibilities Benefits Boundary conditions

LED Directly viewable diagnostics Local at hardware modules

System diagnostics Predefined diagnostic information Set at hardware configuration

Diagnostic devices (CPU-Display / Same concept of displaying diagnostic

Engineering required to read back

User defined program FC

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

2 ERROR (one color LED: red)

3 MAINT (one color LED: yellow)

X2 P1 (two color LED: green/yellow)

* LED-display of S7-1500 CPU (without front flap)

RUN / STOP Lights green CPU in operating mode RUN

Flashs yellow Internal operations in CPU (e.g. STARTUP, FW-Update)

Flashs green/yellow CPU in operating mode STARTUP

ERROR Flashs red Diagnostic event occurs

MAINT Lights yellow Maintenance-alarm of a module

Special cases All lights are flashing CPU - defect

LED flash green Flash test is active

The PROFINET interface receives / transfers

Diagnostics with status LEDs of LEDs Meaning

Flashes green IM deactivated/ not configured / STARTUP /

All LEDs flash IM – defect/ flash test

Overview Diagnostic Modules Settings

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Diagnostics via Programming Device System Status List

Diagnostics via LEDs + Controller Display

Offline <-> Online

Network view Topology view

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Asynchronous errors • If the CPU operating system

OB122 I/O access error

How is it possible to create an alarm with an event in the user program?

Program with function block PROGRAM_ALARM

Multi-instance DB entry in the

Additional values to the alarm

In PLC Alarms Settings the

Each Bit represents one slot

This 4 Bytes can be used in

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Diagnostics via Programming Device System Status List

Diagnostics via LEDs + Controller Display

The trace–editor gets

1 1 Function menu bar for trace

Functions to edit and

Legend for Display areas for

Signal is displayed in Color for the signals

Available signals out

The trace handling contains 3 parts:

 The trace configuration is created in the inspector window including

• With “Trigger on tag” additional settings have to be done

Period of time before the

Pre-trigger is included in recording duration

Unrestricted | © Siemens 2021 | Trần Văn Hiếu | SITRAIN | 2021/2022

Diagnostics via Programming Device System Status List