Siemens Top Mistakes

2011 Automation Summit
Orlando, FL
Navigating the world of automation
Top Ten Programming Mistakes Made by People New to S7

2011 Automation Summit
Title: Top Ten Programming Mistakes Made by
People New to S7
Track:#56
Topic: Learn about some of the common
problems experienced by people learning S7.
Presenter: Tim Jager
Company: DMC

Copyright Siemens Industry, Inc. 2011. All rights reserved.
Page 2
Top Ten Programming Mistakes Made by People New to S7

Page 3
Company Profile
Based In
Based In
Chicago
Chicago
but work
but work
Globally
Globally
DMC has the highest number of
DMC has the highest number of
S7 certified engineers
S7 certified engineers
Since 1996
30 Employees
Our customers

Areas of Expertise
Custom
Test
Manufacturing
and
Software
Measurement
and
Engineering
Automation
& Embedded
Intelligence
Microsoft
SharePoint
Consulting
ServicesSystems

Relevant Siemens Projects
Dulles Airport Transit Tunnel Ventilation System

WinCC Redundancy
S7 400H Redundant PLC
4000 I/O Points

Batch Mixing Systems for Confectionary Company
S7-300
Standardized code base
Deployment at multiple facilities
Mixing/batching control
Recipe management
Web-based reporting system

Automotive Assembly Lines for Tier 1 Supplier
S7 400 PLCs
WinCC Flex HMIs
Standardized code base
User Configurable
JIT - Lean Manufacturing
Deployment at multiple facilities

US Navy LCS-1
Littoral Combat Ship
S7 400H Redundant PLC
Mission Critical Logic

Presenter Info
Tim Jager
Project Director at DMC
Mechanical Engineer (University of Illinois)
Licensed Professional Engineer in Illinois
With DMC since 1999
Top 10 S7 Mistakes
#1
Simple Hardware mistakes

Page 12
Common Hardware Mistakes
My PLC Doesnt Work???

Page 13
It needs a memory card

Page 14
It needs a memory card
Its in STOP Mode

Page 15
I wonder whats on the MMC Card?

Page 16

Page 17

Page 18

Page 19
This is not an RS232 Serial Port!!!

Page 20
Top 10 S7 Mistakes
#2
Using Absolute
Address Priority
instead of Symbolic

Page 21
Set your Address Priority to Symbolic

You Just took the Red pill. You are on your way down the rabbit hole that leads
down the path of true object oriented PLC Programming.

Page 22
A Typical Data Block
DB1 dbGlobals

Page 23
A Typical Data Block
DB1 dbGlobals
Address:
Symbol Name:
DB1.DBX0.0
dbGlobals.bStart
Page 24
A Typical Rung Of Ladder

Page 25
Address Logic
Symbolic Logic

Page 26
Address Logic
Symbolic Logic

Page 27
What happens if we change the Data Block?

Page 28
Absolute vs. Symbolic Priority
In Symbolic Mode the intended logic is maintained
The address
address logic
logic has
has
The
changed from
from 0.1
0.1 to
to 0.2
0.2
changed
The symbolic
symbolic logic
logic is
is
The
maintained
maintained

Page 29
In Absolute Mode the intended logic is NOT maintained!
The Address
Address logic
logic is
is
The
maintained
maintained
But the
the Symbolic
Symbolic logic
logic is
is
But
totally wrong!
wrong!
totally

Page 30

You dont have to know where the server lives or its IP address. You just need the
symbolic name to send an email.
So start forgetting about addresses and start thinking about symbolic names.
VS.
Absolute Address
Symbolic Address
2222N. Elston Ave
tim.jager@dmcinfo.com
Chicago, IL 60614
Page 31
Top 10 S7 Mistakes
#3
I/O Mapping

Page 32
Input / Output Mapping
I'M GONNA PROGRAM LIKE IT'S 1999

Page 33
Traditional Input / Output Mapping

1. At the beginning of the scan,
Each physical input gets mapped
to an internal variable
Physical Input
Internal Variable

Page 34

2. Now run all of the logic (which

references only internal bits)
Internal Variable
Internal Variable
Page 35

2. Now run all of the logic (which

references only internal bits)
3. At the end of the scan,
internal output bits get mapped
to physical outputs
Internal Variable
Physical Output
Page 36

S7 I/O Mapping Just use the Symbol Table
Make sure you are in

Symbolic Priority Mode

Page 37
Top 10 S7 Mistakes
#4
Improper Use of Bit Memory

AKA: Mbits

Page 38
MBits
M0.0 M0.7
M1.0 M1.7
M2.0 M2.7
M2.0 M2.7
Page 39
M0.0
M0.1
M0.2
M0.3
M0.4
M0.5
M0.6
M0.7
M1.0
M1.1
M1.2
M1.3
M1.4
M1.5
M1.6
M1.7
M2.0
M2.1
M2.2
M2.3
M2.4
M2.5
M2.6
M2.7
M3.0
M3.1
M3.2
M3.3
M3.4
M3.5
M3.6
M3.7

MBits
M0.0 M0.7
M1.0 M1.7
M2.0 M2.7
M2.0 M2.7
Page 40
MBytes
M0.0
M0.1
M0.2
M0.3
M0.4
M0.5
M0.6
M0.7
M1.0
M1.1
M1.2
M1.3
M1.4
M1.5
M1.6
M1.7
M2.0
M2.1
M2.2
M2.3
M2.4
M2.5
M2.6
M2.7
M3.0
M3.1
M3.2
M3.3
M3.4
M3.5
M3.6
M3.7
MB0
MB1
MB2
MB3
MBits
M0.0 M0.7
M1.0 M1.7
M2.0 M2.7
M2.0 M2.7
Page 41
MBytes
M0.0
M0.1
M0.2
M0.3
M0.4
M0.5
M0.6
M0.7
M1.0
M1.1
M1.2
M1.3
M1.4
M1.5
M1.6
M1.7
M2.0
M2.1
M2.2
M2.3
M2.4
M2.5
M2.6
M2.7
M3.0
M3.1
M3.2
M3.3
M3.4
M3.5
M3.6
M3.7
MWords
MB0
MW0
MB1
MB2
MW1
MB3
MBits
M0.0 M0.7
M1.0 M1.7
M2.0 M2.7
M2.0 M2.7
Page 42
MBytes
M0.0
M0.1
M0.2
M0.3
M0.4
M0.5
M0.6
M0.7
M1.0
M1.1
M1.2
M1.3
M1.4
M1.5
M1.6
M1.7
M2.0
M2.1
M2.2
M2.3
M2.4
M2.5
M2.6
M2.7
M3.0
M3.1
M3.2
M3.3
M3.4
M3.5
M3.6
M3.7
MWords
MDoubleWords
MB0
MW0
MB1
MD0
MB2
MW1
MB3
When is it OK to use M Bits?
Debugging
Quick prototyping / demonstrations
When you absolutely have to!

Page 43
Critical / Time-sensitive field fixes*
M-Bits
* As long as you promise to put in a permanent fix when the heat is off.
Page 44
If you use
MBits, make
sure they are
NOT IN USE
already.

Page 45
..and make sure to add symbol

names in the symbol table.

Page 46
Or suffer the consequences

Page 47
Clock Byte

Page 48
Top 10 S7 Mistakes
#5
Not using or
Improperly using the
Clock Byte

Page 49
What is the Clock Byte?
Each bit of the clock memory byte is assigned a frequency.

Bit of the Clock Memory Byte 7
Period Duration (s)
2.0
Frequency (Hz)
0.5
6
5
1.6 1.0
0.625 1
4
3
0.8 0.5
1.25 2
2
0.4
2.5
1
0.2
5
0
0.1
10

Page 50
Symbol Table Entry For Clock Byte
Reserve these so nobody uses Memory overlapping the Clock Byte

Page 51
Clock Byte
The bits within the Clock byte can change at

any time during the scan.

Page 52
Clock Byte Synchronous Global
UDT1 udtClockByte

Page 53
DB1 dbGlobals

Page 54
DB1 dbGlobals

Page 55

DB1 dbGlobals

Page 56
MB0
dbGlobals.ClockByte
Page 57
What Happens If
Always_False
Mapped to M0.0
M0.0
M0.1
Always_True
M0.2
Mapped to M0.1
M0.3
M0.4
M0.5
M0.6
M0.7
Page 58
What Happens If
Always_False
Mapped to M0.0
M0.0
M0.1
Always_True
M0.2
Mapped to M0.1
M0.3
Clock Byte
M0.4
Mapped to MB0
M0.5
M0.6
M0.7
Page 59
Overlapping Mbits are BAD!

Page 60
Top 10 S7 Mistakes
#6
Using Uninitialized
Temp Memory

Page 61
What is Temp Memory?

Page 62
Improper Use of Temp Memory

Page 63
Improper Use of Temp Memory
Dont read from a TEMP

unless you have written to it
first!

Page 64
Top 10 S7 Mistakes
#7
Not Using Timed

Interrupts.

Page 65
OB1 vs. OB30..38
OB1
OB30OB38
Runs as fast as it can.
Run at specific time intervals.

Page 66
Timed Interrupts OB30..OB38
PID Control
Data Sampling

Page 67
Top 10 S7 Mistakes
#8
Not using reusable

function blocks

Page 68
What is a Function Block
A Function Block is a piece of reusable code that consists of:
Code is encapsulated in a Highly reusable form

Increases Programming efficiency and reduces errors

Timer
One of the simplest and most

commonly used function block is a
Timer.
TON
T#200ms
IN
PT
ET
178

Creation of Function Block

Isolate Common/Duplicate Code
If the same code is used many times in your program, consider

creating function blocks.

Step 1. locate common code.


Step 1. locate common code.


Step 2. Replace duplicated code with function blocks.

Custom FB Examples
Motor
Motor
FB
FB
Cylinder
Cylinder
FB
FB
Pump
Pump
FB
FB
Valve
Valve
FB
FB
Barcode
Barcode
Scanner
Scanner
FB
FB
Robot
Robot
Interface
Interface
FB
FB
Label
Label
Printer
Printer
FB
FB
Machine
Machine
Vision
Vision
FB
FB

Top 10 S7 Mistakes
#9
Inconsistent Blocks

Page 76
Check Block Consistency
Dont forget to download the Data Block!!

Page 77
Top 10 S7 Mistakes
And last but not least..

Page 78
Top 10 S7 Mistakes
#10
Going it Alone

Page 79
Thank You!

Page 80

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2011 Automation Summit

Navigating the world of automation

Top Ten Programming Mistakes Made by People New to S7

Navigating the world of automation

Top Ten Programming Mistakes Made by People New to S7

Navigating the world of automation

Navigating the world of automation

Navigating the world of automation

Relevant Siemens Projects

Dulles Airport Transit Tunnel Ventilation System

Navigating the world of automation

Relevant Siemens Projects

Batch Mixing Systems for Confectionary Company

Navigating the world of automation

Relevant Siemens Projects

Automotive Assembly Lines for Tier 1 Supplier

Navigating the world of automation

Relevant Siemens Projects

Navigating the world of automation

Simple Hardware mistakes

Navigating the world of automation

Common Hardware Mistakes

My PLC Doesnt Work???

Navigating the world of automation

Common Hardware Mistakes

My PLC Doesnt Work???

It needs a memory card

Navigating the world of automation

Common Hardware Mistakes

My PLC Doesnt Work???

It needs a memory card

Its in STOP Mode

Navigating the world of automation

Common Hardware Mistakes

I wonder whats on the MMC Card?

Navigating the world of automation

Common Hardware Mistakes

I wonder whats on the MMC Card?

Navigating the world of automation

Common Hardware Mistakes

I wonder whats on the MMC Card?

Navigating the world of automation

Common Hardware Mistakes

Navigating the world of automation

Common Hardware Mistakes

This is not an RS232 Serial Port!!!

Navigating the world of automation

Set your Address Priority to Symbolic

Navigating the world of automation

A Typical Data Block

Navigating the world of automation

A Typical Data Block

A Typical Rung Of Ladder

Navigating the world of automation

A Typical Rung Of Ladder

Navigating the world of automation

A Typical Rung Of Ladder

Navigating the world of automation

What happens if we change the Data Block?

Navigating the world of automation

Absolute vs. Symbolic Priority

In Symbolic Mode the intended logic is maintained

Navigating the world of automation

Absolute vs. Symbolic Priority