9 - Troubleshooting

Troubleshooting
SIMATIC S7
Siemens AG 2006. All rights reserved.
Date:
File:
2/23/2012
PRO1_14E.1
SITRAIN Training for

Automation and Industrial Solutions
Troubleshooting
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.2

Objectives
Upon completion of the chapter the participant will ...
...
be able to classify occurring errors as "Errors detected by the system"

and "Functional errors"
...
be familiar with the "Displaying CPU Messages" function
...
be able to read out the diagnostic buffer, interpret it and use it

for troubleshooting
...
be able to read out the I STACK, B STACK and L STACK and

interpret them
...
be able to read out the hardware diagnosis
...
be able to apply the "Monitor/Modify Variables" test function
...
be able to interpret the displays of the "Monitor" test function in the

LAD/STL/FBD Editor and use them for troubleshooting
...
be able to read out the reference data, interpret them and use them
for troubleshooting
...
understand the "Force" function
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.3

Categories of Errors
Errors Detected by the System
Recording, evaluating and indicating
errors within a PLC
(as a rule: CPU STOP)
Module failure
Short-circuit in signal cables
Scan time overrun
Programming error (accessing a
non-existent block)
Functional Errors
Desired function is either not executed at all
or is not correctly executed
Process fault (sensor/actuator, cable defective)
Logical programming error (not detected
during creation and startup)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.4

STEP7 - Debugging Tools, Overview

Error
Error detected by the System:

General Rule: CPU in STOP
(such as accessing a non-existent DB)
(Diagnostic interrupt of a signal module)
Functional fault:
General Rule: CPU in RUN
(process fault, such as a wire break)
(logical programming error, like a double assignment)
Debugging Tools:
Enable Peripheral Outputs (modify outputs)
Monitor / Modify Variable
Monitor Blocks (Block Status)
Reference Data
- Cross References
- Assignment of I/Q/M/T/C
- Program Structure
- Addresses without Symbols
- Unused Symbols
Regardless of the cause of the error you could use:
Force
Enable Peripheral Outputs
Set Breakpoints
Debugging Tools:
Module Information
- Diagnostic buffer
- I STACK
- B STACK
- L STACK
Hardware Diagnostics
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.5

System Diagnostics - Overview
CPU
CPU diagnostics detects

a system error
Diagnostic
interrupt
CPU diagnostics detects

errors in the user program
Error
OB
Diagnostic
buffer
I/O module
Diagnosticscapable module
detects an error
and generates
a diagnostic
interrupt
System
status list
CPU
messages
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.6

Displaying CPU Messages
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.7

Calling the "Module Information" Tool

SIMATIC Manager
LAD/STL/FBD Editor
Module Information
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.8

Module Information Tab: "Diagnostic Buffer"
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.9

Interpreting Error Messages in the Diagnostic Buffer
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.10

Opening a Block Containing an Error
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.11

Diagnostics with I Stack, B Stack, L Stack

Program structure
Block containing error
Point of interruption
Point of interruption
The B stack shows a list of the

blocks that were executed up
to the point of interruption.
You can see the contents of the

accumulators, registers, status word
etc. at the time of interruption in the
I stack.
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.12
You can see the values of the

temporary variables at the
time of interruption in the L stack.

Contents of the B Stack
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.13

Contents of the I Stack
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.14

Contents of the L Stack
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.15

Displaying the Hardware Diagnostics
twice
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.16

Ex 1: Copying a Faulty Program and Preparing for Troubleshooting
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.17

Exercise 2: STOP Troubleshooting
Please Note: That after every STOP error correction, you

must carry out a CPU warm restart. If, after the
warm restart, the CPU once again goes into the
STOP state, there still exists a further STOP
error.
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.18

Calling the "Monitor/Modify Variables" Tool
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.19

Establishing Trigger Points for "Monitor/Modify Variable"

PII
Trigger point
"Beginning of Scan Cycle"
Monitor / Modify
depending on
Trigger setting
Set
Trigger
Cyclic
program
execution
Update Status / Modify

Values (one time
monitor / modify)
Trigger point
"Transition to STOP"
Trigger point
"End of Scan Cycle"
PIQ
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.20

Opening a Variable Table and Establishing a Connection to the CPU
Accessible CPUs
Directly
connected
CPU
Station 1
Configured
CPU
(VAT from
HW Station
"Station 2")
Station 2
Station 3
PG
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.21

Testing (Debugging) Blocks using "Monitor" (Block Status)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.22

Information Displayed with "Block Debug > Monitor"

LAD/STL/FBD Editor -> Options ->Customize
SIMATIC S7
Date:
File:
... or
in running status:
right mouse click
on
2/23/2012
PRO1_14E.23

Displaying Reference Data
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.24

Displaying the Program Structure
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.25

Displaying Cross References
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.26

Filtering Cross References
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.27

Block Correction using Cross References
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.28

Go To Location
1 x right
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.29

"Find" In Reference Data
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.30

Assignment of I, Q, M, T, C
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.31

Unused Symbols / Addresses without Symbols
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.32

Comparing Blocks (1)
...see
next page
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.33

Comparing Blocks (2)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.34

"Force" Variables
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.35

Exercise 3: Testing the Motor Jog
!!!
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.36

Exercise 4: Testing the Quantity Display
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.37

If You Want to Know More
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.38

Selecting Process and Test Operation
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.39

Trigger Conditions for Block Monitoring (1)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.40

Trigger Conditions for Block Monitoring (2)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.41

Exercise 5: Testing the Evaluation of Fault 4
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.42

Testing the Program Execution using Breakpoints (Part 1)
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.43

Testing the Program Execution using Breakpoints (Part 2)
Breakpoint
Next
statement
SIMATIC S7
Date:
File:
2/23/2012
PRO1_14E.44


9 - Troubleshooting

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What are the different debugging tools discussed in the document?

What are the different debugging tools discussed in the document?

What are the two main categories of errors discussed?

What are the two main categories of errors discussed?

Troubleshooting

SITRAIN Training for

SITRAIN Training for

be able to classify occurring errors as "Errors detected by the system"

be familiar with the "Displaying CPU Messages" function

be able to read out the diagnostic buffer, interpret it and use it

be able to read out the I STACK, B STACK and L STACK and

be able to read out the hardware diagnosis

be able to apply the "Monitor/Modify Variables" test function

be able to interpret the displays of the "Monitor" test function in the

understand the "Force" function

SITRAIN Training for

SITRAIN Training for

STEP7 - Debugging Tools, Overview

Error detected by the System:

SITRAIN Training for

System Diagnostics - Overview

CPU diagnostics detects

CPU diagnostics detects

SITRAIN Training for

Displaying CPU Messages

SITRAIN Training for

Calling the "Module Information" Tool

SITRAIN Training for

Module Information Tab: "Diagnostic Buffer"

SITRAIN Training for

Interpreting Error Messages in the Diagnostic Buffer

SITRAIN Training for

Opening a Block Containing an Error

SITRAIN Training for

Diagnostics with I Stack, B Stack, L Stack

Block containing error

The B stack shows a list of the

You can see the contents of the

You can see the values of the

SITRAIN Training for

Contents of the B Stack

SITRAIN Training for

Contents of the I Stack

SITRAIN Training for

Contents of the L Stack

SITRAIN Training for

Displaying the Hardware Diagnostics

SITRAIN Training for

Ex 1: Copying a Faulty Program and Preparing for Troubleshooting

SITRAIN Training for

Exercise 2: STOP Troubleshooting

Please Note: That after every STOP error correction, you

SITRAIN Training for

Calling the "Monitor/Modify Variables" Tool

SITRAIN Training for

Establishing Trigger Points for "Monitor/Modify Variable"

Update Status / Modify

SITRAIN Training for

Opening a Variable Table and Establishing a Connection to the CPU

SITRAIN Training for