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SIMATIC
Process Control System PCS 7
Service Support and Diagnostics
(V8.2)
Service Manual
Valid for PCS 7 as of V8.2
03/2016
A5E36200111-AA
Security information
Preface
Ensuring Availability
Additional support
Configuring diagnostics
conditions
Message concept of PCS 7
Fault - What should I do?
Diagnostics in PCS 7
Failure, replacement and
return
1
2
3
4
5
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7
8
9

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   Summary of Contents for Siemens SIMATIC PCS 7

  • Page 1 Security information Preface Ensuring Availability SIMATIC Additional support Process Control System PCS 7 Service Support and Diagnostics Configuring diagnostics conditions (V8.2) Message concept of PCS 7 Service Manual Fault - What should I do? Diagnostics in PCS 7 Failure, replacement and return Valid for PCS 7 as of V8.2 03/2016...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
  • Page 3: Table Of Contents

    Table of contents Security information............................7 Preface.................................9 Ensuring Availability...........................13 Introduction..........................13 Data backup...........................14 3.2.1 Data backup options......................14 3.2.2 Backing up ES project data....................16 3.2.2.1 How to back up the parameter settings of the SIMATIC station..........16 3.2.2.2 How to archive a project......................17 3.2.2.3 How to retrieve a project......................19 3.2.2.4 How to archive and retrieve a multiproject................20...
  • Page 4 Table of contents 3.3.6.1 Working with GSD files......................49 Software update........................50 3.4.1 Updating software........................50 Licenses and license keys.....................51 3.5.1 Installing and updating license keys..................51 3.5.2 Upgrade of the System Expansion Card for a CPU 410-5H..........52 3.5.2.1 Basic procedure........................52 3.5.2.2 Ordering an upgrade for a CPU 410-5H................53 3.5.2.3 How to prepare for the upgrade of the System Expansion Card..........54 3.5.2.4...
  • Page 5 Table of contents Diagnostics in PCS 7..........................89 Diagnostic options in subsystems of PCS 7................89 Diagnostics with the maintenance station (asset management)..........90 Diagnostics for the PC user settings..................94 Diagnostics for PC components.....................94 Diagnostics for network connections..................96 Diagnostics during configuration....................97 Diagnostics for the CPU......................98 Diagnostics for modules......................99 Diagnostics on PROFIBUS DP....................99 8.10...
  • Page 6 8.18.8 Additional diagnostics options....................134 8.18.8.1 Additional diagnostics options for PCS 7................134 8.18.8.2 SIMATIC PCS 7 Condition Monitoring Library..............135 Failure, replacement and return.......................137 Failure, replacement and return - guide to documentation..........137 Index.................................141 Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 7: Security Information

    Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept.
  • Page 8 Security information Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 9: Preface

    Disclaimer of liability WARNING Siemens assumes no liability for improper use of the instructions provided in this documentation or for any consequences that might result for the customer. ● Only trained service employees should be authorized to work on the process control system.
  • Page 10: Process Control System Pcs

    The following knowledge is required to understand the documentation: ● Basic knowledge of Microsoft Windows operating systems ● Knowledge of the functions and configurations of SIMATIC PCS 7 (Engineering System, PCS 7 Operator Station). Service Support and Diagnostics (V8.2)
  • Page 11 Preface ● Knowledge of the functions and configurations of SIMATIC S7 (S7-400, STEP 7) ● Knowledge of the functions and configurations of SIMATIC NET (network components and transmission media) Important information about this documentation This documentation is a guide for service support. It therefore does not claim to be complete. Due to our lack of knowledge of the particular circumstances in your plant, we cannot guarantee the following with this documentation: ●...
  • Page 12 If you are using the Windows 10 operating system, you can find the Siemens SIMATIC programs in the "Start" menu under All apps > Siemens Automation.
  • Page 13: Ensuring Availability

    Ensuring Availability Introduction Overview This section presents measures for ensuring availability of a PCS 7 system. Process Control System PCS 7; Fault- You can find information on fault-tolerant systems in the Tolerant Process Control Systems manual. The information in this section enables you to perform the following tasks: ●...
  • Page 14: Data Backup

    Ensuring Availability 3.2 Data backup Contents Topic area Information Data backup ● WHAT?: Information on backing up and restoring data in a PCS 7 plant. Backups are necessary if you want to restore the state of a component or configuration (because a hard disk is damaged, for example). ●...
  • Page 15 Ensuring Availability 3.2 Data backup Recommendations for increasing data security ● Always back up the data in the following cases: – After configuration changes – Before and after system component upgrades – Before and after configuration software upgrades ● Keep at least the three most recent versions of your PCS 7 project. ●...
  • Page 16: Backing Up Es Project Data

    Ensuring Availability 3.2 Data backup Backing up SIMATIC Route Control data ● Backing up configuration data (Page 29) ● Backing up project data from SIMATIC Route Control (Page 29) ● Restoring data from a backup (Page 30) Creating an image file ●...
  • Page 17: How To Archive A Project

    Ensuring Availability 3.2 Data backup You can make use of the following backup options: ● Reading data blocks and FBs from the SIMATIC station ● Reading charts with current parameters from the SIMATIC station Note These actions overwrite all settings in the configuration with the current values of the system.
  • Page 18 3.2 Data backup PKZip ( PKZip Server) program is used for archiving: Below, the PKZip on the SIMATIC PCS 7-DVD. PKZip is automatically installed You can find the setup for during the PCS 7 system setup. PKZip from the SIMATIC Manager.
  • Page 19: How To Retrieve A Project

    Backing up configuration data Also back up the following configuration data: ● GSD files (Siemens\STEP 7\S7Data\GSD) to another partition or to another drive ● C scripts of the standard functions Backup of PDM configuration data on the Engineering Station PDM configuration data is included automatically in the backup of your PCS 7 project.
  • Page 20: How To Archive And Retrieve A Multiproject

    Ensuring Availability 3.2 Data backup Procedure 1. In the SIMATIC Manager, select the menu command File > Retrieve. The "Retrieve - Select an archive" dialog box opens. 2. Edit the following settings for the archive file: – In the "Search in" list: Enter the drive and folder where the project was archived.
  • Page 21 Ensuring Availability 3.2 Data backup 5. Make the following settings for archiving: – In the "Save to" drop-down list: Select the drive and folder. – In the "File name" box: Enter the name of the file in which the data are to be saved. 6.
  • Page 22: How To Archive Custom Libraries

    Ensuring Availability 3.2 Data backup 3.2.2.5 How to archive custom libraries Introduction If you have created a custom project library in PCS 7, we recommend that you archive it. Perform the steps below for each library to be backed up. Procedure 1.
  • Page 23: How To Back Up Custom Functions And Actions

    Ensuring Availability 3.2 Data backup Exporting operator and display texts In SIMATIC Manager, you can export information relating to parameters, signals, and messages to a file (in *.csv format). You can edit this file in standard MS Office applications (such as Excel and Access). The same mechanisms that are used for converting to project-specific languages are used for the export.
  • Page 24: Backing Up Os Project Data

    Backing up OS configuration data The configuration data for PCS 7 operator station are saved by default in the following folder: ..\Siemens\WinCC\WinCCProjects. Compress the current project paths in this folder as a backup and save the backup on a suitable medium, such as a CD.
  • Page 25: Backing Up Batch Data

    Ensuring Availability 3.2 Data backup 3.2.4 Backing up batch data 3.2.4.1 Backing up configuration data Data backup options SIMATIC BATCH offers several options for backing up and restoring project data. Data Menu command for backup op‐ Menu command for restore oper‐ eration ation Options >...
  • Page 26 Ensuring Availability 3.2 Data backup ● Rights and roles ● Project settings Rule Note The follow applies when a backup is running: Operator input cannot be executed on the BATCH client where a backup is being generated. Procedure 1. In BatchCC, select the menu command Options > Backup. 2.
  • Page 27: How To Restore Data From A Backup

    Ensuring Availability 3.2 Data backup Start the Import/Export Assistant ● Start the export assistant from BatchCC by selecting the Options > Export menu command. ● Start the import assistant from BatchCC by selecting the Options > Import menu command. Additional information SIMATIC BATCH ●...
  • Page 28: How To Archive A Batch

    Ensuring Availability 3.2 Data backup Result In BatchCC, the data from the backup file is entered into the batch database and made available again to the plant. 3.2.4.4 How to archive a batch Long-term archive You archive batches in long-term archives in BatchCC. Long-term archives are used for long- term storage of batch data in accordance with the FDA.
  • Page 29: Backing Up Simatic Route Control Data

    Ensuring Availability 3.2 Data backup Archiving multiple batches You archive multiple completed batches as follows: 1. Open a Batch overview list from the "Details" shortcut menu. 2. Select the batches to be archived. 3. Right-click to open the shortcut menu and select the Archive menu command. 3.2.5 Backing up SIMATIC Route Control data 3.2.5.1...
  • Page 30: How To Restore Data From A Backup

    Ensuring Availability 3.2 Data backup Preparing the database backups Before performing a backup, you must always carry out the following steps in Route Control engineering: ● Check the database consistency via the menu command Options > Check Consistency. ● Compress the database via the menu command Options > Compress Database. Creating a backup 1.
  • Page 31: Creating An Image

    Ensuring Availability 3.2 Data backup 6. In the "Direction" group, select the check box "CSV file(s) >> RC project engineering (Import). 7. Click "Continue". 8. Select all check boxes. 9. Click "Continue". 10.Click "Finish". The configuration data are imported. Additional information Process Control System PCS 7;...
  • Page 32: Comparing Project Versions

    Called via Additional information tion Process Changes to different project CFC charts In the Start menu, Siemens SIMAT‐ Configuration manual Control System PCS 7; Engineer‐ versions in the user program IC programs: STEP 7 > VXM - Com‐ SFC charts...
  • Page 33: Hardware Update

    Ensuring Availability 3.3 Hardware update Hardware update 3.3.1 Updating hardware Introduction In this section, a hardware update refers to changing the firmware in SIMATIC modules. Updating the firmware of a SIMATIC module is referred to as a "firmware update" in the following.
  • Page 34 Perform these firmware updates at regular intervals when an opportunity presents itself (such as during a scheduled plant shutdown). Supply sources for the latest firmware version You can request the update files for the latest firmware versions from your Siemens contact partner, or download these from the Internet (http://support.industry.siemens.com/cs/ products?dtp=Download).
  • Page 35: How To Make Adjustments After A Hardware Change

    PCS 7 Released Modules. the document If replacement of the CPU is required, contact your Siemens representative. Changing the quantity structure of the CPU for a SIMATIC S7-410 You can find information about this in the section "Upgrade of the System Expansion Card for a CPU 410-5H (Page 52)".
  • Page 36: How To Perform A Firmware Update For The Cpu (as Of V5.0)

    Compare the type and manufacture date of the modules you are using with the information in PCS 7 Released Modules. the document If replacement of the CPU is required, contact your Siemens representative. Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 37 Ensuring Availability 3.3 Hardware update Requirements ● STEP 7 V5.3 or higher is installed on the programming device or PC. ● The update file for the firmware update is available on the programming device / PC. ● The CPU, whose firmware is to be updated, must be accessible online, for example, via PROFIBUS, MPI or Industrial Ethernet.
  • Page 38: How To Perform A Firmware Update For The H-cpu (as Of V4.5)

    ● The device name (NameOfStation) ● The subnet mask ● The static SNMP parameters Updating a CPU with an operating system update card You can find information on this at the following Internet address: http://support.industry.siemens.com/cs/products (http://support.industry.siemens.com/cs/ products?search=Firmware-Update %20S7%20400%20CPU&dtp=Download&o=DefaultRankingDesc&) 3.3.3.2 How to perform a firmware update for the H-CPU (as of V4.5) The firmware version can be changed using the online functionality as of firmware version V4.5.x.
  • Page 39: Updating An Interface Module

    This time period depends on the amount of load memory (size of the inserted memory card) and the amount of working memory. Updating an H-CPU with an operating system update card You can find additional information on this at the following Internet address: http://support.industry.siemens.com/cs/products (http://support.industry.siemens.com/cs/ products?search=Firmware-Update%20S7%20400H %20CPU&dtp=Download&o=DefaultRankingDesc&) 3.3.4...
  • Page 40: How To Perform A Firmware Update Of An Interface Module (im)

    PCS 7 Released Modules. document ● If replacement of the modules is required, contact your Siemens representative. ● A firmware update is possible for some modules. You will find the procedure in the section "How to perform a firmware update of an IM (Page 40)" below.
  • Page 41 Ensuring Availability 3.3 Hardware update Procedure 1. Open SIMATIC Manager. 2. In the component view, select the SIMATIC station in which the IM is located. 3. Double-click the "Hardware" object in the detail window. HW Config opens. 4. Select the IM whose firmware you want to update. 5.
  • Page 42 Ensuring Availability 3.3 Hardware update You can now update the second IM in the redundant system. Each IM must be updated separately. Note Direct firmware update of both IMs in a redundant system via PROFIBUS DP With IM 153-2 firmware as of V4.x, it is possible to update the firmware of both IMs during ongoing operation in redundant mode.
  • Page 43: Updating A Cp Xxx

    As of firmware V2.x (6ES7 341-1xH02-0AE0) you execute the update in HW Config. Select the menu command "PLC > "Update firmware..." in HW Config. For more information, refer to the "S7-300 CP 341 Point-to-Point Communication, Installation and Parameter Assignment (https://support.industry.siemens.com/cs/in/en/view/36037679)" manual. Service Support and Diagnostics (V8.2)
  • Page 44 ● Compare the type and version of the modules you are using with the information in the PCS 7 Released Modules. document ● If you need to replace the CP, contact your Siemens representative. Requirements for the firmware update ● STEP 7 V5.3 or higher is installed on the programming device or PC.
  • Page 45: How To Perform A Firmware Update Of The Cp 443-1

    ● Compare the type and version of the modules you are using with the information in the PCS 7 Released Modules. document ● If you need to replace the CP, contact your Siemens representative. Requirements for the firmware update ● STEP 7 V5.3 or higher is installed on the programming device or PC.
  • Page 46 ● Do not cancel a download operation once it is started. The CP may no longer be usable if you do this and you will have to send it in for repair. 1. Under Siemens SIMATIC programs in the Start menu, select:STEP 7 > NCM S7 Industrial Ethernet > Firmware Loader.
  • Page 47: How To Perform A Firmware Update Of The Cp 443-5 Extended

    ● Compare the type and version of the modules you are using with the information in the PCS 7 Released Modules. document ● If you need to replace the CP, contact your Siemens representative. Requirements for the firmware update ● STEP 7 V5.3 or higher is installed on the programming device or PC.
  • Page 48 ● Do not cancel a download operation once it is started. The CP may no longer be usable if you do this and you will have to send it in for repair. 1. Under Siemens SIMATIC programs in the Start menu, select:STEP 7 > NCM S7 > Firmware Loader.
  • Page 49: Handling Gsd Files

    Ensuring Availability 3.3 Hardware update States of the download operation Where Display State On the PG/PC in the Firm‐ The bar in the dialog box changes. Download procedure is running. ware Loader dialog box On the PG/PC in the Firm‐ The message "Download completed Download procedure is com‐...
  • Page 50: Software Update

    Ensuring Availability 3.4 Software update Troubleshooting When Error Oc‐ Error message Source of Error Remedy curs During insert op‐ The 'SIMATIC 400(1) station' The entry '187.5_supp = 1' is 1. Contact the device eration does not support the transmis‐ not present. manufacturer.
  • Page 51: Licenses And License Keys

    Using the SIMATIC Management Console The SIMATIC Management Console (hereafter referred to as Management Console) is a software from the SIMATIC PCS 7 product family for central administration of SIMATIC software products. You can select the installation of the Management Console in the PCS 7 setup.
  • Page 52: Upgrade Of The System Expansion Card For A Cpu 410-5h

    Ensuring Availability 3.5 Licenses and license keys Upgrading license keys for AS 410 (CPU 410-5H) You can find information on this in the following sections: ● Section "Upgrade of the System Expansion Card for a CPU 410-5H (Page 52)" ● Section "Upgrade of process objects of a CPU 410-5H by replacing the System Expansion Card (Page 61)"...
  • Page 53: Ordering An Upgrade For A Cpu 410-5h

    The System Expansion Card and the PO-Activation-File form a unit once assigned. The upgrade is valid for this System Expansion Card. Support Request You need to create a Support Request and send the PO-Activation-File to Siemens Customer Support as an attachment. You will receive the PO-Release-File as an answer. PO-Release-File File for the upgrade to the requested PO volume.
  • Page 54: How To Prepare For The Upgrade Of The System Expansion Card

    500PO 2 x 500PO or 10 x 100PO 1x 500PO + 5x 100PO Ordering a CPU 410 Expansion Pack The following options are available for ordering: ● Contact your Siemens representative: www.siemens.com/automation/partner (https://support.industry.siemens.com/aspa_app/) ● Order online: www.siemens.com/industrymall (www.siemens.com/industrymall) 3.5.2.3 How to prepare for the upgrade of the System Expansion Card Requirements ●...
  • Page 55 PO upgrade. – Click "Apply". A “SIMATIC PCS 7 AS 410” folder is created under “My Computer”. The automation system and the “Online” subfolder are visible in this folder. The current PO volume of the automation system is shown in the "Online" folder.
  • Page 56: How To Send The Po-activation-file

    Ensuring Availability 3.5 Licenses and license keys You need to create a Support Request and send the PO-Activation-File to Siemens Customer Support as an attachment. You can find information about this in the section "How to send the PO-Activation-File (Page 56)".
  • Page 57 3.5 Licenses and license keys Sending the PO-Activation-File via Support Request 1. Open the following web page in the Internet browser: http://www.siemens.com/automation/support-request 2. Step 1: Select a product – Enter the following in the "Product/Order number" input field:CPU 410 – Click "Search"...
  • Page 58: How To Perform The Upgrade Of The System Expansion Card

    ● You can access the automation system for which you want to perform the PO upgrade with the engineering station via a PCS 7 project. ● The System Expansion Card for which you sent the PO-Activation-File to Siemens is inserted in the automation system.
  • Page 59: Upgrade Of A Redundantly Configured Automation System

    Ensuring Availability 3.5 Licenses and license keys 3.5.2.6 Upgrade of a redundantly configured automation system Objective The PO volume is to be increased for a redundantly configured automation system. Requirements ● You can access the CPU for which you want to perform the PO upgrade with the engineering station via a PCS 7 project.
  • Page 60 Ensuring Availability 3.5 Licenses and license keys Recommendation Avoid the situation in which different PO volumes are licensed on each of the System Expansion Cards of the CPUs. ● If the System Expansion Card is functioning when the CPU fails, insert the System Expansion Card of the failed CPU into a substitute CPU.
  • Page 61: Enabling Expert Mode

    Ensuring Availability 3.5 Licenses and license keys 3.5.2.8 Enabling expert mode You can force an upgrade of the System Expansion Card of a CPU in some situations. To do this, you need to open the "Connect target systems" dialog box in the Automation License Manager.
  • Page 62: Determining Inventory Data And Installing Software

    Ensuring Availability 3.7 Updating the PCS 7 OS in runtime Determining inventory data and installing software Determining inventory data Information on Detailed information Called via Additional information Online help of the SI‐ Determining in‐ Determining hardware and In the Start menu, Sie‐ MATIC Management ventory data of software of PC stations in a...
  • Page 63 Ensuring Availability 3.7 Updating the PCS 7 OS in runtime Updating the PCS 7 OS during running operation offers the following benefits: ● Operation of the PCS 7 system is not disrupted. ● The AS does not enter STOP mode. ●...
  • Page 64 Ensuring Availability 3.7 Updating the PCS 7 OS in runtime Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 65: Additional Support

    Additional support If this manual does not contain the answers to any questions you may have about how to use the products described, please contact your local Siemens representative. You can locate your local representative at: http://www.siemens.com/automation/partner (https://support.industry.siemens.com/ aspa_app/) The guide that provides details of the technical documentation offered for the individual SIMATIC products and systems is available at: http://www.siemens.com/simatic-tech-doku-portal...
  • Page 66 Additional support Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 67: Configuring Diagnostics Conditions

    Configuring diagnostics conditions Requirements for diagnostics Requirements Several requirements must be fulfilled to ensure that the status of a PCS 7 system can be diagnosed effectively. The most important requirements are: ● Diagnostics are enabled for the components. ● Diagnostic options were activated during configuration Information on configuring the diagnostic options The primary configurations can be found in the following documentation: Process Control System PCS 7;...
  • Page 68 Configuring diagnostics conditions 5.1 Requirements for diagnostics 3. Double-click the "Hardware" object in the detail window. HW Config opens. 4. Double-click the module you wish to check. The properties dialog box for the selected module opens. 5. Browse the individual tabs for appropriate options. Activate the diagnostic properties depending on the module type.
  • Page 69: Message Concept Of Pcs 7

    Message concept of PCS 7 Servicing a system - message concept Introduction The message system and diagnostic options of PCS 7 help you to assess the system status. You can find information about the PCS 7 message concept in the following sections: ●...
  • Page 70: Pcs 7 Message System

    You can find detailed information about the message system as follows: WinCC Information System : ● In the In the Start menu under the SIEMENS SIMATIC products, select the menu command WinCC Information System, under "System Overview > How WinCC Works > – Message system of a PCS 7 OS –...
  • Page 71 Message concept of PCS 7 6.2 PCS 7 message system You can use the "Alarm Logging" editor of the PCS 7 OS to modify the selection of message information to be displayed in WinCC. Note Configuring the PCS 7 message system ●...
  • Page 72: Origin Of A Message

    Message concept of PCS 7 6.3 Origin of a message Origin of a message Message path Messages can originate in different locations in PCS 7 depending on the configuration. Each message is given a time stamp. The event which causes a time stamp to be assigned to a message depends on the place where the message has originated.
  • Page 73: How To Determine The Source Of A Message

    Message concept of PCS 7 6.5 Understanding messages How to determine the source of a message. Procedure 1. Enable the message list by clicking 2. "Activate/Deactivate Autoscroll". 3. In the message list, select the message for which you need additional information. 4.
  • Page 74: Message Types In Message Lists And Archives

    Message concept of PCS 7 6.5 Understanding messages 6.5.2 Message types in message lists and archives Message types in message lists and archives Messages are divided into the following classes: Term Definition Operator input messages Operator Input messages are generated when an operator controls process variables, for example, changes the operating mode of a con‐...
  • Page 75: Target Groups Of Messages

    Message concept of PCS 7 6.5 Understanding messages 6.5.3 Target groups of messages Target groups Message type Target group: Proc‐ Target group: Opera‐ Target group: System ess control tions management and specialist and mainte‐ recording nance specialist Operator input messages Process messages Operational messages Process control messages...
  • Page 76 Message concept of PCS 7 6.5 Understanding messages List Contents Operation list The operation list provides a view of the message archive. The operation list con‐ tains the operator log. Examples: ● The operator has set the controller setpoint to 5 bar ●...
  • Page 77: Overflow Of The Message Buffer

    Message concept of PCS 7 6.5 Understanding messages 6.5.5 Overflow of the message buffer Overflow of the message buffer Each component of the overall PCS 7 system can process only a limited number of messages. If messages generated in a component (for example, an AS) within a given time frame are more than it can process, some of these messages will be lost.
  • Page 78: Influencing Messages

    Message concept of PCS 7 6.5 Understanding messages Additional information You can find additional information on configuring message priorities in the configuration Process Control System PCS 7; Operator Station. manual 6.5.7 Influencing messages Options The following options are available to influence messages in PCS 7: ●...
  • Page 79: Fault - What Should I Do

    Fault - What should I do? Activity in the event of a fault Basic procedure in the event of a fault 1. Evaluate the messages with regard to the following aspects: – Time – Sequence – Source 2. Determine the location and area of the fault. Note If the components you are using do not have diagnostics capability, only secondary faults are signaled.
  • Page 80: Preparing For Expert Support

    Fault - What should I do? 7.2 Preparing for expert support Examples of causes Fault Possible causes Initial diagnostics CPU fault CPU diagnostics ● Fault due to internal error ● Fault due to external error CP fault Module Diagnostics > Special Diag‐ ●...
  • Page 81: Plant Documentation

    Fault - What should I do? 7.2 Preparing for expert support Overview You support the work of service experts by providing them with information: ● Service experts need information about your plant and the faulty system in order to provide quick support.
  • Page 82: How To Read The Cpu Diagnostic Buffer

    Fault - What should I do? 7.2 Preparing for expert support ● Components ● Versions – Hardware (version, in case of replacement) – Firmware – Software – Libraries used in the S7 program 7.2.3 How to read the CPU diagnostic buffer Saving diagnostic data You can make it easier for service engineers to perform initial diagnostics on a faulty CPU by saving and having ready the contents of the diagnostic buffer as service data (as of firmware...
  • Page 83: Cpu Fault - Preparing Diagnostics

    Fault - What should I do? 7.2 Preparing for expert support 7.2.4 CPU fault - preparing diagnostics Introduction The following information is important for analyzing a CPU fault: ● Information on the affected CPU ● Information or actions in the event of a fault WARNING Rules Note the following:...
  • Page 84: How To Back Up The Diagnostic Data Of The Pcs 7 Os

    ● All LEDs are flashing. ● All LEDs are off, even though the power supply is switched on. For additional support, contact your Siemens representative or Technical Support. Have the "information in the event of a fault" indicated above ready.
  • Page 85: Remote Diagnostics Of A Pcs 7 System

    Back up the diagnostic folder 1. Close WinCC. 2. Back up all diagnostic folders of WinCC◆ (default: [Installation path]\Siemens\WinCC\Diagnostics). 3. Give this information to the service employees. You can back up the diagnostic files using the shortcut menu command Save to >...
  • Page 86: Interactive Operator Control And Monitoring With The Os Web Option

    Fault - What should I do? 7.2 Preparing for expert support Process Control System You can find additional information on this in the installation manual PCS 7; PCS 7 - PC Configuration . Additional information Security Concept PCS 7 and WinCC - Basic Document , section "Security ●...
  • Page 87 Fault - What should I do? 7.2 Preparing for expert support Transmission paths The data can be transmitted along the following routes: ● Telephone line (modem) ● TCP/IP connection (system-internal network connection) ● Internet Security requirements If you use the OS Web Option in a PCS 7 plant, you must protect this plant against unauthorized access.
  • Page 88 Fault - What should I do? 7.2 Preparing for expert support Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 89: Diagnostics In Pcs 7

    Diagnostics in PCS 7 Diagnostic options in subsystems of PCS 7 Disclaimer of liability Note Siemens assumes no responsibility for inappropriate use of the instructions provided in this documentation or any consequences that might result for the customer. Note Note the following: ●...
  • Page 90: Diagnostics With The Maintenance Station (asset Management)

    Diagnostics in PCS 7 8.2 Diagnostics with the maintenance station (asset management) Diagnostics Diagnostics refers to all activities intended to: ● Ascertain the status of a system ● Find errors and faults as early as possible and identify their cause Diagnostic messages Diagnostic capabilities are used to analyze the system status and to determine the causes of faults.
  • Page 91 Diagnostics in PCS 7 8.2 Diagnostics with the maintenance station (asset management) We particularly recommend the use of a Maintenance Station in medium and large PCS 7 systems. Maintenance Station With the Maintenance Station, PCS 7 enables you to call up information on the states of all PCS 7 components on diagnostics screens which are hierarchically structured.
  • Page 92 Maintenance Station's special diagnostics screens. Area Diagnostics for ... Automation systems ● CPU ● SIMATIC PCS 7 BOX ● Distributed I/O (such as ET 200M, ET 200S), input and output modules ● Field devices (HART, PROFIBUS PA, ...) ● Redundancy –...
  • Page 93 Diagnostics in PCS 7 8.2 Diagnostics with the maintenance station (asset management) Area Diagnostics for ... PROFIBUS components ● PROFIBUS DP – Bus Links - Interface modules (IM) - Couplers – Diagnostic repeaters ● PROFIBUS PA – Interfaces – Couplers ●...
  • Page 94: Diagnostics For The Pc User Settings

    Open WinCC Explorer by selecting the (Page 122) menu command Editors > User Adminis‐ trator > Open PCS 7 users (user roles and In the Windows Start menu, Siemens Au‐ rights in PCS 7 applications) tomation>SIMATIC Logon > Configure SI‐ MATIC Logon Shares Shares for drives, fold‐...
  • Page 95 Note: Only blue icons = "all correct" Function of standard network modules Set PC Station (Page 112) In the Start menu, Siemens SIMATIC programs: SIMATIC NET > Settings > Set PC Station In the tree view, select PC Station > "Network Module"...
  • Page 96: Diagnostics For Network Connections

    Process Control System PCS 7; Main‐ mentation tenance Station . Determining inventory data of network SIMATIC Management Console In the Start menu, Siemens SIMATIC programs: components (Page 62) SIMATIC > SIMATIC Management Console (Li‐ cense required) Plant view > Shortcut menu command "Deter‐...
  • Page 97: Diagnostics During Configuration

    In SIMATIC Manager: Options > Set PG/PC In‐ terface PC Ethernet modules NCM S7 Industrial Ethernet In the Start menu, Siemens SIMATIC programs: (Page 116) STEP 7 > NCM S7 Industrial Ethernet > Diag‐ nostics Status of configured channels and...
  • Page 98: Diagnostics For The Cpu

    Convert pictures Operator Station (WinCC) Connection functions for a PC station Set PC Station (Page 112) In the Start menu, Siemens SIMATIC programs: SIMATIC NET > Settings > Set PC Station Diagnostics for the CPU Overview Diagnostics for Diagnostics tool...
  • Page 99: Diagnostics For Modules

    Additional information is available in the manual Process Control System PCS 7; Maintenance Station Determining inventory data of automa‐ SIMATIC Management Con‐ In the Start menu, Siemens SIMATIC programs: tion systems sole (Page 62) SIMATIC > SIMATIC Management Console (Li‐ cense required) Plant view >...
  • Page 100: Diagnostics On Profinet

    With Diagnostic Repeater (Page 132) Status of PROFIBUS nodes NetPro (Page 115) In the Start menu, Siemens SIMATIC programs: STEP 7 > NetPro Select the menu command View > With DP Slaves to display the DP slaves in the network...
  • Page 101: Diagnostics On Profibus Pa

    Process Control System PCS 7; Main‐ mentation tenance Station Determining inventory data of field devi‐ SIMATIC Management Con‐ In the Start menu, Siemens SIMATIC programs: sole (Page 90) SIMATIC > SIMATIC Management Console (Li‐ cense required) Plant view > Shortcut menu command "Deter‐...
  • Page 102: Diagnostics For The Os

    In WinCC: Tools > Status of Client Connections client (Page 123) Status of channels and connections to WinCC Channel Diagnostics In the Start menu, Siemens SIMATIC programs: the AS (Page 122) WinCC > Tools > Channel Diagnostics Displaying the status of the connected Area overview (Page 124) In WinCC: Area overview >...
  • Page 103: Diagnostics For The Batch Stations

    Diagnostics in PCS 7 8.15 Diagnostics for the Route Control stations Diagnostics for Diagnostics tool Called via OS fault - preparing diagnostics Only to support experts You can find information on this in the section "OS fault - preparing diagnostics (Page 84)". Status PCS 7 Web Server Internet Explorer: http://<server_address>.sta‐...
  • Page 104: Diagnostics For The Time Of Day

    Control Panel > System and Security > Admin‐ istrative Tools > Services"Windows timer" Synchronization status on the terminal Set PG/PC Interface In the Start menu, Siemens SIMATIC programs: (Page 112) SIMATIC NET > Set PG/PC Interface Select interface > Click "Diagnostics" > In the "Time"...
  • Page 105 Reference manual S7-300 Programmable Controller; Module Specifications ● Diagnostic data for the signal modules Additional information is available in the ET 200M Signal Modules for Process Automation (http://support.automation.siemens.com/WW/view/en/7215812) manual or in the ET 200M distributed I/O device HART analog modules (http:// support.automation.siemens.com/WW/view/en/22063748) manual.
  • Page 106 Diagnostics in PCS 7 8.17 Diagnostics for hardware displays Components You can find information about diagnostic options in the following manuals and sections: DP/PA couplers, active field distributor, DP/PA Link and DP/PA Coupler Operating instructions Y Link Diagnostics by means of LED displays ●...
  • Page 107 Diagnostics in PCS 7 8.17 Diagnostics for hardware displays The following table includes information on the LEDs available for an initial diagnostics and the meaning of the LED. Meaning for PROFINET IO Meaning for PROFIBUS DP BUSF Lit up in red: Lit up in red: Bus error (no physical connection to a sub‐...
  • Page 108: Diagnostic Tools

    8.18.1 Diagnostic tools of PCS 7 Disclaimer of liability WARNING Siemens assumes no liability for improper use of the instructions provided in this documentation or for any consequences that might result for the customer. WARNING Note the following: ● All work must be performed by trained service personnel.
  • Page 109: Managing The Operating System

    Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information PC configura‐ Operating system System Overview Online help of the oper‐ tion ating system Operating system version PC NAME Processor BIOS data Users currently logged on Time zone Size of the work memory Information on the swap file...
  • Page 110: Shares For Drives, Folders And Files

    Diagnostics in PCS 7 8.18 Diagnostic tools Information on Detailed information Called via Additional information Network adapt‐ Network adapter type access System Tools > Devie ers and PC levels, users, servers, network Manager > Network cards addresses (IP/MAC address) adapters Network-wide Active users in network, System Tools >...
  • Page 111: System Tools - Local Users And Groups

    SIMAT‐ Application per‐ In the Windows Start Online help for ● Standard users, language missions menu, Siemens Automa‐ IC Logon and password changes tion > SIMATIC Logon > ● Selection of the computer Configure SIMATIC Log‐ from which the user data are to be obtained ●...
  • Page 112: Set Pc Station

    8.18.2.7 Set PG/PC Interface Call Options: ● In the Windows Start menu Siemens Automation > SIMATIC > SIMATIC NET > Set PG/PC Interface ● SIMATIC Manager via menu command Options > Set PG/PC Interface Overview Information on Detailed information...
  • Page 113: Station Configuration Editor

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.2.8 Station Configuration Editor Calling Call this on the Windows taskbar by clicking the following icon: Requirement The components in the configuration list must be entered in the same order as in the component image you created with HW Config.
  • Page 114: Printers And Print Jobs

    Called via Additional information Preparing the PC CPU temperature, In the Windows Start Online help station menu, Siemens SIMAT‐ fan speed, Only a SIMATIC PC can IC programs: be used as a monitored hard disks, PC DiagMonitor > computer. DiagMonitor...
  • Page 115: Installed Simatic Software

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.2.11 Installed SIMATIC software Overview Information on Detailed information Called via Additional information Installed versions Installed software and ver‐ In the Start menu, Sie‐ Online help of the PCS 7 soft‐ sions, language version of mens SIMATIC pro‐...
  • Page 116: Ncm S7 Industrial Ethernet

    Display DP slaves in the net‐ View > With DP Slaves slaves work view 8.18.3.2 NCM S7 Industrial Ethernet Call In the Siemens SIMATIC programs Start menu: STEP 7 > NCM S7 Industrial Ethernet > Diagnostics Overview Information on Detailed information Called via Additional information...
  • Page 117: Scalance Xb-200/x-200/x-300/x-400 "loop Detection

    Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information SIMAT‐ Status redundancy The observer function Enter the following in Documentation IC NET; Industrial Ether‐ manager provides the "Run" dialog of the net Switches error diagnostics and Start menu: "cmd"...
  • Page 118: Ncm S7

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.3.6 NCM S7 Calling In the Siemens SIMATIC programs Start menu: STEP 7 > NCM S7 > Diagnostics Overview Information on Detailed information Called via Additional information General CP diag‐ Operating mode General" tab ●...
  • Page 119: Mbsa

    Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information Devices and in‐ Checking the configured de‐ Online help for Topology ● "Table view" tab > terconnections vices and interconnections Editor > "Table view" tab "Online"...
  • Page 120: Simatic Shell

    Diagnostics in PCS 7 8.18 Diagnostic tools Note Lifebeat monitoring and Maintenance Station If you are running a Maintenance Station in the plant, configuration of lifebeat monitoring with "Lifebeat Monitoring" is prohibited. 8.18.4.2 Simatic Shell Calling 1. Select "My Computer" in the tree view of Windows Explorer. 2.
  • Page 121: Wincc "system Info" Channel

    Diagnostics in PCS 7 8.18 Diagnostic tools Information on Detailed information Called via Additional information WinCC In‐ Computer status When the status of a com‐ Online Help for formation System change puter changes, a message is sent to all station, for exam‐ ple: ●...
  • Page 122: User Administrator

    WinCC Information System , under "Communication > System Info > Configuration Online help of a channel > How to configure the System Info channel". 8.18.4.4 User administrator Call In the Start menu under the SIEMENS SIMATIC products, select the menu command WinCC Explorer. Overview Information on Detailed information Called via...
  • Page 123: Status Of Multi-user Operation

    Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information WinCC Connections Overview of the status of the config‐ Channels/Connec‐ Online Help for Information System , ured channels and their connections tions" tab to the SIMATIC station, directly or by "How to Test the Chan‐...
  • Page 124: Status Of Connections

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.4.7 Status of connections Overview Information on Detailed information Called via Additional information WinCC Infor‐ Connection sta‐ Connection between WinCC Only when OS is in Online help for mation System , topic: tus (OS-AS) and an automation system process mode: in the menu of the WinCC...
  • Page 125: Displaying The Redundancy State

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.4.9 Displaying the redundancy state Overview It is important to always have an overview of the redundancy state for diagnostics in plants with redundant PCs. The redundancy state represents the status of the individual master and standby computers.
  • Page 126: Diagnostics For The Batch Station

    Diagnostics in PCS 7 8.18 Diagnostic tools Information on Detailed information Called via Additional information Time master for Status information Process picture on the OS You can find information on OS server (sta‐ configuration in the online ● Active master ●...
  • Page 127: Status Display At Order Folder

    Diagnostics in PCS 7 8.18 Diagnostic tools Symbol Meaning SIMATIC BATCH is running (Running) on the BATCH master or BATCH single-station system. The BATCH project is loaded, started and BATCH Runtime has started. SIMATIC BATCH is running (Listening) on the BATCH standby. The BATCH project is loaded, started and BATCH Runtime has started.
  • Page 128: Diagnostics For The Route Control Station

    Master server Icon in the task‐ bar of the Stand‐ by server 8.18.7 Diagnostics for the SIMATIC stations 8.18.7.1 SIMATIC Manager Calling In the Siemens SIMATIC programs Start menu: SIMATIC Manager Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 129 Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information STEP 7 , Diagnosing hard‐ Quick view: icons indicate PLC > Diagnostics/Set‐ Online help for ware operating status or module ting > Hardware Diag‐ topic: "Hardware diag‐...
  • Page 130: Hw Config

    CHS__ = Asian lan‐ guage version 8.18.7.2 HW Config Calling In the Siemens SIMATIC programs Start menu: SIMATIC Manager. In the tree view, click on "SIMATIC Station" and double-click "Hardware" in the selection list. Overview Information on Detailed information Called via...
  • Page 131: Module Information

    Diagnostics in PCS 7 8.18 Diagnostic tools 8.18.7.3 Module Information Calling up quick information 1. Call up the quick information in SIMATIC Manager by selecting the menu command Component View > View > Online. 2. Select the SIMATIC station with the menu command PLC > Diagnostics/Settings > Hardware Diagnostics.
  • Page 132: Profibus Diagnostics With Diagnostic Repeater

    Diagnostics in PCS 7 8.18 Diagnostic tools Information on Detailed information Called via Additional information Performance Operand areas and the availa‐ Performance Data" tab data ble blocks of the selected For checking the user (CPU/FM) module program to determine whether the CPU meets the appropriate require‐...
  • Page 133: Simatic Pdm

    Diagnostics in PCS 7 8.18 Diagnostic tools Overview Information on Detailed information Called via Additional information STEP 7 , top‐ Quick over‐ Icons indicate the status "Module Information" dia‐ Online help for view of the PROFIBUS master log box ic: "Hardware diagnostics systems and troubleshooting"...
  • Page 134: Additional Diagnostics Options

    Additional diagnostics options for PCS 7 Disclaimer of liability NOTICE Disclaimer of liability Siemens assumes no liability for improper use of the instructions provided in this documentation or for any consequences that might result for the customer. NOTICE Note the following: ●...
  • Page 135: Simatic Pcs 7 Condition Monitoring Library

    8.18.8.2 SIMATIC PCS 7 Condition Monitoring Library The SIMATIC PCS 7 Condition Monitoring Library is an additional block library based on the blocks of the PCS 7 Advanced Process Library. The library is used for diagnostics and maintenance of mechanical assets (e.g. pumps and valves).
  • Page 136 Diagnostics in PCS 7 8.18 Diagnostic tools Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 137: Failure, Replacement And Return

    Failure, replacement and return Failure, replacement and return - guide to documentation Guide to documentation You can find information on component response and the procedure to be followed in the event of failure, exchange and return in the following documentation: Scenario Information can be found in ...
  • Page 138 Failure, replacement and return 9.1 Failure, replacement and return - guide to documentation Scenario Information can be found in ... Section ... Automation systems Failure of a CPU in a redundant Configuration manual ● Failure of the Master CPU Process Control System PCS 7; Fault-Tol‐ erant Process Control Systems Failure of synchronization be‐...
  • Page 139 Failure, replacement and return 9.1 Failure, replacement and return - guide to documentation Scenario Information can be found in ... Section ... Process Control System PCS 7; Failure of BATCH servers Manual ● Failure of BATCH servers SIMATIC BATCH Switchover response of BATCH Manual Process Control System PCS 7;...
  • Page 140 Failure, replacement and return 9.1 Failure, replacement and return - guide to documentation Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...
  • Page 141: Index

    Index Custom library, 22 Multiproject, 20 Operator and display texts, 22 PC stations in an image file, 31 Access levels, 110 PCS 7 OS data, 24 Activities, 79 PCS 7 ES, 17, 19 In the event of a fault, 79 Project data, 17, 19 Additional diagnostics options for PCS 7, 134 Project data of SIMATIC Route Control, 29...
  • Page 142 Index Of a CPU fault, 79 Default folder, 23 Of a PC component fault, 79 Global actions, 23 Of an I/O module fault, 79 Local actions, 23 Command line commands, 111 Project functions, 23 Command prompt, 111 Standard functions, 23 ipconfig, 111 Device information, 133 netstat, 111...
  • Page 143 Index Failure characteristics, 62 Icons in the taskbar, 126, 128 Redundant interface, 62 BATCH server, 126 Failure, replacement and return - guide to Route Control server, 128 documentation, 137 IM, 40 Fault, 128 Firmware update, 40 On the PROFIBUS, 128 Import Firmware SIMATIC BATCH, 26...
  • Page 144 Index Module Information, 128 PC user settings, 94 Module properties, 67 Diagnostics, 94 Checking for diagnostics, 67 PCS 7 OS data, 24 Modules, 67, 113, 130, 131, 132 Backing up, 24 Checking, 113 PDM - devices, 133 Data, 131 Pending print jobs, 109 State, 130, 131 Performance data, 131 State with diagnostic repeater, 132...
  • Page 145 Index System, 111, 128 Local users and groups, 111 System error, 128 System and system settings, 109 Set PC Station, 112 Call, 112 Set PG/PC Interface, 112 Call, 112 Setting access permissions, 122 Target groups of messages, 74, 75 Shared files, 110 Target system, 131 Sharing, 110 Time, 104, 112, 128, 130...
  • Page 146 Index Working with GSD files, 49 Service Support and Diagnostics (V8.2) Service Manual, 03/2016, A5E36200111-AA...

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