Service & Support. Visualization of SIPLUS CMS2000 Condition Monitoring Diagnostics Data on WinCC SIPLUS CMS2000. Application Example July 2012

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1 Cover Sheet Visualization of SIPLUS CMS2000 Condition Monitoring Diagnostics Data on WinCC SIPLUS CMS2000 Application Example July 2012 Service & Support Answers for industry.

2 0 Warranty and Liability Warranty and Liability This article originates from the Service & Support Portal of Siemens AG, Sector Industry, Industry Automation and Drive Technologies. The respective terms of use are applicable ( This document can be directly downloaded via the following link: Application Example 2 of 22

3 0 Warranty and Liability Note The application examples are non-binding and do not claim to be complete in terms of configuration and equipment or to consider any other contingencies. The application examples do not represent any customer-specific solutions, but are only intended to provide support with typical tasks. The reader shall be solely responsible for assurance of the described products' proper operation. These application examples do not exempt the reader from his obligation to due diligence with regard to application, installation, operation and maintenance. By utilizing these application examples, the reader acknowledges that Siemens cannot be held liable for any damage beyond the liability provisions described herein. We reserve the right to implement changes in these application examples at any time and without prior notice. In case of deviations between the suggestions relating to these application examples and other Siemens publications, e.g. catalogs, the contents of such other documentation shall take priority. Application Example 3 of 22

4 0 Warranty and Liability We do not assume any warranty for the information contained in this document. Our liability for any damage caused by the utilization of examples, notes, programs, configuration and performance data, etc., described in this application example shall be excluded, irrespective of the legal ground, unless liability is legally imposed, e.g. in accordance with the German product liability act ("Produkthaftungsgesetz"), in cases of intent, gross negligence, injury to life, body or health, assumption of a product's guarantee of quality, fraudulent concealment of defects or violation of fundamental contractual obligations. However, claims for damages on the grounds of violation of fundamental contractual obligations shall be limited to the contract-typical, foreseeable damage, except for cases of intent or gross negligence or where liability is legally imposed due to injury to life, body or health. This does not imply a change in the burden of proof to your detriment. Any transfer or reproduction of these application examples or excerpts thereof shall not be permitted, unless expressly approved by Siemens Industry Sector. Application Example 4 of 22

5 0 Warranty and Liability Table of Contents Warranty and Liability Introduction Application Example Target Prerequisites Differentiation Source Code for Application Description Application Description SIPLUS CMS S7 Controller WinCC Connection to the Controller via TCP/IP Definition of Structure Types Structure of the Structure Type Creation of Online Variables Layout of the WinCC Interface Structuring of Diagnostics Information in Type Screens Creation of Instance Screens from Type Screens Chronological Trend Curves via Tag Logging Application Example 5 of 22

6 1 Introduction 1 Introduction 1.1 Application Example Target Fig. 1 Communication overview This application example is to demonstrate the visualization of diagnostics data from SIPLUS CMS2000 on the SIMATIC WinCC operating and monitoring system. In this context, the term diagnostics data refers to condition monitoring information such as numerical characteristic values (RMS = root mean square, DWK = diagnostics characteristics value), operating parameters (speed, analog or temperature values) and status information for limit value monitoring, also of spectra. For data display on WinCC, the information is sent to an S7 controller via a cyclic TCP/IP telegram. WinCC reads the diagnostics data from a data block of the S7 controller and displays them. In addition, the numerical values are archived via the WinCC tag logging function. A Step 7 project and a WinCC project are published together with this description. 1.2 Prerequisites For SIPLUS CMS 2000: Knowledge of the SIPLUS CMS2000 system For parameterization: Firefox V3.6.x web browser Application Example 6 of 22

7 1 Introduction For Step 7 V5.4: Knowledge of SIMATIC Step 7 Basic System requirements The conditions of SIMATIC Step 7 Basic (V5.4 SP5) are applicable For WinCC 7.0 SP3 Knowledge of WinCC configuration Required hardware components SIPLUS CMS2000 Basic Unit VIB V1.1 SIMATIC S CPU315-2 PN/DP with CP Lean PC with WinCC V7.0 software 1.3 Differentiation This application example does not represent a complete system monitoring concept. It merely describes the connection establishment and diagnostics data transfer of SIPLUS CMS2000 information to the controller as well as subsequent data processing in the controller and visualization of such diagnostics information by means of WinCC. The required parameterization of the SIPLUS CMS2000 device has to be carried out via a web browser (Mozilla Firefox V3.6x). For data handling in the S7 controller, the blocks required for this example were taken from the application example "Data Transfer from SIPLUS CMS2000 to S7-300/CP via TCP/IP". The required network configuration and application of these blocks is roughly described in chapter 2.2 S7 Controll. For further information, please refer to the application example Data Transfer from the SIPLUS CMS2000 TCP/IP Data Interface to an S7-300CP. 1.4 Source Code for Application Description The source code for this application description consists of a Step 7 project "Siplus_S7.zip" and a WinCC project "WinCC_Proj.zip". A complete configuration was already implemented in both projects. With identical hardware and IP configuration, the following steps have to be carried out in order to reproduce the complete information chain: 1) De-archive the S7-300 project "Siplus_S7.zip" in the SIMATIC Manager and load it into the controller ( CP contains IP: ) 2) If required, re-assign the IP address on the CMS2000 device (in the example, the default device IP was retained) 3) Configure the CMS2000 device for cyclic transfer of TCP/IP telegrams: Under Ethernet, set "Send Cyclic Ethernet", "Destination IP" ( ), "Destination Port" (2045) and "Extended telegram" 4) Unpack the WinCC project and start the WinCC file "CMS2000.MCP" from the folder "WinCC_Proj." 5) Start runtime select start screen: "Startbild.pdl"; diagnostics data are visualized Application Example 7 of 22

2 Application Description 2.1 SIPLUS CMS2000 The SIPLUS CMS2000 device generally features an Ethernet interface which can be accessed via a web browser (Mozilla Firefox V3.6).

8 2 Application Description 2.1 SIPLUS CMS2000 The SIPLUS CMS2000 device generally features an Ethernet interface which can be accessed via a web browser (Mozilla Firefox V3.6). Device parameterization as well as display of process data and messages are realized in this manner. Also TCP/IP telegrams with diagnostics information can be transferred from the device via this interface. In this context, a differentiation between two types of TCP/IP telegrams is made: The "compact telegram", which contains messages only, and the "extended telegram", which additionally contains 64 measured values as well as all status information on measured values and spectra. The extended telegram was used for the following application example. For configuration of SIPLUS CMS2000, the device has to be connected to a PC via Ethernet. In its default state, the SIPLUS CMS2000 can be reached by means of the Firefox V3.6x web browser under IP address The following steps are required to parameterize the device for extended telegram transfer: First, log onto the "Home" page to make the device settings. Under the menu item "Ethernet", click "Send cyclic ethernet telegram (TCP)" to enable cyclic TCP telegram transfer of SIPLUS CMS2000. Specify the telegram's destination under "Destination IP address" and "Destination Port". In this application example, the telegram is transferred to the CP of the S7-300 controller with the IP address The "Destination Port" represents the port number set under SIMATIC NetPro (in the example: 2045). The "Cycle Time" determines the cyclic intervals of telegram transfer. The extended telegram type is required for the example. Next, enable parameterization via the button "Write to Device" and switch the device to the "RUN" mode. Fig. 2 Settings - "Send cyclic ethernet telegram (TCP)" For further information on SIPLUS CMS2000, refer to the "SIPLUS CMS2000 Manual". Application Example 8 of 22

2.2 S7 Controller For connection establishment and diagnostics data transfer from SIPLUS CMS2000 to the S7 controller, the following two points are decisive: 1.

9 2.2 S7 Controller For connection establishment and diagnostics data transfer from SIPLUS CMS2000 to the S7 controller, the following two points are decisive: 1.) Corresponding function blocks are required for the reception and processing of diagnostics data from SIPLUS CMS2000. These blocks are exemplarily contained and interconnected in the S7 project "Siplus_S7.zip" OB1: Cyclic call-up of FB101 FC6 "AG_RECV": NetPro block from the "SIMATIC_NET_CP" library; required in FB101 for data reception via TCP/IP. FB101 " RCV_TCPProxy_EXTD": Processing of the extended telegram's data FC100 "LDW_TO_BREAL": Used in FB101 for conversion of a 32 bit floating point number received in LittleEndian format into BigEndian format and return transfer as real value FC101 "DW_TO_H_L_Word": Analogous to FC100, FC101 is used in FB101; this function divides a DWORD into a "High" and "Low" WORD OB 35 "Watchdog interrupt": Required according to S7-300 HW-Config DB 80 "ReceiveDB" : In addition to these function blocks, a further data block is required for saving of the data processed via FB101; the values from this block are directly transferred to WinCC Fig. 3 Diagnostics data transfer from SIPLUS CMS2000 to S7-300 CP Application Example 9 of 22

2.) Configuration of an Ethernet network via SIMATIC NetPro. Please note that this is an unspecific TCP connection. The application example is based on the following network configuration: Fig.

10 2.) Configuration of an Ethernet network via SIMATIC NetPro. Please note that this is an unspecific TCP connection. The application example is based on the following network configuration: Fig. 4 IP network configuration of SIPLUS CMS2000 and S7 controller For further information on connection establishment and data transfer from SIPLUS CMS2000 to the S7 controller, refer to the application example Data Transfer from the SIPLUS CMS2000 TCP/IP Data Interface to an S7-300CP. 2.3 WinCC Analogous to the Step 7 project, a complete example configuration for the visualization of SIPLUS CMS2000 diagnostics data was also implemented in the WinCC project "WinCC_Proj.zip". This refers to: Variable connection to the controller via a TCP/IP connection Creation of the data structure "CMS2000_Structure" under structure types The Graphics Designer not only contains prepared screens such as o Startbild.PDL o Charts.PDL but also type screens as well as derived instances o Bildfenster _Home.PDL o Bildfenster _CurrentValues Under "Tag Logging", an archive "CMS2000_Device1" is defined for archiving of the current measured values Application Example 10 of 22

2.3.1 Connection to the Controller via TCP/IP In the variable household of WinCC, a TCP/IP connection to the controller was created via the SIMATIC S7 PROTOCOL SUITE.

11 2.3.1 Connection to the Controller via TCP/IP In the variable household of WinCC, a TCP/IP connection to the controller was created via the SIMATIC S7 PROTOCOL SUITE. Depending on the configuration of the PC's programming device / PC interface, the corresponding logical access point for the WinCC application has to be selected. This is done as follows: Select "Variable household" "SIMATIC S7 PROTOCOL SUITE" "TCP/IP" with the right mouse button and call up "System parameters". Under the tab "Unit", select the interface under "Logical device name" (e.g.: TCP/IP(Auto) Realtek..) and confirm with "OK". Fig. 5 Selection of the logical device name and access point of the application Depending on the configuration of the IP network, the IP address for the CP is assigned to the control: Click "Connection S7 controller" with the right mouse button and select "Properties". Under the navigation bar "General", select "Properties" and enter and confirm the IP address of the CP (in this example ) and the slot number of the CPU (2). Application Example 11 of 22

12 Fig. 6 Setting of the CP's IP address Definition of Structure Types The diagnostics data which are cyclically transferred to the CP of the S7 controller by SIPLUS CMS2000 are processed by FB101 "RCV_TCPProxy_EXTD" and then saved in a data block. This "ReceiveDB" is created as DB80 in this application example. To ease data handling in WinCC, a structure type analogous to the "ReceiveDB" was created. As a result, the individual measured values and status information are represented in WinCC identically with the controller. Application Example 12 of 22

Fig. 7 Structure "ReceiveDB" and structure type"cms2000_structure" 2.3.

13 Fig. 7 Structure "ReceiveDB" and structure type"cms2000_structure" Structure of the Structure Type The tables below provide an overview of the individual variables and variable and spectra states as well as their relevance for visualization (Fig. 8, 9, 10). Variable name S7 data WinCC Description type data type REV REAL FLOAT Measured value revolution/speed AI1 REAL FLOAT Measured value analog input 1 AI2 REAL FLOAT Measured value analog input 2 TEMP11 REAL FLOAT Measured value temperature 1 TEMP12 REAL FLOAT Measured value temperature 2 TEMP13 REAL FLOAT Measured value temperature 3 VIB1_RMS REAL FLOAT Measured value RMS VIB1 VIB1_DKW REAL FLOAT Measured value DKW VIB1 Stat_REV WORD WORD Measured value state revolution/speed Stat_AI1 WORD WORD Measured value state analog input 1 Stat_AI2 WORD WORD Measured value state analog input 2 Stat_TEMP11 WORD WORD Measured value state temperature 1 Stat_TEMP12 WORD WORD Measured value state temperature 2 Stat_TEMP13 WORD WORD Measured value state temperature 3 Stat_VIB1_RMS WORD WORD Measured value state RMS VIB1 Stat_VIB1_DKW WORD WORD Measured value state DKW VIB1 Wrong_Type BOOL BIT "True" when incorrect telegram is used, "false" with correct telegram Index INT SHORT Telegram length OP_Status BYTE BYTE State indication of SIPLUS CMS2000 Act_Proc_Alerts BYTE BYTE Number of currently active process alarms Application Example 13 of 22

14 Act_Sys_Alerts BYTE BYTE Number of currently active system alarms Act_Proc_Warnings BYTE BYTE Number of currently active process warnings Act_Sys_Warnings BYTE BYTE Number of currently active system warnings T_Q_Proc_Messages BYTE BYTE Number of currently active process messages which have to be acknowledged T_Q_Sys_Messages BYTE BYTE Number of currently active system messages which have to be acknowledged LED1_GR BYTE BYTE Current state LED "Normal" (green); 0=OFF; 1=ON LED2_YE BYTE BYTE Current state LED "Warning" (yellow) 0=OFF; 1=ON LED3_RE BYTE BYTE Current state LED "Alarm" (red) 0=OFF; 1=ON Stat_Spec_VIB1_V WORD WORD Spectrum state "Spectrum velocity" Stat_Spec_VIB1_A WORD WORD Spectrum state "Spectrum acceleration" Stat_Spec_VIB1_ENV WORD WORD Spectrum state "Envelope spectrum" Tel_Timeout BOOL BIT "True" when communication between S7 and CMS2000 is interrupted, "false" with active connection between S7 and CMS2000 TEMP21 REAL FLOAT Measured value temperature 4 TEMP22 REAL FLOAT Measured value temperature 5 TEMP23 REAL FLOAT Measured value temperature 6 Stat_TEMP21 WORD WORD Measured value state temperature 4 Stat_TEMP22 WORD WORD Measured value state temperature 5 Stat_TEMP23 WORD WORD Measured value state temperature 6 VIB2_RMS REAL FLOAT Measured value VIB2_RMS VIB2_DKW REAL FLOAT Measured value VIB2_DKW Stat_VIB2_RMS WORD WORD Measured value state RMS VIB2 Stat_VIB2_DKW WORD WORD Measured value state DKW VIB2 Stat_Spec_VIB2_V WORD WORD Spectrum state "spectrum velocity" Stat_Spec_VIB2_A WORD WORD Spectrum state "Spectrum acceleration " Stat_Spec_VIB2_ENV WORD WORD Spectrum state "Envelope spectrum" Fig. 8 Diagnostics data OP state: Operating state of the SIPLUS CMS2000 device: 3 = Fault state ("Not ready") 4 = Stop ("Ready") 5 = Measuring 6 = Teaching 7 = Run-inhibit 8 = Run Fig. 9 Operating states Measured value state Field with 1 status word (16 bit) for each measured value; indexation see blow; assignment as follows: Bit 0: 0 = Measured value not configured 1 = Measured value configured Bit 1: 0 = Signal not or incorrectly detected 1 = Signal correctly detected Bit 2: 0 = Measured value not calculated / not valid 1 = Measured value calculated and valid Bit 3: 0 = "not green" 1 = "green": Measured value is monitored, no threshold limit violation Application Example 14 of 22

15 Spectrum state Bit 4: 0 = "not yellow" 1 = "yellow": Measured value is monitored, warning threshold violated Bit 5: 0 = "not red" 1 = "red": Measured value is monitored, alarm threshold violated Bit 6: 0 = No warning acknowledgement required 1 = Warning has to be acknowledged for this measured value Bit 7: 0 = No alarm acknowledgement required 1 = Alarm has to be acknowledged for this measured value Field with 1 status word (16 bit) for each spectrum v(f) / a(f) / env(f); indexation see blow; assignment as follows: Bit 0: 0 = Spectrum not configured 1 = Spectrum configured Bit 1: 0 = Vibration signal not or incorrectly detected 1 = Vibration signal correctly detected Bit 2: 0 = Spectrum not calculated / not valid 1 = Spectrum calculated and valid Bit 3: 0 = "not green" 1 = "green": Spectrum is monitored, no threshold limit violation Bit 4: 0 = "not yellow" 1 = "yellow": Spectrum is monitored, warning threshold violated Bit 5: 0 = "not red" 1 = "red": Spectrum is monitored, alarm threshold violated Bit 6: 0 = No warning acknowledgement required 1 = Warning has to be acknowledged for this spectrum Bit 7: 0 = No alarm acknowledgement required 1 = Alarm has to be acknowledged for this spectrum Fig. 10 State overview of the individual bits' significance Creation of Online Variables An online variable was created for the reception of data from the control in WinCC. The previously defined structure type "CMS2000_Structure" represents the data type of this online variable. In the application example, the variable is interlinked with the address of "ReceiveDB" from the control (in the example: DB80). Application Example 15 of 22

Fig. 11 Creation of online variable on the basis of the structure type To create online variables, proceed as follows: Right mouse click on "Connection_S7_control" "New variable".

16 Fig. 11 Creation of online variable on the basis of the structure type To create online variables, proceed as follows: Right mouse click on "Connection_S7_control" "New variable". Under the tab "General", select a name and under "Data type", select "CMS2000_Structure". Under "Select", enter the DB number (e.g. DB 80). The values of DB80 are now saved in "CMS2000_Structure". Application Example 16 of 22

Fig. 12 Creation of online variable on the basis of the structure type 2.3.

17 Fig. 12 Creation of online variable on the basis of the structure type Layout of the WinCC Interface The following WinCC interfaces were created for information visualization in this application example: Screen name Type Description Startbild.pdl Bildfenster_Home.pdl Bildfenster _CurrentValue.pdl Charts.pdl WinCC screen Instance screen Instance screen WinCC screen Start screen after activation of WinCC runtime Derived Derived Chart display of all archive data In the start screen, the contents for the screen window are activated via "Home", "Current Values" and "Charts". Application Example 17 of 22

18 Fig. 13 Layout Startbild.pdl Structuring of Diagnostics Information in Type Screens The visualization of diagnostics information from SIPLUS CMS2000 was exemplarily realized via type screens for this application example. For future use, this offers the major advantage of rapid expendability to multiple SIPLUS CMS2000 devices. The structure type "CMS2000_Structure" serves as the basis for the dynamization of graphics properties in both type screens. For a clearer arrangement, all diagnostics information was divided into two separate WinCC screens which are identical with the web browser views. Application Example 18 of 22

19 Fig. 14 Type Fig. 15 Type Application Example 19 of 22

2.3.7 Creation of Instance Screens from Type Screens Before type screens can be displayed on the runtime interface, instance screens have to be generated from the type screens.

20 2.3.7 Creation of Instance Screens from Type Screens Before type screens can be displayed on the runtime interface, instance screens have to be generated from the type screens. Upon the creation of instances, all screen properties are interlinked with the corresponding online variables on the basis of the general structure description. Fig. 16 Definition level vs. instance level Type Instance screen in the example: "Bildfenster_Home.PDL" Type Bildfenster_CurrentValues.PDL Instance screen in the example: The generation of an instance is carried out via a dynamic wizard in WinCC: Open the Graphics Designer in a new WinCC screen. Open the dynamic wizard under faceplates "Generate instances in system screen V.1.14" via a double-click. In the dialog, select the corresponding type screen in the input field "Generate instance for the following faceplate". In the next dialog, create a new link to the structure variable (online variable) "CMS2000_1" via the button "Link" and confirm with OK. Close the dynamic wizard via the button "Next" or "Complete". Application Example 20 of 22

21 Fig. 17 Generation of "instances" Chronological Trend Curves via Tag Logging In order to trace the chronological curve of process data, the online variables are additionally saved in a WinCC archive (in the example: CMS2000_Device1). The recorded archive variables can be displayed in a chart via the trend control archive. Application Example 21 of 22

For this purpose, click the individual variables with the right mouse button.

22 Fig. 18 Overview Tag Logging For archiving, proceed as follows: Open Tag Logging. Enter the process variables under the archive "SIPLUS_CMS2000_Device1". For this purpose, click the individual variables with the right mouse button. Click "Select" under "Properties" and enter the name of the process variable. Fig. 19 Variable connection Tag Logging Application Example 22 of 22

Service & Support. Data Transfer from the SIPLUS CMS2000 TCP/IP Data Interface to an S7-300CP SIPLUS CMS2000. Application Example May 2012

Service & Support. Data Transfer from the SIPLUS CMS2000 TCP/IP Data Interface to an S7-300CP SIPLUS CMS2000. Application Example May 2012 Cover Sheet Data Transfer from the SIPLUS CMS2000 TCP/IP Data Interface to an S7-300CP SIPLUS CMS2000 Application Example May 2012 Service & Support Answers for industry. Warranty and Liability Warranty