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Introduction This document is intended to provide a quick introduction to the described System.
It is not intended to replace any specific product documentation. On the contrary, it offers
additional information to the product documentation, for installing, configuring and starting up the
system.
A detailed functional description or the specification for a specific user application is not part of
this document. Nevertheless, the document outlines some typical applications where the system
might be implemented.
Word/Expression Explanation
PC Personal Computer
V AC Alternating Current
V DC Direct Current
FB Function Block
Using the The example software contains two Unity projects, one each for the Quantum and
Example Premium PLCs respectively. Please note that the Unity projects are import files, which
Software can be opened by selecting Open from the File menu and the file type *.xef.
Introduction Application diagnostics are used to clarify the causes of a system or machine
malfunction for operating personnel in order to rectify the problem as quick as possible.
For this purpose, function blocks known as diagnostics blocks have been integrated into
the PLC program which monitor the program for specific values and temporal
sequences and report any deviations from set values as possible faults.
Once a fault has been detected, it is written to the fault memory (i.e. the diagnostics
buffer) in the form of a description comprising the block name, a comment, the time of
the fault, etc. As the buffer can be accessed from an external source, e.g., Unity or the
OPC server, fault data can be displayed directly. Moreover, once a fault has been
detected, its program logic is analysed for incorrect variable values, i.e., the variables
whose incorrect values triggered the malfunction can be detected. These variables are
also entered in the fault memory as causes of the fault.
The following diagnostic functions are supported:
• Static diagnostics:
Monitoring of a logical network for the Boolean values "false" or "true". If the relevant
Boolean value is not detected within a certain tolerance window, a message is
generated and the network is analysed for missing or incorrect signals.
Function Blocks: Process requirements (D_PRE) and signal groups (D_GRP)
• Dynamic diagnostics:
Here, the enabling of an action, its execution and the reaction to its execution are
monitored. The action must be enabled within a tolerance window on the basis of a
locking network. The execution must be indicated within a specific period of time and
remain pending as a permanent reaction until a deactivation signal is sent. Incorrect
signals are detected and displayed by the diagnostics function.
Function Blocks: Locking diagnostics (D_LOCK), reaction diagnostics (D_REA), action
diagnostics (D_ACT) and combined diagnostics (D_DYN)
• Sequencer diagnostics
The dynamic reaction of individual steps can be monitored for undershooting the
minimum execution time and overshooting of the maximum execution time. The
incorrect signals associated with the next transition are detected and displayed.
Function Blocks: None; setting is directly in sequencers.
Introduction The system chapter describes the architecture, components and dimensions of the
devices and parts used.
Architecture
Overview The system is a PLC on which the program code for an application is loaded. The
application diagnostics function must be added to the program code in order to monitor
and analyse specific application states. If a fault state is detected (diagnosed) the
associated data is written to the diagnostics buffer as a fault. Faults can be read out and
displayed, for example, via Unity or the OPC server.
The figure below illustrates the essential elements of diagnostics, starting with the
diagnostics logic, which sends its messages to the diagnostics buffer. The viewers then
access the buffer.
In the example system below, the various types of diagnostics, the associated function
blocks and their operation are illustrated.
Layout
Software:
• Unity Pro 2.0.2 (PLC)
Introduction This chapter describes the steps required to install the hardware and set up the software
for the task associated with the following application:
Layout The following points are relevant for application diagnostics in the PLC program:
• Application diagnostics must be activated in the PLC project and the diagnostics
functions, e.g., function blocks must be configured in the program.
• A display unit, usually a PC, must be available for viewing the diagnostics data. In its
simplest form, this will be the programming device for the PLC as the Unity
programming software with integrated diagnostics viewer is installed on this unit.
• There must be a connection between the PLC and the display unit via which
diagnostics data can be exchanged between the two devices.
The following options are available for displaying diagnostics data but are not described
in more detail in this document:
• Diagnostics data on the PLC can optionally be polled via an OPC server, with the
result that the data is available for viewing on any display unit.
• The OPC server may poll a number of PLCs and then display all the data recovered
for viewing on a single unit.
• Similarly, data polled via the OPC server can be distributed to a number of different
display units.
General • Either a Premium or Quantum Unity PLC can be used (the minimum configuration
must include a power supply and a rack).
• Depending on the power supply card used, a 230 V AC or 24 V DC supply is required.
• A connection between the programming device (PC) and PLC is required in order to
program and display the diagnostics messages. This can be established either via a
serial link or, if available, via a USB or Ethernet link.
1 Display LEDs
2 Eject button for PCMCIA-SRAM card
3 Terminal port (TER)
5 Slot for a memory expansion card (PCMCIA)
6 Slot for a communication card (PCMCIA)
8 RJ45 connector for Ethernet connection
9 USB port
10 RESET button
1 LED panel
2 Model number, module description, color code
3 Field wiring port
4 Cover for field wiring port
5 Removable flap
6 Labeling plate
General The Unity Pro configuration software must be installed for the Premium PLC.
The following installation requirements apply in respect to all software packages:
Software
General A connection between the programming device (PC) and PLC is required in order to
program and display diagnostics messages. This can be established either via a serial
link or, if available, via a USB or Ethernet link.
Introduction The Implementation chapter describes all the steps required to initialize, parameterize,
program, and start up the system.
Functional Application diagnostics comprises of three essential elements: the diagnostics logic, the
Description diagnostics buffer and the diagnostics viewer.
The diagnostics logic must be created and programmed in accordance with the
application during PLC configuration. Depending on the requirements, static and
dynamic diagnostics, as well as sequencer and DFB diagnostics, can be set up.
The diagnostics buffer is located on the PLC and does not require configuration.
Either the internal viewer in Unity or the OPC server (polling of diagnostics messages)
can be used to display diagnostics data. The message display format can be
customised to meet the needs of the user and/or process. If an external viewer is used
via the OPC server, communication between the OPC server and viewer must be
configured.
Layout
Introduction This chapter describes how to activate the diagnostics functions for a PLC project and
the information settings common to all diagnostics blocks.
2 Application diagnostics is
activated on the Build tab.
When activating diagnostics,
you must select the Local
diagnostic application level.
Information As in blocks, the same information settings are available for sequencers, although the
Settings data entry procedure differs from that for blocks. The instance name and comment are
Sequencers assigned directly as the step name and step comment, when the step is programmed,
but the area number and acknowledgement procedure are assigned to the entire
sequencer.
Introduction Static diagnostics describes the monitoring of signals and networks not linked directly to
an action such as the controlling of a drive. This means the blocks for static diagnostics
only have one fault output and no action output. Static diagnostics is divided into
process requirements and signal-group monitoring.
Process Process requirements are signals that are absolutely essential for the operation of a
Requirements system, such as a sign-of-life signal from a fieldbus or activated cooling. For this reason
process requirements are always monitored for the value "true". Monitoring is performed
via the D_PRE block.
1 Block connection:
• ED enables monitoring.
• DTIME is the time during
which the signal at IN must
adopt the value "true".
• IN: The network connected to
this signal is monitored for the
value true and analysed for
incorrect values.
• ERR indicates an active fault
(message in buffer).
2 In the example programming
example, there is an AND block
with four signals at the IN input.
In the event of a fault (IN =
false) the block identifies which
signals at the AND block are at
false and makes entries in the
diagnostics buffer accordingly.
Signal Groups Signal groups are signals that are not essential for the operation of a system but can
have an adverse effect on it. An example of such a group would be the fault signal from
a fan running in a group of fans. Unlike process requirements, signal groups are
monitored for the value false. Monitoring is performed using the D_GRP block.
Introduction In dynamic diagnostics, an action output is set on the basis of a trigger and an input
network (locking network) that is to be monitored. If the locking conditions are met, an
action output is switched. If the locking conditions are not met, an entry is made in the
diagnostics buffer (as per static diagnostics). The absent locking-condition signals
causing the switching of the output are written to the buffer.
It is also possible to check for a reaction to the triggering of the action output within a
specific time limit (action monitoring) and, if required, to check for the maintaining of that
reaction until a stop signal is received (reaction monitoring).
An example would be a cam that can only travel once the gap monitoring function at the
cam input and output cannot detect anything (locking condition). When the run
command is received, the cam must reach the next stage within a specific period of time
(action monitoring) and remain there until the next run command (reaction monitoring) is
received.
The blocks available for dynamic diagnostics are locking diagnostics (D_LOCK),
locking/action diagnostics (D_ACT), locking/action/reaction diagnostics - also known as
combined diagnostics - (D_DYN), and reaction diagnostics (D_REA).
Locking Locking diagnostics describes the monitoring of the locking condition. If this is met
Diagnostics during the delay when the trigger is set, the output will be set. The occurrence of the
reaction to the setting of the output is simply used to deactivate the output (the function
does not check whether the reaction occurs within a specific period of time).
Locking/Action Locking/action diagnostics describes the monitoring of locking and action execution.
Diagnostics The locking condition must be met during the delay when the trigger is set in order for
the output to be set. Similarly, once the output has been set, the action must be
executed within a delay time of a second. The execution of the action is indicated by
the setting of the reaction input. This signal is then used to deactivate the output.
1 Block connection:
• ED enables monitoring.
• DTIMEL is the time during
which the lock at UNLOCK
must adopt the value "true".
• DTIMEA is the time during
which the execution of the
action must be indicated with
the value "true" at REACT.
• DTIMER is the maximum time
during which the reaction
signal may be interrupted
following initial occurrence.
• TRIGR is the trigger to start switch:= true I mode
the action; the delay is switch:= false M mode
activated on a rising edge.
• UNLOCK is the locking
condition which must be met
in order to enable ACT.
• REACT: Feedback signal
indicating that the action has
been completed.
• SWITCH: Changeover from/to
M and I modes.
• STOP is used to deactivate
reaction monitoring.
• ERR indicates an active fault
(message in buffer).
• ACT: Action output which
must be set while the locking
condition is true and the
trigger is pending and until
REACT is received.
1 Block connection:
• ED enables monitoring.
• DTIME is the maximum time
during which the reaction
signal may be interrupted
following initial occurrence.
• REACT: Feedback signal
indicating that the action has
been completed.
• STOP is used to deactivate
reaction monitoring.
• ERR indicates an active fault
(message in buffer).
2 By way of a feedback signal for
the action, an AND block with
two signals is connected at the
REACT input. If this signal
changes to "false", the block
identifies which signals at the
AND block are set to "false" and
makes entries in the diagnostics
buffer accordingly.
Introduction Sequencer diagnostics is used to monitor the dynamic response of the individual steps
in a sequencer. It analyzes the transition conditions if a step is not completed within the
specified time and enters the causes, i.e., the faulty transition signals, in the diagnostics
buffer. The same analysis is performed in the event of a step being completed
prematurely (undershooting of minimum time).
Introduction Derived function block (DFB) diagnostics serve a number of different purposes: First, it
can be used to diagnose the logic of user-defined function blocks and, therefore, to
achieve a complete diagnosis of the entire PLC program. Secondly, the DFBs can
themselves be user-defined diagnostics blocks offering more extensive diagnostics
options than the blocks outlined above.
In the first instance of logic monitoring of DFBs, two options are available. First, the
values of the DFB's Boolean input pins can be monitored (the REGDFB, UREGDFB and
DEREG functions are available for this purpose). Second, the internal logic can be
monitored using the REGEXT function. However, it is not possible to use type D_*
instances of the diagnostics blocks described above within the DFB.
The REGDFB, UREGDFB and DEREG functions are also used for the creation of user-
defined diagnostics blocks and the blocks' input-pin values are monitored. The example
project contains an example of a user-defined diagnostics DFB in the form of a DFB for
first-fault monitoring. With this DFB, four inputs are monitored in parallel and only the
first pin that detects an incorrect value indicates a fault.
Diagnosing DFB inputs are diagnosed in the same way as type D_* instances of the blocks
DFB Inputs described, i.e., Boolean inputs can be monitored for the value "true" or "false". If the
required value is not pending at the input, the network connected to the input is
analysed and the faulty signals are entered in the buffer along with the fault message.
In order for inputs to be monitored in this way, the REGDFB and DEREG functions must
be invoked in the DFB for each input to be monitored. REGDFB writes the fault to the
buffer and DEREG deletes it. The extended function UREGDFB can be used instead of
REGDFB.
Introduction Unity features an integrated diagnostics viewer for displaying diagnostics messages and
messages from the local PLC.
• Basic information
• Transition/block name
• Step/pin name
• Trigger variables
6 The diagnostics viewer also
features a dedicated menu bar
via which the following functions
can be executed:
Or
140CPU65160 Quantum CPU; 640KB INTEGR.ETH
140CPS11400 115/230 V 8 A power supply
140XBP00400 Backplane with 4 slots
UNYXCAUSB033 Communication cable USB
110XCA28201 Modbus cable 1 m, RJ45
110XCA203 00 RJ45 adapter on DSUB9