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Hardware Troubleshooting GuideCreating a Program for the Creating a Program for the Using the USS Protocol Library to Using the Modbus Protocol... Audience This manual provides informati

Hardware Troubleshooting Guide

Creating a Program for the

Creating a Program for the

Using the USS Protocol Library to

Using the Modbus Protocol

Safety Guidelines

This manual contains notices which you should observe to ensure your own personal safety, as well as toprotect the product and connected equipment These notices are highlighted in the manual by a warningtriangle and are marked as follows according to the level of danger:

Caution used with the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury

Caution

Caution used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage

Notice

Notice indicates a potential situation which, if not avoided, may result in an undesirable result or state

Qualified Personnel

Only qualified personnel should be allowed to install and work on this equipment Qualified persons are

defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and tems in accordance with established safety practices and standards

This product can only function correctly and safely if it is transported, stored, set up, and installed

correctly, and operated and maintained as recommended

Trademarks

SIMATICR, SIMATIC HMIR and SIMATIC NETR are registered trademarks of SIEMENS AG.

Some of other designations used in these documents are also registered trademarks; the owner’s rights may be violated

if they are used by third parties for their own purposes.

We have checked the contents of this manual for agreement with the hardware and software described Since deviations cannot be precluded entirely, we cannot gua- rantee full agreement However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions Suggestions for impro- vement are welcomed.

Disclaimer of Liability Copyright Siemens AG 2003 All rights reserved

The reproduction, transmission or use of this document or its contents is not

permitted without express written authority Offenders will be liable for damages.

All rights, including rights created by patent grant or registration of a utility model

or design, are reserved.

Siemens AG

Bereich Automation and Drives

Geschaeftsgebiet Industrial Automation Systems

Postfach 4848, D- 90327 Nuernberg ETechnical data subject to change.Siemens AG 2003

Siemens Aktiengesellschaft 6ES7298-8FA23-8BH0

Preface

The S7-200 series is a line of micro-programmable logic controllers (Micro PLCs) that can control avariety of automation applications Compact design, low cost, and a powerful instruction set make theS7-200 a perfect solution for controlling small applications The wide variety of S7-200 models and theWindows-based programming tool give you the flexibility you need to solve your automation problems

Audience

This manual provides information about installing and programming the S7-200 Micro PLCs and isdesigned for engineers, programmers, installers, and electricians who have a general knowledge ofprogrammable logic controllers

Scope of the Manual

The information contained in this manual pertains in particular to the following products:

- S7-200 CPU models: CPU 221, CPU 222, CPU 224, CPU 226, and CPU 226XM

- S7-200 EM 22x expansion modules

- STEP 7 Micro/WIN, version 3.2, a 32-bit programming software package for the S7-200

- STEP 7 Micro/WIN Instruction Libraries and TP-Designer for TP070, Version 1.0, a set ofsoftware tools for customers who use an S7-200 with other components, such as the TP070Touch Panel, Modbus, or a MicroMaster drive

Standards Compliance

The SIMATIC S7-200 series meets the following standards:

- European Community (CE) Low Voltage Directive 73/23/EEC

EN 61131 2: Programmable Controllers Equipment requirements

- European Community (CE) EMC Directive 89/336/EEC

Electromagnetic emissions standard

EN 61000 6 3: residential, commercial, and light industry

EN 61000 6 4: industrial environment

Electromagnetic immunity standards

EN 61000 6 2: industrial environment

- Underwriters Laboratories, Inc

UL 508 Listed (Industrial Control Equipment) Registration number E75310

- Canadian Standards Association: CSA C22.2 Number 142 (Process Control Equipment)

- Factory Mutual Research: FM Class I, Division 2, Groups A, B, C, & D Hazardous Locations, T4Aand Class I, Zone 2, IIC, T4

Refer to Appendix A for compliance information

Tip

The SIMATIC S7-200 series meets the CSA standard

The cULus logo indicates that the S7-200 has been examined and certified by Underwriters

Laboratories (UL) to standards UL 508 and CSA 22.2 No 142

Maritime Approvals

The S7-200 products are periodically submitted for special agency approvals related to specific marketsand applications This table identifies the agency and certificate number that the S7-200 products havebeen approved for Not all S7-200 products in this manual have been approved for these special agencyapprovals Consult your local Siemens representative if you need additional information related to thelatest listing of exact approvals by part number

How to Use This Manual

If you are a first-time (novice) user of S7-200 Micro PLCs, you should read the entire S7-200

Programmable Controller System Manual If you are an experienced user, refer to the table of contents

or index to find specific information

The S7-200 Programmable Controller System Manual is organized according to the following topics:

- Chapter 1 (Product Overview) provides an overview of some of the features of the S7-200 family

- Chapter 4 (PLC Concepts) provides information about the operation of the S7-200

- Chapter 5 (Programming Concepts, Conventions, and Features) provides information about thefeatures of STEP 7 Micro/WIN, the program editors and types of instructions (IEC 1131-3 orSIMATIC), S7-200 data types, and guidelines for creating programs

- Chapter 6 (S7-200 Instruction Set) provides descriptions and examples of programming

instructions supported by the S7-200

- Chapter 7 (Communicating over a Network) provides information for setting up the differentnetwork configurations supported by the S7-200

- Chapter 8 (Hardware Troubleshooting Guide and Software Debugging Tools) provides informationfor troubleshooting problems with the S7-200 hardware and about the STEP 7 Micro/WINfeatures that help you debug your program

- Chapter 9 (Creating a Program for the Position Module) provides information about the

instructions and wizard used to create a program for the EM 253 Position module

- Chapter 10 (Creating a Program for the Modem Module) provides information about the

instructions and wizard used to create a program for the EM 241 Modem module

- Chapter 11 (Using the USS Protocol Library to Control a MicroMaster Drive) provides informationabout the instructions used to create a control program for a MicroMaster drive It also providesinformation about how to configure the MicroMaster 3 and MicroMaster 4 drives

- Chapter 12 (Using the Modbus Protocol Library) provides information about the instructions used

to create a program that uses the Modbus protocol for communications

- Appendix A (Technical Specifications) provides the technical information and data sheets aboutthe S7-200 hardware

The other appendices provide additional reference information, such as descriptions of the error codes,descriptions of the Special Memory (SM) area, part numbers for ordering S7-200 equipment, and STLinstruction execution times

v

Additional Information and Assistance

Information about the S7-200 and STEP 7 Micro/WIN

In addition to this manual, STEP 7 Micro/WIN provides extensive online help for getting started withprogramming the S7-200 Included with the purchase of the STEP 7 Micro/WIN software is a freedocumentation CD On this CD you can find application tips, an electronic version of this manual andother information

Programming Tips

The documentation CD includes Programming Tips, a set of application examples with sample

programs Reviewing or modifying these examples can help you find efficient or innovative solutions foryour own application You can also find the most current version of Programming Tips on the S7-200Internet site

Internet: www.siemens.com/S7 200

For additional information about Siemens products and services, technical support, frequently askedquestions (FAQs), product updates, or application tips, refer to the following Internet addresses:

- www.ad.siemens.de for general Siemens information

This Siemens Automation & Drives Internet site includes information about the SIMATIC productline and other products available from Siemens

- www.siemens.com/S7 200 for S7-200 product information

The S7-200 Internet site includes frequently asked questions (FAQs), Programming Tips

(application examples and sample programs), information about newly released products, andproduct updates or downloads

Technical Assistance and Purchasing S7-200 Products

Local Siemens Sales Office or Distributor

For assistance in answering any technical questions, for training on the S7-200 products, or for orderingS7-200 products, contact your Siemens distributor or sales office Because your sales representativesare technically trained and have the most specific knowledge about your operations, process andindustry, as well as about the individual Siemens products that you are using, they can provide thefastest and most efficient answers to any problems that you might encounter

Technical Services

The highly trained staff of the S7-200 Technical Services center is also available to help you solve anyproblems that you might encounter You can call on them 24 hours a day, 7 days a week:

- For calls originating from within the United States of America

Local time: Monday to Friday 0800 to 1900 Eastern timeTelephone: +1 800 241 4453

Fax: +1 (0) 770 740 3699E-Mail: drives.support@sea.siemens.com

- For calls originating from the Americas outside of the USA

Local time: Monday to Friday 0800 to 1900 Eastern timeTelephone: +1 (0) 770 740 3505

Fax: +1 (0) 770 740 3699E-Mail: drives.support@sea.siemens.com

- For calls originating from Europe and Africa

Local time (Nuremberg): Monday to Friday 0700 to 1700Telephone: +49 (0) 180 5050 222

Fax: +49 (0) 180 5050 223E-Mail: techsupport@ad.siemens.de

- For calls originating from Asia and Australia

Local time (Singapore): Monday to Friday 0830 to 1730Telephone: +65 (0) 740 7000

Fax: +65 (0) 740 7001E-Mail: drives.support@sae.siemens.com.sg

Contents

1 Product Overview 1

S7-200 CPU 2

S7-200 Expansion Modules 3

STEP 7 Micro/WIN Programming Package 3

Communications Options 4

Display Panels 4

2 Getting Started 5

Connecting the S7-200 CPU 6

Creating a Sample Program 9

Downloading the Sample Program 12

Placing the S7-200 in RUN Mode 12

3 Installing the S7-200 13

Guidelines for Installing S7-200 Devices 14

Installing and Removing the S7-200 Modules 15

Guidelines for Grounding and Wiring 18

4 PLC Concepts 21

Understanding How the S7-200 Executes Your Control Logic 22

Accessing the Data of the S7-200 24

Understanding How the S7-200 Saves and Restores Data 34

Storing Your Program on a Memory Cartridge 36

Selecting the Operating Mode for the S7-200 CPU 37

Using Your Program to Save V Memory to the EEPROM 38

Features of the S7-200 39

5 Programming Concepts, Conventions, and Features 47

Guidelines for Designing a Micro PLC System 48

Basic Elements of a Program 49

Using STEP 7 Micro/WIN to Create Your Programs 51

Choosing Between the SIMATIC and IEC 1131 3 Instruction Sets 53

Understanding the Conventions Used by the Program Editors 54

Using Wizards To Help You Create Your Control Program 56

Handling Errors in the S7-200 56

Assigning Addresses and Initial Values in the Data Block Editor 58

Using the Symbol Table for Symbolic Addressing of Variables 58

Using Local Variables 59

Using the Status Chart to Monitor Your Program 59

Creating an Instruction Library 60

Features for Debugging Your Program 60

6 S7-200 Instruction Set 61

Conventions Used to Describe the Instructions 63

S7-200 Memory Ranges and Features 64

Bit Logic Instructions 66

Contacts 66

Coils 69

Logic Stack Instructions 71

Set and Reset Dominant Bistable Instructions 73

Clock Instructions 74

Communications Instructions 75

Network Read and Network Write Instructions 75

Transmit and Receive Instructions (Freeport) 80

Get Port Address and Set Port Address Instructions 89

Compare Instructions 90

Comparing Numerical Values 90

Compare String 92

Conversion Instructions 93

Standard Conversion Instructions 93

ASCII Conversion Instructions 97

String Conversion Instructions 101

Encode and Decode Instructions 106

Counter Instructions 107

SIMATIC Counter Instructions 107

IEC Counter Instructions 110

High-Speed Counter Instructions 112

Pulse Output Instruction 126

Math Instructions 141

Add, Subtract, Multiply, and Divide Instructions 141

Multiply Integer to Double Integer and Divide Integer with Remainder 143

Numeric Functions Instructions 144

Increment and Decrement Instructions 145

Proportional/Integral/Derivative (PID) Loop Instruction 146

Interrupt Instructions 156

Logical Operations Instructions 163

Invert Instructions 163

AND, OR, and Exclusive OR Instructions 164

Move Instructions 166

Move Byte, Word, Double Word, or Real 166

Move Byte Immediate (Read and Write) 167

Block Move Instructions 168

Program Control Instructions 169

Conditional End 169

Stop 169

Watchdog Reset 169

For Next Loop Instructions 171

Jump Instructions 173

Sequence Control Relay (SCR) Instructions 174

ix

Shift and Rotate Instructions 180

Shift Right and Shift Left Instructions 180

Rotate Right and Rotate Left Instructions 180

Shift Register Bit Instruction 182

Swap Bytes Instruction 184

String Instructions 185

Table Instructions 190

Add To Table 190

First-In-First-Out and Last-In-First-Out 191

Memory Fill 193

Table Find 194

Timer Instructions 197

SIMATIC Timer Instructions 197

IEC Timer Instructions 202

Subroutine Instructions 204

7 Communicating over a Network 209

Understanding the Basics of S7-200 Network Communications 210

Selecting the Communications Protocol for Your Network 214

Installing and Removing Communications Interfaces 220

Building Your Network 222

Creating User-Defined Protocols with Freeport Mode 227

Using Modems and STEP 7 Micro/WIN with Your Network 229

Advanced Topics 235

Configuring the RS-232/PPI Multi-Master Cable for Remote Operation 241

8 Hardware Troubleshooting Guide and Software Debugging Tools 245

Features for Debugging Your Program 246

Displaying the Program Status 248

Using a Status Chart to Monitor and Modify the Data in the S7-200 249

Forcing Specific Values 250

Running Your Program for a Specified Number of Scans 250

Hardware Troubleshooting Guide 251

9 Creating a Program for the Position Module 253

Features of the Position Module 254

Configuring the Position Module 256

Position Instructions Created by the Position Control Wizard 267

Sample Programs for the Position Module 279

Monitoring the Position Module with the EM 253 Control Panel 284

Error Codes for the Position Module and the Position Instructions 286

Advanced Topics 288

10 Creating a Program for the Modem Module 297

Features of the Modem Module 298

Using the Modem Expansion Wizard to Configure the Modem Module 304

Overview of Modem Instructions and Restrictions 308

Instructions for the Modem Module 309

Sample Program for the Modem Module 313

S7-200 CPUs that Support Intelligent Modules 313

Special Memory Location for the Modem Module 314

Advanced Topics 316

Messaging Telephone Number Format 318

Text Message Format 318

CPU Data Transfer Message Format 320

11 Using the USS Protocol Library to Control a MicroMaster Drive 321

Requirements for Using the USS Protocol 322

Calculating the Time Required for Communicating with the Drive 323

Using the USS Instructions 324

Instructions for the USS Protocol 325

Sample Programs for the USS Protocol 332

USS Execution Error Codes 333

Connecting and Setting Up the MicroMaster Series 3 Drive 334

Connecting and Setting Up the MicroMaster Series 4 Drive 337

12 Using the Modbus Protocol Library 339

Requirements for Using the Modbus Protocol 340

Initialization and Execution Time for the Modbus Protocol 340

Modbus Addressing 341

Using the Modbus Slave Protocol Instructions 342

Instructions for the Modbus Slave Protocol 343

A Technical Specifications 347

General Technical Specifications 348

CPU Specifications 351

Digital Expansion Modules Specifications 357

Analog Expansion Modules Specifications 363

Thermocouple and RTD Expansion Modules Specifications 373

EM 277 PROFIBUS DP Module Specifications 385

EM 241 Modem Module Specifications 397

EM 253 Position Module Specifications 399

(CP 243 1) Ethernet Module Specifications 405

(CP 243 1 IT) Internet Module Specifications 407

(CP 243 2) AS Interface Module Specifications 410

Optional Cartridges 412

I/O Expansion Cable 412

RS-232/PPI Multi-Master Cable and USB/PPI Multi-Master Cable 413

Input Simulators 417

B Calculating a Power Budget 419

C Error Codes 423

Fatal Error Codes and Messages 424

Run-Time Programming Problems 425

Compile Rule Violations 426

xi

D Special Memory (SM) Bits 427

SMB0: Status Bits 428

SMB1: Status Bits 428

SMB2: Freeport Receive Character 429

SMB3: Freeport Parity Error 429

SMB4: Queue Overflow 429

SMB5: I/O Status 430

SMB6: CPU ID Register 430

SMB7: Reserved 430

SMB8 to SMB21: I/O Module ID and Error Registers 431

SMW22 to SMW26: Scan Times 432

SMB28 and SMB29: Analog Adjustment 432

SMB30 and SMB130: Freeport Control Registers 432

SMB31 and SMW32: Permanent Memory (EEPROM) Write Control 433

SMB34 and SMB35: Time Interval Registers for Timed Interrupts 433

SMB36 to SMB65: HSC0, HSC1, and HSC2 Register 433

SMB66 to SMB85: PTO/PWM Registers 435

SMB86 to SMB94, and SMB186 to SMB194: Receive Message Control 436

SMW98: Errors on the Expansion I/O Bus 437

SMB130: Freeport Control Register (see SMB30) 437

SMB131 to SMB165: HSC3, HSC4, and HSC5 Register 437

SMB166 to SMB185: PTO0, PTO1 Profile Definition Table 438

SMB186 to SMB194: Receive Message Control (see SMB86 to SMB94) 438

SMB200 to SMB549: Intelligent Module Status 439

E S7-200 Order Numbers 441

F Execution Times for STL Instructions 445

G S7-200 Quick Reference Information 451

Index 457

xii

Product Overview

The S7-200 series of micro-programmable logic controllers (Micro PLCs) can control a wide variety of devices to support your automation needs

The S7-200 monitors inputs and changes outputs as controlled by the user program, which can include Boolean logic, counting, timing, complex math operations, and communications with other intelligent devices The compact design, flexible configuration, and powerful instruction set combine to make the S7-200 a perfect solution for controlling a wide variety of applications

In This Chapter

S7-200 CPU 2

S7-200 Expansion Modules 3

STEP 7 Micro/WIN Programming Package 3

Communications Options 4

Display Panels 4

I/O LEDs Status LEDs:

System Fault RUN STOP Optional cartridge:

EEPROM Real-time Clock Battery Communications port

Terminal connector (removable on CPU 224, CPU 226 and CPU 226XM)

Clip for installation on a standard (DIN) rail

Access door:

Mode selector switch (RUN/STOP) Analog adjustment potentiometer(s) Expansion port (for most CPUs)

Figure 1-1 S7-200 Micro PLC

Siemens provides different S7-200 CPU models with a diversity of features and capabilities that help youcreate effective solutions for your varied applications Table 1-1 briefly compares some of the features ofthe CPU For detailed information about a specific CPU, see Appendix A

Table 1-1 Comparison of the S7-200 CPU Models

Feature CPU 221 CPU 222 CPU 224 CPU 226 CPU 226XM

Physical size (mm) 90 x 80 x 62 90 x 80 x 62 120.5 x 80 x 62 190 x 80 x 62 190 x 80 x 62

Memory backup 50 hours typical 50 hours typical 190 hours typical 190 hours typical 190 hours typical

High-speed counters Single phase Two phase

Floating-point math Yes Digital I/O image size 256 (128 in, 128 out) Boolean execution

1 You must calculate your power budget to determine how much power (or current) the S7-200 CPU can provide for your configuration If the CPU power budget is exceeded, you may not be able to connect the maximum number of modules See Appendix A for CPU and expansion module power requirements, and Appendix B to calculate your power budget.

Product Overview Chapter 1

3

S7-200 Expansion Modules

To better solve your application requirements, the S7-200 family includes a wide variety of expansion

modules You can use these expansion modules to add additional functionality to the S7-200 CPU

Table 1-2 provides a list of the expansion modules that are currently available For detailed information

about a specific module, see Appendix A

Table 1-2 S7-200 Expansion Modules

Expansion Modules Types

Output Combination

4 x DC In / 4 x DC Out 8 x DC In / 8 x DC Out 16 x DC In / 16 x DC Out

4 x DC In / 4 x Relay 8 x DC In / 8 x Relay 16 x DC In / 16 x Relay

Output Combination

2 x Analog Out

4 x Analog In / 1 Analog Out

STEP 7 Micro/WIN Programming Package

The STEP 7 Micro/WIN programming package provides a user-friendly environment to develop, edit,

and monitor the logic needed to control your application STEP 7 Micro/WIN provides three program

editors for convenience and efficiency in developing the control program for your application To help you

find the information you need, STEP 7 Micro/WIN provides an extensive online help system and a

documentation CD that contains an electronic version of this manual, application tips, and other useful

information

Computer Requirements

STEP 7 Micro/WIN runs on either a personal computer or a Siemens programming device, such as a

PG 760 Your computer or programming device should meet the following minimum requirements:

- Operating system:

Windows 95, Windows 98,

Windows 2000, Windows Me (Millennium

Edition), Windows NT 4.0 (or later