3.

2 HMI and Systemdiagnostics SICAR Standard

Disclaimer

Because of the variety of uses for SICAR described in this publication, those responsible for the use of

SICAR must satisfy themselves that all necessary steps have been taken to assure that each use meets all

performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for

purposes of example. Since there are many variables and requirements associated with any particular

installation Siemens does not assume responsibility or liability (to include intellectual property liability) for

actual use based upon the examples shown in this publication.

Reproduction of the contents of this copyrighted manual, in whole or in part, without the written permission of

Siemens, is prohibited.

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 3.2 HMI and Systemdiagnostics SICAR Standard

Table of contents

1. Introduction 5

2. Basic PLC configuration 5

2.1 Available PLC interface blocks 5
2.1.1 Working with the data blocks 6
2.1.2 Procedure for the configuration 6

3. Global settings and functionality 7

3.1 Layout of the screens and basic screen elements 7
3.2 Menu structure 9
3.3 ’’Template’’ screen 11
3.4 Designation conventions 12
3.5 Clock memory byte of the controller 14
3.6 PLC system time 14
3.6.1 System timer 14
3.6.2 System timer and date 14
3.7 Identification of the selected screen 15
3.8 SICAR job mailbox 19
3.9 FC_HMI_BASIC 21
3.10 Connection of several operator panels to a controller 22

4. Header and operator information 23

4.1 Header 23
4.1.1 Layout of the header 23
4.1.2 Display of current operating mode 24
4.1.3 Status display 24
4.1.4 Display of the initial state 25
4.1.5 Text boxes 25
4.1.6 Sign of life of the CPU 26
4.1.7 Changing the display of the status signals in the header 27
4.2 Operator information 28

5. Manual Operating 29
5.1 Overview 29
5.1.1 Layout and basic functionality of the manual operating screens 29
5.1.2 Elements of the movment / function line 32
5.1.3 Assignment of the function numbers 34
5.2 Purpose of the individual manual operating screens 35
5.2.1 Manual operation 35
5.2.2 User operation screens 35
5.2.3 Special function screens 35
5.3 Configuration and runtime interface 36
5.4 Configuration 37
5.4.1 Global configuration 37

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5.4.2 Number of movement or function 37

5.4.3 Grouping of the movement lines in the manual operating panel 38
5.4.4 Hiding elements of the function line 39
5.4.5 Display text 42
5.5 Runtime interface 44
5.5.1 Interface for information about the binary state 44
5.5.2 Display the current position 46
5.6 Control interface 48
5.6.1 Job mailbox 48
5.6.2 Binary control interface 50
5.7 FC_HMI_MANUAL 51
5.8 Step-by-step procedure 54

6. Production-Data 55
6.1 Overview production data 55
6.2 Process Counter 56
6.2.1 Programming FB982 57
6.2.2 Reset Process counter in the PLC 57
6.2.3 Parameterization of Texts 58
6.3 Shift counter 59
6.3.1 Programming FB982 60
6.3.2 Reset Shift counter in the PLC 60
6.3.3 Reset Shift counter in the HMI 61
6.3.4 Parameterization of Target Values 62
6.3.5 Parameterization of Texts 63
6.4 Cycle time 64
6.4.1 Programming FB982 65
6.4.2 Parameterization of Target Values 66
6.4.3 Parameterization of Texts 67
6.5 Limit values 68
6.5.1 Alarm handling 69
6.5.2 Indication of active Prealarm or Alarm 70
6.5.3 Programming FB982 71
6.5.4 Parameterization of Set- and Prealarm values 72
6.5.5 Parameterization of Texts 72
6.6 Used PLC-Blocks and structure 73
6.7 Initialization of additional screens 74

7. Diagnostics 75
7.1 RSE – Report system error 75
7.1.1 Activating RSE 76
7.2 Messages screen and Message archive screen 78
7.2.1 Layout of the screen and functionality 78
7.2.2 Runtime interface 79
7.2.3 Configuration 79
7.3 DataInterface screen 80
7.3.1 Layout of the screen 80
7.3.2 Runtime interface 81
7.3.3 Configuration 81
7.3.4 PLC-Interface 82
7.4 Version screen 84

8. Hardware Diagnostics 86

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8.1 PROFINET/PROFIBUS diagnosis 87

8.1.1 PROFINET/PROFIBUS overview screen 87
8.1.2 Legend screen 88
8.1.3 Detailed diagnosis screen 89
8.1.4 Trigger screen 91
8.1.5 Runtime interface (FB_PNIODiag) 92
8.2 Drive screen 93
8.2.1 Drive status screen 93
8.2.2 Drive alarms screen 94
8.2.3 Drive values screen 95
8.2.4 Configuring the WinCC flexible screens 96
8.2.5 Runtime interface (FB_G120) 96
8.3 RF300 screen 97
8.3.1 Layout of the screen and functionality 97
8.3.2 Supported RF300 interface moduls 98
8.3.3 Configuring the WinCC flexible screens 98
8.3.4 Runtime interface (FC_HMI_RF300) 99
8.4 SINAMICS screen 101
8.4.1 SINAMICS status screen 101
8.4.2 SINAMICS alarms screen 102
8.4.3 SINAMICS position screen 103
8.4.4 Configuring of the WinCC flexible screens 104
8.4.5 Runtime interface (FB_HMI_SINAMICSCU3x0) 105

9. System screens 106

9.1 System screen 106
9.1.1 Layout of the screen and functionality 106
9.2 Panel Control screen 109
9.2.1 Layout of the screen and functionality 109
9.3 Status Variable screen 110
9.3.1 Layout of the screen and functionality 110

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1. Introduction

The following description contains the information of the SICAR standard for HMI and the
corresponding PLC interface .

2. Basic PLC configuration

2.1 Available PLC interface blocks

Block numbers Symbolic name of the blocks Comment

DB67 DB_HMI_DATA SICAR interface
DB68 DB_HMI_CONFIG SICAR configuration
FC68 FC_HMI_BASIC General PLC program
FC69 FC_HMI_MANUAL PLC program for the operating screens
DB69 DB_HMI_DEVICE_DIAG Interface of the device diagnosis
FC106 FC_HMI_MOBY Moby diagnostic program code
FB461 FB_HMI_SINAMICSCU3x0 SICAR SINAMICS CU 310/320
DB461 diagnostic
FB126, DB126, FB_PNIODiag Profinet/Profibus IO diagnotic
DB128
FC920, FB982, Prod_data Production data
FB997, DB996

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2.1.1 Working with the data blocks

The two DB_HMI_DATA and DB_HMI_CONFIG data blocks form the interfaces between the
HMI screens and the PLC program.
In contrast to the DB_HMI_DATA data block, the DB_HMI_CONFIG data block contains only
the data for configuring the HMI masks and the PLC program.
The configuration settings for the machine must be made with Step7 in the DB_HMI_CONFIG.

2.1.2 Procedure for the configuration

The following table shows a simple possibility for entering the configuration data.

Step 6 Proceed as follows

1 Open the DB_HMI_CONFIG data block with STEP 7 in the declaration
view.
2 Enter the appropriate values for the machine as initial values.
3 Change to the data view of the data block ([View] [Data view] menu).
4 Accept the initial vlaues as current values using the ([Edit] [Initialize
data block]) command.
5 Save the data block ([File] [Save] menu).
6 Load the data block into the controller ([Target system] [Load] menu).
7 Testing the changed configuration.

Note
A detailed description for working with data blocks is contained in the Step7
online help.

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3. Global settings and functionality

3.1 Layout of the screens and basic screen elements

All screens have a standard structure (see Figure 3-1).

(1) Header information - plant status

(2) Message line for alarms and messages
(3) Working area with vertical softkeys (optional)
(4) Line for operator notes
(5) Horizontal softkeys with screen-dependent functions
Figure 0-1 Screen elements

(1) Header
The upper area of each screen contains the header. It contains significant status information,
such as operating mode, initial state, etc. This area also contains the message line for alarms
and messages.
The header can be configured in two different types of representation. Whereas one of the
representation types shows the status information as text, the other representation type shows
the status information as graphic elements. Further details about the header are contained in
Chapter 4 of this manual.

(2) Message line for alarms and messages

The message line is part of the header and so is visible in each screen. All fault and operational
messages are displayed with number, time, status and message text. By default, the most
recently occurring message is always displayed. However, the message settings in WinCC
flexible can be changed so that the oldest associated message is always displayed.

(3) Working area

The working area shows the screen-dependent screen elements.

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(4) Operator notes

Notes for the machine operation can be displayed in this line for the machine operator. The
operator note is output as a single line of text.

(5) Horizontal softkeys

The horizontal softkeys are used primarily to select other screens and are always located in the
lower screen area. Other than their use to call other screens, the function keys are used to
scroll within the selected screen (e.g. page up / page down in the operator screens) or to
activate special functions (e.g. to activate and deactivate the manual operation in the
"PROFIBUS Diagnosis" screen).
By default, the menu structure is based on a two-level structure (main menu and submenu
level). A third menu level is used only when a grouping of inter-related screen forms is required.

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3.2 Menu structure

Although the menu structure of the SICAR basic project has the following form, it can at anytime be
customized by the user for the specific project.
Operator panels with 10" screen

DetaiFigure 0-2 Structure of the menu for operator panels with 10" screen display
Main OEM
menu

Special User Manual Seq Process Hardware Main OP-Mode

Overview Overview_1 Overview_1 Diag Diagnostic Diagnostic menu

Special User Manual Seq Process Hardware Main Manual

Overview Overview_1 Overview_2 Diag Diagnostic Diagnostic menu Operation

Alarm Alarm Manual Detail Cursor Line Page Line Page Main Seq
History Operation Diag to right Up Up Dn Dn menu Diag

Alarm Manual Seq Interlocks Version Main Process

History Operation Diag menu Diagnostic

Web RF300 Manual Seq Process Drives Main Hardware

Server Diag Operations Diag Diagnostics menu Diagnostic

Manual Seq Process Hardware Main Production

Operation Diag Diagnostic Diagnostic menu data

Version Panel Manual Seq Process Save Monitor Main System

control Operation Diag Diagnostic Settings Variables menu

Submenus Main
menu

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Screen forms of the machine manufacturer

The machine manufacturer should give the operator a graphic overview of the associated
machine in the main screen. From this screen, the horizontal softkeys can be used to change to
one of the eight main menus.

Note

The menu structure shown here is the standard menu structure for SICAR. The
menu structure can be customized for specific projects.

Navigation and function keys:

The gray-shaded buttons are navigation and function keys assigned to the individual screens in
the corresponding submenus.
Click the "Main menu" button to return from the current menu to the main menu ("Plant
overview" screen). The "Return" button is configured in the third menu level to return to the
second menu level.
The "Page up"/"Page down" keys and the "Absolute/Symbolic" toggle keys required in the
operating screens are described in Chapter 5.

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3.3 ’’Template’’ screen

The "SS_90_Template" screen is used to add machine-specific screens while retaining the
screen layout and the menu structure.
This results in the following procedure:
Duplicate the "SS_90_Template" screen
Rename the screen
Configure the screen
Include the screen in the menu structure

Figure 0-3 "SS_90_Template" screen for creating your own screens

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3.4 Designation conventions

All WinCC flexible elements, such as screens, variables, graphics and symbol lists have been
named using uniform designation conventions.
The designation structure must provide the following information:
Who created the associated element?
Who changed the element?
How are the individual elements linked with each other?
In other words: All WinCC flexible elements that can be changed by the user (configuring) are
designated with "SO_". When the elements in WinCC flexible are sorted according to name,
these elements appear at the start of the list.
In addition, the designations can be used to determine all elements assigned to a screen.

Designation convention syntax

All WinCC flexible elements, such as screens, variables, graphics and symbol lists must be
named using these uniform designation conventions (see Table 3-1).

Name structure of the screen elements: AB_XX_Name

Icon Description
A Who created the associated screen element?
S: Siemens
O: OEM (machine manufacturer)
C: Customer
B Who should change the screen element?
S: Siemens
O: OEM (machine manufacturer)
C: Customer
XX Assignment of the screen elements to each other
(e.g. 62: means all elements of the "Workpiece counter" screen)
Name Designation of the screen element
(e.g. "PartCounter")

Table 0-1 Syntax of the designation convention for screen elements in Pro Tool

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Example

S S _ 11 _ManualMovement
The name of the screen form is
"ManualMovement”
The number of the screen element is 11.
The screen form may only be changed by
Siemens.
The screen form was created by Siemens.

All other elements only used in the "ASIDiagnostic" screen, such as variables or symbol lists,
also have the identification 51.
E.g.: Variable: SS_11_ManualMovment
Text list: SO_11_ManualMovement

Global screen elements (identification 00)

All screen elements not uniquely assigned to a specific screen have the identification 00 (e.g.
the variables or symbol lists used in the header).

Screen element groups

In some cases, screen elements, e.g. variables, are used together by complete screen groups.
A common group identification is then assigned to such screen elements.
For example, all screen elements used by all operating screens have the identification 10.
Screen elements used only for a specific operating screen have the associated identification of
the corresponding screen to which they are assigned (e.g. for the "SS_11_ManualMovement"
screen).

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3.5 Clock memory byte of the controller

The 8 bits of the clock memory byte change their binary value cyclically in the pulse pause ratio
1:1 with a period of 0.1 second to 2 seconds.
The clock memory byte is used by the SICAR blocks for internal, time-based trigger events (e.g.
monitoring of the controller <> OP communication).
The clock memory byte must be transferred as input parameter to the "FC_HMI_BASIC". The
FC_HMI_ BASIC function creates pulses of the individual clock signals and cyclically updates
the variables of the data blocks.

3.6 PLC system time

3.6.1 System timer

To avoid using any timer of the CPU, all time functions within the SICAR blocks
are realized using the CPU system time. The system time is fetched with the
SFC64 and further processed.

3.6.2 System timer and date

The SFC 1 ("READ_CLK") is used to read the date and time of the PLC from the
"FC_HMI_BASIC" block. The system time will be written in the
"AREAPOINTER.DATE_TIME_PLC [1..12]" data area of the "DB_HMI_DATA".
The "Controller date/time" area pointer is read from the panel with an acquisition cycle of 120
seconds and a synchronization with the OP clock is performed. If, for some reason, the
synchronization of the clocks has been disabled, the "Controller date/time" area pointer must be
deleted from the WinCC flexible configuration.

Note

The acquisition cycle of the "PLC date and time" area pointer should not be
chosen too small, because it affects the communications capability of the
operator panel. By default, 120 seconds (2 minutes) are set for the acquisition
cycle.

The area pointer is located in WinCC flexible in the sub-tab of the

Communication > "Connections" screen.

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3.7 Identification of the selected screen

The information which screen is selected on the operator panel is made available in the WinCC
flexible "SS_00_ScreenIdentification" variable. For the screen construction, the corresponding
value is written in the variable; for screen removal, the variable is set to zero.
To keep the cycle time of the controller as small as possible, the program code for a specific
screen should be executed only when the corresponding screen is selected.

The WinCC flexible "SS_00_ScreenIdentification" variable is defined as follows:

Tag: SS_00_ScreenIdentification
Format: WORD
PLC address: "DB_HMI_DATA".GLOBAL.SCREEN_ID

Configuring screen events

For details of configuring screen events, see Figure 3-5.

(1) Properties dialog of a screen

(2) Register [events]
(3) Event [established] when the function is initiated
(4) Function [SetValue] to be performed
Figure 0-4 Configuring the screen event to identify the selected screen

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Codes to identify the individual screens

WinCC Designation of the system screen Code to identify the screen form
flexible High Low [dec.] [hex.]
screen byte byte
number

General screen forms

1 SO_01_MainScreen 01 1 257 0x0101
2 SS_02_Status 01 2 258 0x0102
4 SS_04_SystemScreen 01 4 260 0x0104
5 SS_05_PanelControl 01 5 261 0x0105
6 SS_06_Version 01 6 262 0x0106
9 SS_09_Operation mode for Seq_Diag
10 SS_10_Operation mode for FB301

"Manual" screen forms

11 SS_11_ManualMovement 10 1 2561 0x0A01
12 SS_12_UserOperation 10 2 2562 0x0A02
13 SS_13_SpecialFunction 10 3 2563 0x0A03

111 SO_111_Man_Overview_1
112 SO_112_Man_Overview_2

121 SO_121_User_Overview_1
122 SO_121_User_Overview_2

131 SO_131_Special_Overview_1

reserved
21 SS_21
22 SS_22
23 SS_23
24 SS_24
25 SS_25
26 SS_26

Alarms and messages

31 SS_31_Alarm 30 1 7681 0x1E01
32 SS_32_AlarmHistory 30 2 7682 0x1E02
35 30 5 7685 0x1E05
36 SS_LAD Detail diagnosis 30 6 7686 0x1E06
37 SS_STL Detail diagnosis 30 7 7687 0x1E07
38 SS_Sequence diagnosis CE + message block
screens
39 SS_Sequence diagnosis PC + message block
screens

Drive G120
41 SS_41_FB307_CU240x_Status
42 SS_42_FB307_CU240x_Values
43 SS_43_FB307_CU240x_Alarms
44 40 4 10244 0x2804
45 40 5 10245 0x2805

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WinCC Designation of the system screen Code to identify the screen form
flexible High Low [dec.] [hex.]
screen byte byte
number
50 SS_50_Drive_Overview

57 SS_57_MobyDiagnostics 50 7 12807 0x3207

58 SO_58_RF300Data 50 8 12808 0x3208

Machine information
61 SO_61_MachineOverview 60 1 15361 0x3C01
62 60 2 15362 0x3C02
63 60 3 15363 0x3C03
65 60 5 15365 0x3C05
67 SS_67_DataInterface 60 7 15367 0x3C07

PNIO diagnostics
70 SS_70_HardwareDiagnostic 70 0 17920 0x4600
71 SS_71_StationOverview1 70 1 17921 0x4601
72 SS_72_StationOverview2 70 2 17922 0x4602
73 SS_73_StationOverview3 70 3 17923 0x4603
74 SS_74_StationOverview4 70 4 17924 0x4604
75 SS_75_StationDetail 70 5 17925 0x4605
76 SS_76_DiagnosticRepeater 70 6 17926 0x4606
77 SS_77_HistoryTrigger 70 7 17927 0x4607
78 SS_78_Legend 70 8 17928 0x4608

SINAMICS CU3x0 diagnostics

81 SS_81_ControlStatusword 80 1 20481 0x5001
82 80 1 20481 0x5001
83 SS_83_EPOSStatus 80 1 20481 0x5001
84 80 1 20481 0x5001
85 SS_85_FaultsAndWarnings 80 1 20481 0x5001
86 80 1 20481 0x5001

Customer/project-specific screen forms

70-79 Customer-specific screens *** 70 - - -
80-89 Customer-specific screens *** 80 - - -

OEM-specific screen forms

90 OEM-specific screens (template) *** 90 - - -
91
92

TEC-Unit Diag screens (300-399) delivered with basic project

300 SS_
301 SS_
302 SS_
303 SS_
304 SS_

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WinCC Designation of the system screen Code to identify the screen form
flexible High Low [dec.] [hex.]
screen byte byte
number
305 SS_

TEC-Unit Faceplates (without screen number)

Faceplates delivered with basic project

Production data screens

210 SS_210_Prod_data_Overview
211 SS_211_Process counter
212 SS_
213 SS_213_Shift counter
214 SS_214_Cycle times
215 SS_215_Limit_values

OEM TEC-Unit Diag screens (220-299) ***

220 SO_
221 SO_
222 SO_
223 SO_
*** Placeholder for project- or customer-specific screens
(not available in the standard version).

Table 0-2 Identification code of the individual screens

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3.8 SICAR job mailbox

The job mailbox forms the primary interface between the HMI system and the control program
for initiating an operator action.

Structure
The job mailbox has a defined length of four words. The structure is shown in the following
table:

Address Data type Name Description

n+0 WORD JOBNUMBER Job number
n+2 WORD PARAMETER_1 1st parameter of the job
n+4 WORD PARAMETER_2 2nd parameter of the job
n+6 WORD PARAMETER_3 3rd parameter of the job
Table 0-3 Structure of the job mailbox

The first word always contains the job number. Depending on the associated control job, up to
three parameters can be specified.

Number of the job and parameters

The job number corresponds to the screen identification number. This enables all actions
initated by a specific screen to be determined exactly by the screen identification. The
parameters specify the action to be performed. Details can be found in the descriptions of the
associated screens.

Monitoring the connection

Because only status changes for keys and buttons can be transferred to the controller, the
connection between the operator panel and the controller must be monitored for correct
operation. This monitoring is performed using the sign-of-life bit of the operator panel from the
"Coordination" area pointer. The sign-of-life bit is inverted by the operator panel in one second
intervals.
The "FC_HMI_MANUAL" function checks cyclically whether the sign-of-life bit has been inverted
to determine whether the connection to the operator panel still exists. If no inversion of the sign-
of-life bit has been determined during a time interval, the job mailbox will be cleared. The time
interval is defined by the following parameters:
DB_HMI_CONFIG.MANUAL_COMMON. SCREEN_ACTIVE_TIME

! Important

Because the sign-of-life bit is not a real-time signal, depending on the data traffic
on the network and the number of processes running on the operator panel, it can
take longer than one second before the signal has changed its status. To ensure
shorter response times and a faster shutdown of the manual operations, we
recommend that the function keys of the operator panel are used as PROFIBUS
DP direct keys.
The machine manufacturer is responsible for the reliable execution of the manual
operation.

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"Coordination" area pointer

The controller can use this data area to query the status of the operator panel, e.g. startup of
the operator panel, current operating mode and ready for communication.

Structure of the "Coordination" area pointer

The structure of the "Coordination" area pointer with the length of one word:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Startup
bit
Operating
mode
Sign-of-life bit

Bit assigned
Bit not assigned (reserved)

Figure 0-5 Layout of the "Coordination" area pointer

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3.9 FC_HMI_BASIC

The basic functions of SICAR are realized using the "FC_HMI_BASIC" function. This FC is
responsible for the coordination of the interface DBs and HMI screens.

Figure 3-7 shows the parameters of the FC; Table 3-4 describes its parameters.

Figure 0-6 Interface of the "FC_HMI_BASIC" function

FC_HMI_BASIC parameters

Name Type Default Example Description

HMI_DATA_DB INT 67 67 Number of the HMI runtime
data block
HMI_CONFIG_DB INT 68 68 Number of the HMI
configuration data block
CLOCK_PULSES BYTE MB1 MB1 Clock memory byte, configured
in the object properties of the
CPU (HW Config)
FIRST_SCAN BOOL M0.5 M0.5 Restart flag,
1 – signal for the first cycle
after CPU startup
RET_VAL WORD - TEMP Error message of the
VARIABL "FC_HMI_BASIC" function:
E W#16#80C1 => internal SFC1
(READ_CLK) call with error
RET_VAL_EXT INT - TEMP Error message from the SFC1
VARIABL "READ_CLK", see online help
E for the SFC1
Table 0-4 Description of the FC_HMI_BASIC parameters

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3.10 Connection of several operator panels to a controller

If several SICAR operator panels are to be connected with a controller, a new DB interface must
be provided in the controller for the second and each additional operator panel. This requires
the duplication of the SICAR DBs and the modification of the numbers in Step7 and WinCC
flexible.
The following table lists the steps required to change the DB numbers.

Step Proceed as follows

1 Duplicate the DB_HMI_DATA (DB67) as runtime interface for the second
operator panel.
2 Duplicate the DB_HMI_CONFIG (DB68) for the configuration of the
second operator panel.
3 The FC_HMI_BASIC (FC68) must be called once in the program for each
operator panel. The "HMI_DATA_DB" and "HMI_CONFIG_DB" input
parameters must be supplied with the appropriate DB numbers.
4 The FC_HMI_MANUAL (FC69) must be called once in the program for
each operator panel. The "HMI_DATA_DB" and "HMI_CONFIG_DB"
input parameters must be supplied with the appropriate DB numbers.
5 The number of the DB_HMI_DATA (DB67) is parameterized in the
WinCC flexible "SO_00_DBNumberData" variable. This number must be
changed in the corresponding WinCC flexible configuration. The new
number of the duplicated DB_HMI_DATA must be entered as start value
in the properties dialog of the WinCC flexible "SO_00_ DBNumberData"
variable for the "initial settings".
6 The number of the DB_HMI_CONFIG (DB68) is parameterized in the
WinCC flexible "SO_00_DBNumberData" variable. This number must be
changed in the corresponding WinCC flexible configuration. The new
number of the duplicated DB_HMI_CONFIG must be entered as start
value in the properties dialog of the WinCC flexible
"SO_00_DBNumberConfiguration" variable for the "initial settings".
7 The WinCC flexible area pointers with the DB67 (DB_HMI_DATA)
absolute address must receive the duplicated DB_HMI_DATA as new
absolute address.
8 The user-specific fault and operational messages must be assigned new
addresses, unless the same messages should be displayed on both
operator panels.
Table 0-5 Changing the numbers of the SICAR standard DBs.

Because at any one time only a single operator panel can access the hardware diagnosis, an
operator panel change must be configured for this purpose.

! Important

Manual operations performed from both operator panels must be mutually

interlocked. This remains the responsibility of the user.

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4. Header and operator information

4.1 Header

4.1.1 Layout of the header

The SICAR header shows the operator general information about the machine status.

Figure 4-1 shows the structure of the header in SICAR.

(1) (2) (3) (4) (5) (8) (6)

(7)

(1) Display of current operating mode

(2) Line status
(3) Display of the current position
(4) Line name
(5) Screen name
(6) CPU sign-of-life display
(7) Alarm and message line
(8) System time

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4.1.2 Display of current operating mode

See “31_Initialization and Operation modes.doc”, chapter 4.2

4.1.3 Status display

The following states are possible for the machine status display:

Text Icon Meaning Description

O.K. No fault message or operation
message is present.
Warning One or more operation messages are
present.
Fault One or more fault messages are
present.
Table 4-4 – Status display

Runtime interface

The "Status display" is controlled with the following status bits in the DB_HMI_DATA data block:

Meaning Interface Type

O.k. --- (if no additional status bit has the status "1"– BOOL
status = ready)
Warning DB_HMI_DATA.HEADER.STATUS.WARNING BOOL
Interrupt DB_HMI_DATA.HEADER.STATUS.ALARM BOOL
Table 4-5 Status display
By default, the status bits are not linked with other variables or objects (e.g. with alarm or
message bits).
Configuration
No configuring required.

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4.1.4 Display of the initial state

The following states are possible for the initial state display:

Text Icon Meaning Description

Empty The machine is not in the "initial state"
Initial state The machine is in the "initial state"
Table 4.6 – "Initial state" display

Interface

The "initial state" display is made using the following bit in the
DB_HMI_DATA data block:

Meaning Interface Type

Empty ---
Initial state DB_HMI_DATA.HEADER.POSITION.HOME BOOL
Table 4-7 – "Initial state" display
The "initial state" status is displayed when the bit is "TRUE".

Configuration

No configuring required.

4.1.5 Text boxes

The user has two text fields available to display machine-specific text.

Runtime interface

The text is controlled using two variables in "DB_HMI_DATA". The text assigned to the value of
the variable of the WinCC flexible – text list is displayed as text.

Address: DB_HMI_DATA. HEADER.TEXTINDEX_1

DB_HMI_DATA. HEADER.TEXTINDEX_2
Format: WORD
Range of values: 1..
Default setting: W#16#0

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Configuration

Text list SO_00_HeaderText1

SO_00_HeaderText2
Display Text
Format Decimal
Value Text
1 [Text to be displayed]
… …

The "SO_00_HeaderText2" text list is preconfigured so that the screen name of the selected
screen is displayed.
This requires that the screen number of the selected screen is transferred from the WinCC
flexible "Screen number" area pointer into the "DB_HMI_DATA.HEADER.TEXTINDEX_2"
variable.
For example:
L DB_HMI_DATA.AREAPOINTER.SCREEN_NUMBER.SCREENNUMBER
T DB_HMI_DATA.HEADER.TEXTINDEX_2
This is programmed in the FC67 in the Demo program.
The machine manufacturer must extend the "SO_00_HeaderText2" text list if new screens are
to be added to the WinCC flexible configuration.

4.1.6 Sign of life of the CPU

The sign-of-life in the header displays the operating mode of the PLC. A periodic flashing in
intervals of approximately one second indicates that the controller is in the "RUN" operating
mode.
The "STOP" operating mode is indicated by a orange smiley.

Field Interface
No communication between HMI and PLC

The communication between HMI and PLC has been

established, PLC in Stop

The communication between HMI and PLC has been

established, PLC in Run

Display of the sign-of-life of the PLC

Runtime interface

Field Interface
Sign-of-life DB_HMI_DATA. HEADER.WATCHDOG
Display of the sign-of-life of the CPU

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4.1.7 Changing the display of the status signals in the header

The machine status display in the header can be displayed as a symbol or as text.
The "SS_00_SelectHeader" screen provides both views.
The replacement of the header elements in the permanent window for WinCC flexible with the
corresponding elements from the "SS_00_SelectHeader" screen can be used to change the
display of the status signals.

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4.2 Operator information

The operator information is a text output field used to display information for the operator. The
text display is located above the horizontal buttons.

Runtime interface

Two runtime variables are used to control the dynamic behavior of the text output field.
The first variable, "DB_HMI_DATA. GLOBAL.PROMPT.INDEX", is used to select which text
from the WinCC flexible text list is to be displayed.
The second variable, "DB_HMI_DATA.GLOBAL. PROMPT.ATTRIBUT", is linked with the
attribute of the text output field. The variable so controls the color change of the flashing of the
text output field.

Address: DB_HMI_DATA. GLOBAL.PROMPT.INDEX

Format: WORD
Range of values: 1..
Default setting: W#16#0

Address: DB_HMI_DATA. GLOBAL.PROMPT.ATTRIBUT

Format: WORD
Range of values: 1..
Default setting: W#16#0

Configuration

The WinCC flexible SO_00_OperatorPrompt text list contains the text to be displayed in the text
field for operator information.

Text list SO_00_OperatorPrompt

Display Text
Type Decimal
Value [Text number] [Text to be displayed]
… … …

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5. Manual Operating

5.1 Overview

5.1.1 Layout and basic functionality of the manual operating screens

The operator can use the manual operating screens to perform movements, activate/deactivate
machine elements, select cycle type and perform other actions for which a selection must be
made.
All screens from the manual operation area have the same general structure (see Figure 5-1)

(1) Movement or function line

(2) Switch between symbolic/absolute
(3) Scroll up/down
(4) Current page / total number of pages
Layout of the manual operating screens

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Movement and function line

Each movement and each function is represented by a line.

Every movement or function can be performed in two directions, such as input/output,
open/close, up/down, forwards/backwards. One direction of the movement or function is shown
on the left-hand side of the screen and the other direction is shown on the right-hand side of the
screen.
The two keys to the immediate left or right of the function line are assigned to each movement
as shown in thr figure. These keys are used to activate the associated movement or function.

(1) The two upper vertical softkeys are not assigned to any function line.
(2) This button is assigned to the left-hand function in the first line.
(3) This button is assigned to the right-hand function in the first line.
Assignment to the corresponding function lines

Absolute and symbolic view

The "symbolic/absolute" toggle key can be used to switch between the symbolic and the
absolute designation of the inputs and outputs (e.g. I1.0, O1.0) that are assigned to the
corresponding movements/functions (see Figure 5-3).
The represention in absolute form is displayed only for a parameterizable time. After this time
has expired, the SICAR system switches automatically to the symbolic representation.

(1) Symbolic view

(2) Absolute view
Figure 0-7 Manual operating screens - absolute and symbolic view

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Scrolling

A scroll function can be used to fetch all configured actions for a maximum display of five (10"
device) or three (6" device) movements/functions per page.
When the scroll function is performed, the complete screen is always opened (all displayed
function lines will be replaced by the function lines present on the next page).
When the last page is reached and the page-up key is pressed, the display changes back to the
first page. Similarly, when the first page is reached and the page-down key is pressed, the
display jumps to the last page.
You cannot change the screen (the page is locked) while a movement or function is being
performed.

Selection and display of the page number

The current page number and the total number of pages are displayed at the bottom in each
screen. The page number field, which is an input field, can be used to directly select a page by
entering the appropriate page number from the keyboard or keypad.

Touch panel suppor

Other than the keys at the immediate left and right of each movement or function, the screens
for the manual operation also support touch panel operation (for operator panels with touch
functionality).

As shown in Figure 5-4, each movement/function can be initiated by touching the corresponding
function in the appropriate areas.

(1) Touch-sensitive area (button not visible)

(2) Button activated / display pressed
Manual operating screens – touch panel support

To prevent the inadvertent initiation of a movement, the system is designed so that to initiate a
movement, it must first be selected by touching the appropriate touch-sensitive surface. The
selection of the movement is confirmed by a flashing square next to the movement arrow (see
number (2) in the figure.

Once the movement has been confirmed, the movement can be initiated by subsequently
touching the touch-sensitive area. As confirmation, the square next to the triangle becomes dark
blue.

The function remains selected until one of the following events occurs:
Another movement is selected.
Scroll to another page.
Select another screen.
The sign-of-life monitoring deactivates the movement.

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5.1.2 Elements of the movment / function line

Each movement line consists of the basic elements

(1) Executability, left-hand side

(2) Key/button activated, left-hand side
(3) Will be executed, left-hand side
(4) Name of function
(5) Will be executed, right-hand side
(6) Key/button activated, right-hand side
(7) Executability, right-hand side
(8) Final status (end position), left-hand side
(9) Position (optional)
(10) Final status (end position), right-hand side
Manual operating screens - elements of the individual line

Designation (4)

The "Designation" object is the title for the movements/functions. Scrolling the screen updates
the designations of the functions with the associated description of the associated line on the
current page.
The text items are configured in text lists for WinCC flexible. The "Designation" element does
not have any runtime interface.
Position (9)

The "Position" object can be used to display a numeric position value. The position field is
optional and can be hidden for each movement or function.

Executability (1 and 7)

The "Executability" object indicates whether or not a movement can be performed.

If the motion can be executed, the triangle is filled dark blue.
If the movement cannot be performed because it is disabled or interlocked (e.g. target
position reached), the triangle is displayed as an unfilled contour.
The status information must be supplied as binary signals via the runtime interface.

Final state (end position) (8 and 10)

The "Final state" element represents movement- or function-specific end positions in both
directions (e.g. left/right, up/down, open/closed).
If a target position has not yet been reached, the associated text of this position appears on
a gray background.
If the target position has been reached, the appropriate text is displayed with a yellow (left-
hand side) or green (right-hand side) background.

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Various text items for the symbolic and the absolute view can be displayed for each "Final state"
element. The text items are configured in text lists for WinCC flexible.
The status information must be supplied as binary signals via the runtime interface.

Execution (3 and 5)

The "Execution" element shows the status of the output from which the associated
movement/function is controlled.
If the output is deactivated, the associated text appears with a gray background.
If the output is activated, the appropriate text is displayed with a yellow (left-hand side) or
green (right-hand side) background.
Various text items for the symbolic and the absolute view can be displayed for each "Execution"
element. The text items are configured in text lists for WinCC flexible.
The status information must be supplied as binary signals via the runtime interface.

Key/button activated (2 and 6)

The "Key/button activated" element indicates whether or a key, button or a touch-sensitive area
has been confirmed by the control program (processed). The status information is supplied by
the corresponding function block from SICAR.
The "Key/button activated" element acts as follows for a key-operated panel:
When a key is pressed and confirmed by the controller, the rectangle becomes dark blue.
If a key has not been pressed or not confirmed by the PLC, the rectangle is represented as
an unfilled contour.
The "Key/button activated" element confirms the preselection or selection of a function on the
touch display with the following states (further details for the preselection are contained in the
"Touch panel support" section):
If a function has been preselected, this is indicated by the flashing of the rectangle (a dark-
blue and contoured rectangle flashes in intervals of approximately 0.25 seconds).
If the touch-sensitive surface of a function is activated a second time and this is confirmed
by the controller, the rectangle becomes dark blue.
If the function is not active or preselected, the rectangle is displayed as an unfilled contour.

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5.1.3 Assignment of the function numbers

Each assigned function line is assigned to a fixed function number. The first line is assigned
function number 1, the second line is assigned function number 2, etc.
Lines that are not displayed (all elements hidden) do not interrupt the assignment.
Figure 5-6 shows the assignment of the function numbers over several pages.

Manual operating screens – assignment of the function numbers

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5.2 Purpose of the individual manual operating screens

5.2.1 Manual operation

The manual operating screen contains a maximum of 100 movement or function lines. This
allows special movements to be performed manually using keys. Every movement can be
performed in two directions, such as input/output, open/close, up/down, forwards/backwards.
It is also possible to track each movement during its execution.
If there are more movements than can be displayed on the screen at the same time, the
movements will be displayed on several pages. The individual pages can be grouped. This
means each group forms its own manual operating screen for the operator and, for example,
can be assigned to a specific plant section.

5.2.2 User operation screens

The user opration screen contains up to 64 function lines.

Here, the user can select/deselect his line specific functions.

5.2.3 Special function screens

The special function screen contains up to 32 function lines.

This screens can be used to select/deselect functions like”Control voltage on/off”

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5.3 Configuration and runtime interface

Each manual operating screen has its own text lists, parameter records and controller interface.
These parameters and text lists have the same basic structure and are defined using the name
of the associated screen.

The "DB_HMI_CONFIG" configuration DB and the "DB_HMI_DATA" runtime DB have their own
data area for each screen; this data area is also defined by the designation of the associated
screen. The name of the variable areas of each manual operating screen in the data blocks is
shown in the table.

The name of the screen in The name of the area in "DB_HMI_DATA" and
WinCC flexible "DB_HMI_CONFIG"
SS_11_ManualMovement SCREEN_MANUAL
SS_12_UserOperation SCREEN_USER
SS_13_SpecialFunction SCREEN_SPECIAL

Manual operating screens – structure of the configuration interface

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5.4 Configuration

Changes must be performed both in WinCC flexible and in STEP7.

All text items are stored in text lists for WinCC flexible. Numeric parameters are stored in the
SICAR DB_HMI_CONFIG configuration data block.

5.4.1 Global configuration

The "DB_HMI_CONFIG.MANUAL_COMMON" data area is used for the general configuration

valid for all manual operating screens.

Display time of the absolute view

The time after which the absolute designation is switched back to the symbolic designation is
stored in DB_HMI_CONFIG:

Address: DB_HMI_CONFIG.MANUAL_COMMON.
ABSOLUTE_DISPLAY_TIME
Format: TIME
Range of values: T#1MS…T#24D20H31M23S647MS
Default setting: T#10S (10 seconds)
This parameter is independent of the screen.

"Touch operation preselection" timeout status

The time factor that determines how long a preselection initiated by touch remains active for a
function is defined in DB_HMI_CONFIG in the following data address:

Address: DB_HMI_CONFIG. MANUAL_COMMON.

TOUCH_PRESELECTION_TIME
Format: TIME
Range of values: T#1MS…T#24D20H31M23S647MS
Default setting: T#2S (2 seconds)
This parameter is required only for touch panels and does not depend on the screen (also refer
to the "Touch panel support" section).

5.4.2 Number of movement or function

The number of required movement or function lines must be defined for each manual operating
screen in the associated data block variable in DB_HMI_CONFIG.

Address: DB_HMI_CONFIG.
SCREEN_AAAAAA.NUMBER_OF_ROWS
where AAAAAA = name of the screen (see Table 5-1)
Format: INT
Range of values: 1…64 – for the "setup" and "power up condition"
1…32 – for units, nut runners and nut runner groups
1…16 – for the cycle type and the OEM screen
Default setting: The maximum number of available lines

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5.4.3 Grouping of the movement lines in the manual operating panel

To assign the manual operation to function groups, the manual operating screen can be
selected more than once with different movement lines on the operator panel. When the screen
is selected, the first and the last page number of the pages relevant for this screen selection
must be entered for the variables specified below. This is done using the WinCC flexible
"SetzeWert" function that is configured in addition to the "ActivateScreen" function on the key or
button that selects the manual operating screen. Note that the page number of the last page
must be assigned before the page number of the first page.

Address: WinCC flexible variables:

SS_10_NumberOfFirstPageAtManualScreen (first page)
SS_10_NumberOfLastPageAtManualScreen (last page)
Format: BYTE
Range of values: 1…Max – the maximum value depends on the number of
movement lines (see Section 5.4.2) and on the number of
lines per page (see Section 5.7).
Example
For 64 movement lines and 5 lines per page, this gives 13
pages with movement lines, consequently, the value range
is 1...13.

WinCC flexible configuration of the screen selection of the manual operating screen in groups:

WinCC flexible configuration of the screen selection of the manual operating

screen in groups

Note

Note that the page number of the last page must be assigned before the page
number of the first page.

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5.4.4 Hiding elements of the function line

It is possible to hide elements from the function line.

Depending on the associated configuration, the following elements can be hidden/displayed:
Executability and "key pressed" on the left-hand side;
Executability and "key pressed" on the right-hand side;
"Position";
All elements

(1) All elements are visible (Configuration = 0x0).

(2) The left-hand side is hidden (Configuration = 0x1).
(3) The right-hand side is hidden (Configuration = 0x2).
(4) Both sides are hidden (Configuration = 0x3).
(5) The position is hidden (Configuration = 0x4).
(6) Position and left-hand side are hidden (Configuration = 0x5).
(7) Position and right-hand side are hidden (Configuration = 0x6).
(8) Position, left- and right-hand side are hidden (Configuration = 0x7).
(9) All elements are hidden (Configuration = 0xF).
Manual operating screen – hiding screen elements

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The individual function lines are configured at the following address in the

DB_HMI_CONFIG as described above:

Address: DB_HMI_CONFIG.SCREEN_AAAAAA.ROW_XX
where AAAAAA = name of the screen (see Table 5-1)
and XX is the number of the associated function line
Format: BYTE
Range of values: See Figure 5-9 and Figure 5-2
Default setting: B#16#00

Two configurations (configuration 1 and configuration 2) are possible for each

movement/function.

Byte n
Nibbling n Nibbling n+1
7 6 5 4 3 2 1 0
Configuration 1: hidden left
Configuration 1: hidden right
Configuration 1: position hidden
Configuration 1: all other elements hidden

Configuration 2: hidden left

Configuration 2: hidden right
Configuration 2: position hidden
Configuration 2: all other elements hidden

Bit assigned
Bit not assigned (reserved)
Manual operating screen – structure of the configuration interface

Only one configuration can be active for all movements or functions at any one time. The
associated active configuration (configuration 1 or 2) can be selected dynamically using the
"SELECT_CONFIG" input parameter for the "FC_HMI_MANUAL" function.
The dynamic changing of the configuration settings allows movement or function elements to be
displayed or hidden depending on the associated machine status (e.g. machine in manual
operation). Typical examples are:

Hide the "Executability" and "Key pressed" elements in automatic operation

manual operation configuration 1 BIN 0000, HEX 0
automatic operation configuration 2 BIN 0011, HEX 3
parameter value: BIN 0011 0000 = HEX 03 = B#16#30

Hide the "Position" display in automatic operation

manual operation configuration 1 BIN 0000, HEX 0
automatic operation configuration 2 BIN 0100, HEX 4
parameter value: BIN 0100 0000 = HEX 40 = B#16#40

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The table shows all possible parameter values for the various configurations.

All others Item Right-hand Left- Value

side hand
side:
BIN DEC HEX
0000 0 0x0
yes 0001 1 0x1
yes 0010 2 0x2
yes yes 0011 3 0x3
yes 0100 4 0x4
yes yes 0101 5 0x5
yes yes 0110 6 0x6
yes yes yes 0111 7 0x7
yes yes yes yes 1111 15 0xF
Manual operating screens – values of the configuration interfaces

Example configurations

Several configuration examples follow:

The "Position" element is hidden for both configuration settings:
all types of machine elements (e.g. pumps, valves) that do not supply any confirmation of the
position.
The "Executable" and "Key pressed" elements are hidden for both configuration settings:
Machine elements that are not controlled from the operator panel; only the status needs to be
displayed here (e.g. the "on/off" state controlled by the pushbutton).
The "Executable" and "Key pressed" elements are hidden for one configuration setting: Machine
elements that can be controlled only in manual operation (e.g. machine axis); only the status of
these elements (e.g. "axis moves left" "execution" and "axis has reached the left-hand limit
switch" "end state") is displayed in automatic operation.
All elements are hidden for both configuration settings:
if this setting is made, a blank line results so that the movement or function groups (e.g. axis –
blank line – clamping – blank line – lubrication) can be separated from each other.

Note

SICAR does not interlock the output signals with the "hidden" configuration
settings. This means, even when the "Executable" and "Key pressed" elements
are configured as hidden, the output signals will still be initiated by pressing the
keys to the left or right of the movement or function or by touching the buttons.
The machine-specific control program must realize any required interlock
functionality.

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5.4.5 Display text

All text items displayed in the manual operating screens are configured in the WinCC flexible
text lists. Each screen has its own text list, where the text can be specified for each element.
The text lists have the structure shown in the figure.

(1) Left confirmation

(2) Name
(3) Right confirmation
(4) Left final state
(5) Right final state
Manual operating screens – text lists

All text lists have the same structure.

Text list SO_11_Manual

SO_12_UserOperation
SO_13_SpecialFunction

Display Text
Format Decimal
Value 10 Line #1 - function name – symbolic
Value 11 Line #1 - function name – absolute
Value 12 Line #1 – left confirmation – symbolic
Value 13 Line #1 – left confirmation – absolute
Value 14 Line #1 – left final state – symbolic
Value 15 Line #1 – left final state – absolute
Value 16 Line #1 – right confirmation – symbolic
Value 17 Line #1 – right confirmation – absolute
Value 18 Line #1 – right final state – symbolic
Value 19 Line #1 – right final state – absolute
Value 20 Line #2 - function name – symbolic
Value 21 Line #2 - function name – absolute
…
Manual operating screens – structure of the text lists

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Each screen element is always assigned two text list positions:

The first position contains the text for the symbolic representation.
The second position specifies the text for the absolute view.
Example

The following examples show all required steps for configuring the display text for a movement
to be displayed in the third line on the first screen page.
The movement to be specified is a numeric axis that is to move left or right.
The movement is initiated by the Q0.1 and Q1.1 outputs. The movement is limited by limit
switches connected to the I0.1 and I0.1 inputs. Consequently, the display text is as follows:

Text element of the movement line Text to be displayed

"Designation" text for the symbolic view: "X axis"
"Designation" text for the absolute view: "X axis"
"Execution left" text for the symbolic view: "Moves left"
"Execution left" text for the absolute view: "Q0.1"
"Final state left" text for the symbolic view: "Left"
"Final state left" text for the absolute view: "I0.1"
"Execution right" text for the symbolic "Moves right"
view:
"Execution right" text for the absolute "Q1.1"
view:
"Final state right" text for the symbolic "Right"
view:
"Final state right" text for the absolute "I1.1"
view:

The following tables show all required positions of the text lists based on the above assignment:

Text list SO_11_Manual

Value 30 X axis
Value 31 X axis
Value 32 Moves left
Value 33 Q0.1
Value 34 Left
Value 35 I0.1
Value 36 Moves right
Value 37 Q1.1
Value 38 Right
Value 39 I1.1

The specified movement is displayed as follows:

(1) Symbolic view

(2) Absolute view
Manual operating screens – example for the configuration of a text

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5.5 Runtime interface

Color changes show the details of the binary state of a movement or function
Only the "Position" element shows a numeric position value.

(1) Executable (interlock), left-hand side

(2) Executable (interlock), right-hand side
(3) "Will be performed" / "Moving" confirmation, left-hand side
(4) "Will be performed" / "Moving" confirmation, right-hand side
(5) Final status / end position, left-hand side
(6) Final status / end position, right-hand side
(7) Item
Manual operating screens – dynamic movement elements

5.5.1 Interface for information about the binary state

The data addresses in the DB_HMI_DATA data block control the details concerning the binary
state of a movement or function.

Address: "DB_HMI_DATA".SCREEN_AAAAAA.ROW[XX]
where AAAAAA = name of the screen (see Table 5-1)
and XX is the number of the associated function
Format: BYTE
Range of values: See Figure 5-13 and Figure 5-14
Default setting: ---
Each grouping element represents a movement or function.

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The figure describes the structure of the interface for the function byte.

Byte n
7 6 5 4 3 2 1 0
Executability, left-hand side
executable, right-hand side
Execution confirmation, left-hand side
Execution confirmation, right-hand
Finalside
position, left-hand side
Final position, right-hand side

Bit assigned
Bit not assigned (reserved)
Manual operating screens – structure of the runtime interface

Bits 0…5 control the display of the information concerning the binary status (the function for bits
6 ... 7 is described in Section 8.6).

! Important

Bits 6 and 7 of the runtime data interface are used as control signals (operator
panel controller). This means the bits that supply information about the status
must be addressed individually. If all status information was written concurrently
with a single byte transfer command, the control signals would be overwritten and
falsified.

Guidelines

The information items that provide the binary status are not mutually interlocked so that a real
representation of the input and output signals is produced.
The following guidelines, however, provide a general statement of how the information items
that provide the binary status can be used in practice:
The two "Execution" displays should never be active concurrently for a single movement.
Otherwise this would provide the impression that the movement would be performed at the
same time in both directions.
The two "Final status" displays should never be active concurrently for a single movement.
This would provide the impression that the movement had reached both end positions (at
opposite directions) at the same time.
The two "Executable" and "Final status" displays should never be active concurrently for a
single movement. Otherwise this would provide the impression that the movement is
executable although the final position has already been reached.
The "Execution" and "Final status" displays should never be active concurrently for a single
movement. This would indicate that a movement or function is currently active although the
final position has already been reached.

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5.5.2 Display the current position

In contrast to the interface for the binary status, the "Position" interface does not have its own
data address for the individual movements or functions.

The following data interface is shared in the "SS_11_ManualMovement" screen:

Address: DB_HMI_DATA.MANUAL_COMMON.
POSITION[1] … POSITION[8]
Format: REAL
Range of values: Maximum 18 digits are displayed (4 decimal places)
Default setting: ---
The machine-specific program must copy the movement-specific position value into the variable
for the position display.

Example

A position value should be displayed for the manual movement no. 3 (display in the
"SS_11_ManualMovement" screen, page 1, line 3).
Consequently, the machine-specific program must implement the following logic:
IF (active screen == "SS_11_ManualMovement" screen) AND
IF (current page == 1), THEN
DB_HMI_DATA.MANUAL_COMMON.POSITION[3] = value

The selected screen and the active page can be determined using the following data addresses
in the DB_HMI_DATA data block:

Selected screen

Address: DB_HMI_DATA.
GLOBAL.SCREEN_ID
Format: WORD
Range of values: W#16#0000 … W#16#FFFF (1…65535)
for the idenitification of the screen, see Table 5-4
Default setting: ---

Current page

Address: DB_HMI_DATA.
MANUAL_COMMON.CURRENT_PAGE
Format: BYTE
Range of values: B#16#01…B#16#13 (1…13)
Default setting: ---

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First and last visible line

Address: DB_HMI_DATA.MANUAL_COMMON.
ROW_VISIBLE_FIRST

DB_HMI_DATA.MANUAL_COMMON.
ROW_VISIBLE_LAST
Format: WORD
Range of values: W#16#0001…W#16#0040 (1…64)
Default setting: ---
The "first and last line" details can be used as an alternative method to determine whether the
movement is currently being displayed.

! Important

The following DB_HMI_DATA data addresses:

GLOBAL.SCREEN_ID
MANUAL_COMMON.CURRENT_PAGE
MANUAL_COMMON.ROW_VISIBLE_FIRST
MANUAL_COMMON.ROW_VISIBLE_LAST
contain internal data for SICAR.
Like all other addresses, these variables should only be used read-only.

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5.6 Control interface

A movement or function can be initiated using one of the following operator actions:
with the keys indicated by the corresponding triangle icon;
by touching the appropriate button for the corresponding movement.
SICAR provides two different interfaces that the machine-specific program can use to evaluate
these operator commands.
The "job mailbox" is used as data interface to send jobs from the operator panel to the
controller. A job to be performed by the control program is then initiated with an operator input.
The "job mailbox" is used by all SICAR screens.
The other interface is screen-specific and, in contrast to the "job mailbox", uses binary signals.
Either the "job mailbox" or the "binary control interface" can be used to initiate a movement or
function.

5.6.1 Job mailbox

The data addresses of the "job mailbox" belong to the DB_HMI_DATA.GLOBAL and defined as
follows:

Address: DB_HMI_DATA.
GLOBAL.JOB.NUMBER
GLOBAL.JOB.PARAMETER_1
GLOBAL.JOB.PARAMETER_2
GLOBAL.JOB.PARAMETER_3
Format: WORD
Range of values: W#16#0000…W#16#FFFF
Default setting: ---

When the operator panel initiates a movement or function (for example, an operator presses a
key at the left or right of the movement), the following information will be displayed in the "job
mailbox":

Job number: Screen identification code,

e.g. W#16#0A01 for the "SS_11_ManualMovement" screen
(see Table 5-4)
Parameter 1: Number of the movement/function
(e.g. W#16#0001 for the first movement)
Parameter 2: Direction of motion
W#16#0001: "right" direction (bit 0)
W#16#0002: "left" direction (bit 1)
Parameter 3: Reserved for internal use

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The code for identifying the screen ("job number" parameter in the job mailbox) for the manual
operating screens is described in table:

Screen Identification code of the associated screen

SS_11_ManualMovement W#16#0A01
SS_12_UserCondition W#16#0A02
SS_13_SpecialFunctions W#16#0A03
Operating screens - code for identifying the screen in the "job mailbox"
Example

The "SS_11_ManualMovement" screen is active and displays the first screen page.
When the operator presses the left key that shows the triangle of the second movement line
(function number 2), the following data will be displayed in the "job mailbox":

Job number: W#16#0A01 "SS_11_ManualMovement" screen

Parameter 1: W#16#0002 "Second movement line" function
Parameter 2: W#16#0001 "Left" direction

When the operator releases the key, the values for parameter 1 and parameter 2 will be cleared
(value W#16#0000).

! Important

The "job number" will not be cleared when the operator releases a key used to
initiate a movement.
The "job number" will be set when one of the operating screens becomes active.

The machine-specific user program must analyze the "job mailbox" data and initiate the required
commands for performing the movement or function.

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5.6.2 Binary control interface

The "binary control interface" is a interface that uses binary signals. Each movement or function
is assigned two binary signals that represent a possible direction of the associated movement or
function.

Address: DB_HMI_DATA.SCREEN_AAAAAA.ROW[XX]
where AAAAAA = name of the screen (see Table 5-1)
and XX is the number of the associated function
Format: BYTE
Range of values: See Figure 5-13 and Figure 5-14
Default setting: ---

Byte n
7 6 5 4 3 2 1 0
Left movement/function activated
Right movement/function activated

Bit assigned
Bit not assigned (reserved)
Manual operating screens – structure of the control interface

When a movement or function is initiated from the operator panel (for example, when the
operator presses a key assigned to a function line), the control bits will be set; the control bit will
be reset when the function key is released.
Example

A manual operating screen is active and displays the first screen page.
When the operator presses the left key that shows the triangle of the second movement line
(function number 2), bit 6 for DB_HMI_DATA.SCREEN_MANUAL.ROW[2] will be set.
The bit will be reset when the operator releases the key.

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5.7 FC_HMI_MANUAL

The FC_HMI_MANUAL function provides the following functionality:

Scroll in the manual operating screens when more movements/functions have been
specified than can be displayed on the screen.
Switch between the symbolic and the absolute representation.
Switch between the first and the second configuration of the movement or function line.
Representation of the key signals on the control interfaces.
Monitor the connection between the operator panel and the controller.
Interlock the signals for the key-operated panel or the interfaces of the touch operated
panels or the direct keys.

FC_HMI_MANUAL must be called cyclically.

FC_HMI_MANUAL call interface

FC_HMI_MANUAL – interface for calling the function

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FC_HMI_MANUAL parameters

Name Type Default Example Description

HMI_DATA_DB Int 67 67 The number of the HMI
runtime data block.
HMI_CONFIG_DB Int 68 68 The number of the HMI configuration
data block.
ROWS_PER_PAGE Int --- B#16#5 The number of function lines that can
be displayed on the screen at the
same time.
Three lines for the 6-inch operator
panel with header.
Five lines for the 10-inch operator
panel with header.
FIRST_ROW Int 2 2 The function keys located at the side
to be used for the first movement
line.
1 = first movement will be performed
by F1 and F2; optional for operation
without header.
2 = first movement will be performed
by F3 and F4; optional for operation
without header.
KEY_BUTTON Word -- IW 5 Input word of the PROFIBUS DP
direct keys.
Assignment:
Bit 0: line 5, left key
Bit 1: line 5, right key
Bit 2: line 6, left key
Bit 3: line 6, right key
Bit 4-7: Reserve
Bit 8: line 1, left key
Bit 9: line 1, right key
Bit 10: line 2, left key
Bit 11: line 2, right key
Bit 12: line 3, left key
Bit 13: line 3, right key
Bit 14: line 4, left key
Bit 15: line 4, right key
If no direct keys are used, the value
W#16#FFFF must be specified.
KEY_MODE Int --- 0 Mode for executing the operation.
0: Function active while a key
remains pressed.
1: Function active while a button
remains pressed.
2: Function active after the button
has been clicked twice.
3: Function active while an external
key remains pressed; selection of the
function by the function keys located
at the side.
4: Function active while an external
key remains pressed; selection of the
function by the function buttons.
EXTERNAL_LEFT_ Bool --- --- Only relevant in the 3 and 4 key
KEY modes.
Performs the left command of the
selected function.

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Name Type Default Example Description

EXTERNAL_RIGHT_ Bool --- --- Only relevant in the 3 and 4 key
KEY modes.
Performs the right command of the
selected function.
SELECT_CONFIG Bool --- M5.3 Switch between the two
configurations for hiding of individual
elements of the function line.
FIRST_SCAN Bool --- --- Restart flag,
1 – signal for the first cycle after CPU
startup
RET_VAL Word --- MW2 Error message:
0000: No error
7000: No operating screen selected,
block will not be processed currently
7002: No sign-of-life from the OP,
operation is disabled
8091: Invalid screen ID
DB_HMI_DATA.GLOBAL.BILD_ID is
invalid
8092: Invalid key mode
TASTEN_MODUS < 0 or > 4
Description of the FC_HMI_MANUAL parameters

Note

An additional safety function must be programmed for the parameterization of key

mode 3 and 4 (use of external keys) for performing movements.
The program must set the DBX296.0 bit in the DB67 (DB_HMI_DATA) when the
selection of a movement is to be disabled. For example, this can be implemented
by activating a key switch.
The DB67.DBX296.1 bit causes the program code to reset the selection and re-
release the selection of other movements.

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5.8 Step-by-step procedure

The following table summarizes the steps required to create a manual operating screen.
All other operating screens differ only in the listed data addresses and the WinCC flexible
textlists.

Step 6 Proceed as follows

1 Use the data block editor in STEP 7 (declaration view) to open the
DB_HMI_CONFIG data block.
2 Specify the display time for the absolute view:
HANDBEDIENUNG_ALLGEMEIN.ZEIT_ABSOLUTE_ANZEIGE:
3 Specify the number of movements/functions for the manual operating screen:
BILD_HANDBEDIENUNG.ANZAHL_ZEILEN
4 Specify which elements are to be hidden for all function lines:
BILD_HANDBEDIENUNG.ZEILE_01 … ZEILE_64
5 Now switch to the data view and initialize the data block.
6 Save and close the DB_HMI_CONFIG data block.
7 Use STEP 7 to open the FC_HMI_MANAG function.
8 Call FC_HMI_MANUAL and set the parameters appropriately for your
requirements.
10 Load all changed blocks into the controller.
11 Use WinCC flexible to open the WinCC flexible project from SICAR.
12 Open the SO_11_Manual text list and define for the corresponding function
lines the display text for the symbolic and the absolute view.
13 Close the text list.
15 Save and generate the WinCC flexible project, and transfer it to the operator
panel.
16 To display the status of the movement/function, the corresponding signals
must be assigned in the DB_HMI_DATA to the interface area of the operating
screens.
17 The user program can use two interfaces to perform movements/functions.
Binary interface:
DB_HMI_DATA.BILD_HANDBEDIENUNG.ZEILE_01 … 64
Or job mailbox:
DB_HMI_DATA.GLOBAL.AUFTRAEGE.AUFTRAGSNUMMER
DB_HMI_DATA.GLOBAL.AUFTRAEGE.PARAMETER_1
DB_HMI_DATA.GLOBAL.AUFTRAEGE.PARAMETER_2
Procedure for creating a manual operating screen

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6. Production-Data

6.1 Overview production data

Max. number of
Number per screen
screens

Shift counter 10 8
Process counter 20 8
Limit value 10 8
Cycle time 20 8

The production data screens can be selected via the function button “Production data” from the Main menu.

Per default one screen of each type is initialised in the PLC:

1 Process counter
1 Shift counter
1 Cycle time
1 Limit value

The initialization of additional pictures is described in chapter 6.7.

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6.2 Process Counter

The function process counter offers the possibility to realize shift independent production counters.
8 screens with 20 counters are available.
The current value of each counter is displayed.

Depending on the number of activated screens in the PLC, you can select with the buttons on the left side
the respective screen.
The buttons are automatically shown on the screen, no user action necessary.
The naming for this buttons is to realize directly in WinCC flexible ES.

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6.2.1 Programming FB982

For each counter a counting bit for increase and decrease is available.

6.2.2 Reset Process counter in the PLC

There is a reset bit available to reset the counter to 0.

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6.2.3 Parameterization of Texts

In WINCCflex for one screen one Textlist with 10 entries for each process counter is available.
SS_211_Process counter picture 1..8 contains the texts for all 10 process counter.
The user has to insert the description of the respective process counter.

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6.3 Shift counter

With the function shift counter the number of produced parts, machine throughput etc. can be recorded.
Per shift counter the targed shift value, current shift value, targed value of the last shift and the value of the
last shift are indicated.
8 screens with 10 shift counters are available for the user.

Depending on the number of activated screens in the PLC, you can select with the buttons on the left side
the respective screen.
The buttons are automatically shown on the screen, no user action necessary.
The naming for this buttons is to realize directly in WinCC flexible ES.

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6.3.1 Programming FB982

For each shift counter one counting bit is available.

6.3.2 Reset Shift counter in the PLC

In the PLC a common reset bit for all 10 shift counters of a screen is available.
Note: The reset bit must be programmed with a positive edge and a set command.
Reset of the “Reset bit” is done in the FB997.

Reset of shift counter:

With a reset, the Current “Target and Value” is copied into a save area and indicated on the right side as
“Previous”

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6.3.3 Reset Shift counter in the HMI

In the shift counter screen a Button “Reset Total” is available.

While pressing the Reset Total button, two additional buttons appear.
Pressing “Reset” resets the 10 shift counter of the selected screen.
Pressing “Cancel” abort the Reset function.

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6.3.4 Parameterization of Target Values

There are two ways to parameterize Taget values:
- Per Screen
Click into the desired field and insert the value.

- Per PLC-Programm FB982

Transfer the Value from, e.g. supervising system, into the destination field.

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6.3.5 Parameterization of Texts

In WINCCflex for one screen one Textlist with 10 entries for each process counter is available.
SS_213_Shift counter picture 1..8 contains the texts for all 10 shift counter.
The user has to insert the description of the respective shift counter.

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6.4 Cycle time

In this screen the time values of 20 cycle time measurements are indicated.
The last measured value is displayed per cycle time.
8 screens with 20 cycle times are available.

Pressing one of the indication fields change the indication between Target / Value and Average / Count.
The value “Average” is the calculated result of the number of indicated cycles “Counts”.
The values Average and Counts can be reset in the PLC.

Depending on the number of activated screens in the PLC, you can select with the buttons on the left side
the respective screen.
The buttons are automatically shown on the screen, no user action necessary.
The naming for this buttons is to realize directly in WinCC flexible ES.

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6.4.1 Programming FB982

For each cycle time a “Run bit” and a “Hold bit” is available.
The measurement starts with the “Run bit” = 1 and can be interrupted using the “Hold bit” = 1.
Measurement is triggered by every falling edge of the “Run bit”.

In order to measure the runtimes of individual steps in a sequence cascade, the appropriate sequence
markers could, for example, be pointed at the “Run bits”.

For reset of Average and Count in all screens you have to assign value 1 to the variable
“#Cycle_time_pic_1.Cycle_time_Reset_Average”
Value 1 will be reset from the block FB997.

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6.4.2 Parameterization of Target Values

There are two ways to parameterize Target values:
- Per Screen
Click into the desired field and insert the value.

- Per PLC-Programm FB982

Transfer the Value from, e.g. supervising system, into the destination field.

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6.4.3 Parameterization of Texts

In WINCCflex one Textlist with 20 entries per screen is available.
SS_214_Cycle time picture 1..8 contains the texts for all the 20 cycle times.
The user has to insert the description of the respective cycle time.

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6.5 Limit values

This screen displays the value of 16 limit values.
This functionality can be used to supervise values for quality checks, maintenance cycle, etc.

The “Set” and “Remain” values must be setup by the user.

The remaining value (Remain) is provided by the user with a count bit in the PLC.

If value “Remain” has reached the “value “Prewarn” the respective line is indicated in orange colour and in
the PLC a bit is available for further use e.g. in an alarm system.

If value “Remain” has reached 0 the respective line is indicated in red colour and in the PLC a bit is available
for further use e.g. in an alarm system.
While reaching value 0, a button “Reset” appears on the right side of the respective limit value.

Depending on the number of activated screens in the PLC, you can select with the buttons on the left side
the respective screen.
The buttons are automatically shown on the screen, no user action necessary.
The naming for this buttons is to realize directly in WinCC flexible ES.

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6.5.1 Alarm handling

Preliminary alarm:
If Remain value = Prewarn value, the appropriate line is given an orange background and a user bit is
supplied for further evaluation.

Alarm:
If Remain value = 0, the appropriate line is given a red background and a user bit is supplied for further
evaluation.
The Line could be stopped with this bit, using the basic start condition for the respective zone.

Reset of alarms:
During every time it is possible to set the “Remain” value to the “Set” value.
Press the field with the describing test of the limit value you wish to set.
On the right a “Reset” button appears.

If value “Remain” has reached 0, a button “Reset” appears automatically on the right side of the respective
limit value.

While pressing the Reset button, two additional buttons appear.

Pressing “Reset” resets the selected limit value. Pressing “Cancel” abort the Reset function.
A multiple selection of “Reset” is possible.

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6.5.2 Indication of active Prealarm or Alarm

The colour of the left buttons in the limit value screen shows if there is a Prewarning or an Alarm active.

If there is one active prealarm or alarm in the limit value screens, this is indicated on each button “Production
data”.

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6.5.3 Programming FB982

For each limit value a “Count bit” is available to decrease the “Remain” value.

There are “Prewarn” and “Alarm” bits available for each limit value for further use in the PLC.

There are also information about "Prewarn" and "Alarm" per screen, as well as the information for
"Prewarn_active" and "Alarm_active" overall is available.
These values are only provided in "Limit_value_pic_1.x"

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6.5.4 Parameterization of Set- and Prealarm values

There are two ways to parameterize Taget values:
- Per Screen
Click into the desired “Set” or “Prealarm” field and insert the value.

- Per PLC-Programm FB982

Transfer the Value from, e.g. supervising system, into the destination field.

6.5.5 Parameterization of Texts

In WINCCflex for one screen one Textlist with 10 entries for each limit value is available.
SS_215_Limit_value picture 1..8 contains the texts for all 10 limit values.
The user has to insert the description of the respective limit values.

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6.6 Used PLC-Blocks and structure

FC920 -> Prepares information depending on DB996
DB920 -> Global-DB, Contains information from DB996 provided by FC920
FB997 -> Evaluation of User programming and providing all informations in DB996
FB982 -> User interface: Activate additional screens, Programming necessary bits
DB996 -> Instance-DB of FB982
UDT993 -> used in the static section of FB982, IF-Process counter
UDT995 -> used in the static section of FB982, IF-Shift counter
UDT996 -> used in the static section of FB982, IF-Cycle time
UDT997 -> used in the static section of FB982, IF-Limit values

The Blocks are called in OB1-> FC151-> …...

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6.7 Initialization of additional screens

To save memory in the PLC, the Line can be adjusted to the real used number of production data screen.
Default in delivery state: Static variables of FB982, one screen Process counter, Shift counter, Cycletime,
Limit values.

If there is a need of additional screens the respective entries must be done in the section static variables of
the FB982.
The following example shows the initialisation for 3 process counter screens, 3 shift counter screens, 2 cycle
time screens and 2 limit value screens.

After each modification in the static part of the FB982, the DB996 has to be regenerated:
In FC151, select network with the call FB982, DB996 and regenerate the DB996.
Download the blocks to the PLC.

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7. Diagnostics

7.1 RSE – Report system error

The usage of RSE distributes all relevant information about current faults in the system to the user
The Information is packaged into Messages, which are combined to create the following
components…
Module: e.g.: "Module: 2 DO DC24V HF" & "Diagnostic addr: Q33"
Message text: e.g.: „Short circuit at Channel 0"
Message status: e.g.: „I - Incoming", „O - Outgoing", „A - Acknowledged"
Automatic Generation of Messages is based on the specific hardware configuration and provides
the following advantages:
Reduced programming effort , faster & less cost to configure
Reduced mistakes in programming
Easy to integrate hardware configuration changes
Repeat generation of RSE

RSE diagnostics are generated based on the specific Hardware Configuration, the required Diagnostic
blocks, and the configured Message and Error texts

Sample of a RSE generated message in the WINCCflex Alarm_view:

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7.1.1 Activating RSE

Open HW-Konfig
Mark PLC
Select Options, Report System Error

Default values for Diagnostic blocks are FB,FC,DB49, DB50.

If necessary the numbering can be changed.

Press generate and RSE generates four Blocks

This Blocks must be loaded into the CPU after each Generation!
• After loading the CPU must be Restarted!

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Adjustments to call the RSE-blocks.

The call of the RSE blocks is automatically inserted by the system.

Select this both check box if the dialog for configuring RSE should be called up while the configuration is
being saved and compiled

Note:
If you are working with an integrated WINCCflex project no further actions are necessary in WINCCflex.

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7.2 Messages screen and Message archive screen

7.2.1 Layout of the screen and functionality

The alarm screens display the alarm messages, general messages and system messages in
tabular form. The "messages" screen displays the messages and alarms currently pending; the
"message archive" screen displays the contents of the alarm buffer.

Alarm events are saved to an internal, non-volatile buffer. The size of this alarm buffer depends
on the HMI device type.

The screen structure of the two "messages" and "message archive" screen forms is identical.

"Alarms and messages" screen

The following information is displayed in tabular form:

whether the message can be diagnosed (yes = * / no = no entry);
the message number;
the time stamp of the message;
the message status (K: arrived, G: gone, Q: acknowledged);
the message text;
the acknowledge group.

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7.2.2 Runtime interface

The "interface for alarms and messages" data block is defined by the WinCC flexible
"SO_00_Alarm" and "SO_00_Message" variables for fault messages and operational
messages, respectively.

7.2.3 Configuration

The alarm or message text is configured in the area of the message display object. For further
information, refer to the documentation for WinCC flexible.

Settings of the alarm archive

The message display of the alarm view displays selected message events from the alarm
buffer. The configuration specifies which events are displayed. The alarm window shows the
alarm events selected in the properties dialog.

Setting for the alarm display object in the "Alarm archive" screen

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7.3 DataInterface screen

7.3.1 Layout of the screen

The "DataInterface" screen can be used to display for diagnostic purposes the signals
transferred between the controller and the external devices. Up to sixteen diagnostic interfaces
with freely configurable names can be created. Each diagnostic interface can display 16 inputs
and 16 outputs. The interface can be selected in a selection window.

(1) Window for selecting the interface

(2) Display of the states of the associated inputs
(3) Display of the states of the associated outputs
"DataInterface" screen

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7.3.2 Runtime interface

The runtime interface for the "Interface" screen consists of three variables. The first,
DB_HMI_1_DATA.SCREEN_INTERLOCK.SELECTION, represents the current interface
selected from the selection window.

Address: DB_HMI_1_DATA. SCREEN_INTERLOCK.SELECTION

Format: INT
Range of values: 1..16
Default setting: 1

The inputs/outputs to be visualized must then be copied to the following addresses depending
on the currently selected interface:
Address: DB_HMI_1_DATA
SCREEN_INTERLOCK.SIGNALS.INPUT
Format: WORD
Range of values: The status of each bit is displayed in the screen by the
associated LED element.
Default setting: -

Address: DB_HMI_1_DATA
SCREEN_INTERLOCK.SIGNALS.OUTPUT
Format: WORD
Range of values: The status of each bit is displayed in the screen by the
associated LED element.
Default setting: -

7.3.3 Configuration

Up to sixteen interface descriptions can be defined and selected from a selection window. A
WinCC flexible text list can be used to specify a name for each of these interfaces:

Text list SO_67_InterlocksSelection

Display Text
Format Decimal
Value 01 Name for interface no. 1
Value 02 Name for interface no. 2
…
Value 16 Name for interface no. 16
Selection window for the interlocks – screen caption of the text list

The following text lists can be used to specify a designation for each input and output of all the
interfaces:

Text list SO_67_InterlocksInput

SO_67_InterlocksOutput
Display Text
Format Decimal
Value 01 Name for input/output #1 of interface #1
Value 02 Name for input/output #2 of interface #1
…
Value 16 Name for input/output #16 of interface #1
Value 17 Name for input/output #1 of interface #2
Designation of the input/outputs

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7.3.4 PLC-Interface
Programming of the DataInterface has to be done in FC64.
FC64 is called in FC67.

NW1: Clear Input and Output Interface

NW2-4: Networks for DataInterface 1

For each DataInterface you have to copy amd adjust these three network.
Change in first network the number of the DataInterface (Parameter IN2).

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Change in the next two networks the respective inputs and outputs,

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7.4 Version screen

The version screen selection is available in the system screen.

You can see here the current SICAR Version as well as the versions of all encrypted Sicar system blocks.
This screen shows the Set-Version belonging to the current SICAR Version and the Online block version in
the PLC.
If there are differences the respective blocks are indicated with red or orange colour.
Orange: Development block is loaded
Red: Versions are different

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PLC-blocks:
DB940: Block-name, Block-number, Set -and Online version are stored in DB940. and is prepared for 40
blocks.
E.g. FB943, Version 1.1

The Online version is written from each system block itself into the DB940.

FC942: Comparision of Set –and Online version, result is stored in DB940, Check_x.

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8. Hardware Diagnostics

With the button “Hardware Diagnostic” the following screen is coming up and displays
the actual status of the DP-Mastersystem/PNIO-System, MLFB of PLC and the
Firmware Version

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8.1 PROFINET/PROFIBUS diagnosis

The "PROFINET/PROFIBUS diagnosis" screens are used to perform a diagnosis of a
PROFINET IO or PROFIBUS DP network.

The diagnosis is based on the PNIODiag standard diagnostic package that can be
downloaded from the article ID:26996747 in the Siemens product support.

8.1.1 PROFINET/PROFIBUS overview screen

(1)

(2)

(1) Number of the PROFINET IO or PROFIBUS DP system

(2) Network overview with the configured stations
"PROFINET/PROFIBUS overview" screen

The "PROFINET/PROFIBUS overview" screen provides an overview of which configured

stations are present on the bus and what state they have.

The selection box can be used select a single station for which detailed diagnostic data can be
displayed.

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8.1.2 Legend screen

The "Legend" screen shows the states that a station can assume in the network overview.

"PROFINET/PROFIBUS overview" legend screen

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8.1.3 Detailed diagnosis screen

The "Detailed diagnosis" screen displays detailed diagnostic information for the selected station
and groups them into two main areas.

(1)

(2)

(1) Station status and information

(2) Detailed fault information
"PROFINET detailed diagnosis" screen

Station diagnosis

The station diagnosis of the screen shows the basic information for the selected station.

Information on the left side :

ID of the system to which the station is connected

Device number (station number)

Station status

Manufacturer identification

Module order number

Plant designation (identification assigned in the hardware config)

Location designation (identification assigned in the hardware config)

Installation date (identification assigned in the hardware config)

Additional information (identification assigned in the hardware config)

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Information on the right side :

Device name

MAC address of the device

IP address of the device

Subnetmask

Gateway address

Number of faults present, sorted according to fault type and total number of faults
(This information are only diplayed in case of an error)

Detailed fault information

The information actually displayed in the "Detailed fault information" screen area depends on
the diagnostic capabilities of the selected station.

The fault information supplies the fault location (slot number, subslot number, channel) and the
designation of the fault (wire breakage). Additional details, such as the data format and the
channel type, are also displayed. The fault information is also displayed in hexadecimal
notation.
If required, the device manual can be consulted to obtain the meaning of the hexadecimal
value.
A station diagnosis can be fetched for each detected station. The format of the displayed data
depends on the station type:
For PROFIBUS DP slaves, the channel diagnosis is output in text form with the device-specific
diagnosis shown in hexadecimal notation.
The diagnosis of PROFINET IO stations differentiates between direct PROFINET IO devices
and PROFIBUS slaves connected with a PROFINET IO system using an IE/PB link:
- PROFINET device:
The channel and slot diagnosis is output in text form. The manufacturer-specific diagnostics are
displayed in hexadecimal notation.
- PROFIBUS slaves on the IE/PB link:
The diagnostic data (structure, see EN 50 170 Volume 2, PROFIBUS) is shown only in
hexadecimal format. Only the status of the module is displayed for an IE/PB link itself.

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8.1.4 Trigger screen

You can set in the "Trigger history" screen which station in which system is to be monitored in
order to monitor transient events and also view the recorded events.
This is particularly useful when the events are too fast for them to be evaluated in the station
diagnosis.

(1)
(2)

(3)

(1) Set the trigger mode

(2) Operate the trigger
(3) Events display
"PROFIBUS detailed diagnosis" screen

Setting the trigger mode

In this window, specify which station you want to trigger.

The setting is made using either the logical address of the station or the station number and the
subsystem ID.
The address can only be entered in the stop state.

Operating the trigger

Press "Start trigger" to activate the trigger. The state remains active even for a change to a
different screen and continues to run in the background. The trigger is running when the
background is green.
Press "Stop trigger" to deactivate the trigger after which the events can be viewed. The trigger is
stopped when the background is red.
Press "Clear ring buffer" to clear the ring buffer. To prevent data falsification, clear the ring
buffer before using the trigger and when the address is reset. Clearing the ring buffer places the
trigger in the stopped state should it be active.

Displaying the events

In this window you can display the recorded events.

If several events are present, the arrows can be used to scroll left and right. The arrows are
enabled only when the trigger is in the stopped state.

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8.1.5 Runtime interface (FB_PNIODiag)

The PNIODiag function block can be used for the diagnosis of PROFINET IO and PROFIBUS
DP systems. For this purpose, the PNIODiag function block determines general system status
information and, if required, detailed diagnostic information. This information is then displayed
using the visualization.
The PNIODiag function block provides the following functions for PROFIBUS DP and
PROFINET IO systems:

Obtain an overview of the state of the individual systems

Show the station states as overview diagnosis
Detailed diagnosis of the individual stations
Save the transient state changes
Record the diagnostic events
Deactivate and activate PROFIBUS DP slaves and PROFINET IO devices (option)

The PNIODiag function block call must be made in the OB1, OB82, OB83, OB86 and OB100
(OB101, OB102) execution levels. The order and content of the 20-byte temporary local data of
the organization blocks must not be changed.

The IN0 input parameter specifies the DB number 128 for saving the diagnostic data. Because
the creation of the data block for the data storage is specified in OB100, the DB number must
also be specified in the OB100. If no value is specified, the DB200 data block will be created
automatically.

Should an error occur while processing the block, the "OUT1" output parameter will contain an
error code that helps the Support department with troubleshooting.

Note

The required S7 data blocks and the S7 function block do not contain any symbol
information. An interface description for the S7 modules is not available. The S7
modules should be used only in conjunction with the provided visualization.

Note

The download of the PNIO standard package contains more detailed

documentation for the FB_PNIODIAG (see Introduction).

Note

In the PNIO standard package, the FB_PNIODIAG is also provided as a variant

for CPUs with a maximum block size of 16 KB.

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8.2 Drive screen

8.2.1 Drive status screen

The "Drive status" screen displays the control and status signals of the drive selected from the
selection window.

(1)

(2) (3)

(1) Selection of the drive (selection window)

(2) Control signals of the selected drive
(3) Status signals of the selected drive
"Drive status" screen

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8.2.2 Drive alarms screen

The "Drive alarms" screen displays the malfunctions and warnings of the selected axis.

(1)

(2)

(3)

(1) Selection of the drive (selection window)

(2) Area for displaying the malfunctions
(3) Area for displaying the warnings
"Drive alarms" screen

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8.2.3 Drive values screen

The "Drive values" screen displays the actual values, set values and the staus of the
Drive FB.

(1)

(2) (4)

(5)

(4)

(6)

(1) Selection of the drive (selection window)

(2) Status information of drive-FB
(3) Faults of drive-FB
(4) Actual values
(5) Set value
(6) Display of any pending fault/warning
"Drive position" screen

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8.2.4 Configuring the WinCC flexible screens

WinCC flexible "SO_40_Drive_G120_Name" text list. Each configured drive must have a
position in the text list.

The "SO_40_Drive_G120_name" text list has the following structure:

Text list SO_40_Drive_G120_Name
Display Text
Format Decimal
Value 1 Designation of the first drive
Value 2 Designation of the second drive
… … …
Text list for the axis designations

8.2.5 Runtime interface (FB_G120)

The FB307 “FB_G120” is a standard block of the liberary “Technological functions”

and is decribed in chapter 5.1.2 in the document “33_Technological units”.

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8.3 RF300 screen

The "Moby-I diagnostics" screen shows the status signals and error messages of a read-write
device (SLG). The data is fetched and assigned by a standard block from the Moby interface
module (ASM).

The signals and error messages from several interface modules can be displayed in the screen.

8.3.1 Layout of the screen and functionality

(1) Select the MOBY read/write device (selection window)

(2) Status signals of the MOBY SLG
(3) Error messages of the MOBY SLG
"MOBY-I" screen

Selection of the MOBY SLG

You can select several Moby SLGs in the selection field. Each Moby SLG provides its own
interface.

Status of the SLG

"Status of the SLG" area displays the states of the selected SLG.

Moby SLG error messages

The "MOBY SLG error messages" area displays MOBY-specific error messages.

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8.3.2 Supported RF300 interface moduls

The following table contains a list of all supported MOBY interface modules with the
associated FC:

Interface Module Block

ASM 450 FC 44
ASM 452 FC 45
ASM 456
ASM 473
ASM 475
ASM 452 - file handler FC 46
Supported MOBY interface modules

The data exchange between the controller and the ASM is performed using the FC44, FC45 or
FC46 function, depending on the ASM type. The control and feedback signals to and from the
ASM, and the error messages can be found in the so-called command data block.

The "Moby I diagnostics" screen displays the information contained in these command data
blocks.

The structure of the command data block depends on the associated block.

8.3.3 Configuring the WinCC flexible screens

Configuring the text list in WinCC flexible

The designations of the read-write devices must be specified. The text items are stored in the
WinCC flexible "SO_57_MobySLGName" text list. Each configured MOBY SLG must have an
entry in the text list.

The "SO_57_MobySLGName" text list has the following structure:

Text list SO_57_MobySLGName

Display Text
Format Decimal
Value 1 Designation of the first MOBY read-write device
Value 2 Designation of the second MOBY read-write device
… … …
Text list for the designations of the Moby SLGs

! Important

The text items for non-configured (unused) MOBY SLGs must be deleted.

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8.3.4 Runtime interface (FC_HMI_RF300)

The FC_HMI_MOBY supplies data to the WinCC flexible screens for the Moby diagnostics. The
displayed data is fetched from the command data block.

The user must call this function once cyclically in the OB1 for each configured MOBY SLG,
where MOBY_INDEX matches the corresponding values from the WinCC flexible "SO_57_
MobySLGName" text list (see sample program).

Call interface of the FC_HMI_MOBY function

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Name Type Default Example Description

HMI_DATA_DB INT 67 67 The number of the HMI runtime
data block
HMI_ INT 69 69 The number of the HMI
DIAGNOSTIC_DB diagnostic data block
MOBY_INDEX INT -- -- Selection of the SLG
(the value comes from the
"SO_57_MobySLGName" text
list)
MOBY_DB INT --- --- The number of the Moby
command data block
MOBY_DBB INT 0 0 The start address of the SLG
in the command data block
MOBY_TYPE INT --- --- Moby block type:
1: FC44 - Word
2: FC45
3: FC46
5: FC44 - Byte
ALARM_ BOOL --- --- When TRUE, the FC generates
MESSAGES_ON a message when a fault is
present at the SLG.
RET_VAL WORD --- --- Function return value
0000: no error
7000: block not processed
8096: invalid Moby type
Parameters of the FC_HMI_MOBY function

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8.4 SINAMICS screen

8.4.1 SINAMICS status screen

The "SINAMICS status" screen shows the control and status signals of the SINAMICS axis
selected from the selection window.

1. Selection of the axis (selection window)

2. Control signals of the selected axis
3. Status signals of the selected axis
"SINAMICS status" screen

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8.4.2 SINAMICS alarms screen

The "SINAMICS alarms" screen shows the faults and warnings of the selected SINAMICS axis.

1. Selection of the axis (selection window)

2. Area for displaying the faults
3. Area for displaying the warnings
"SINAMICS alarms" screen

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8.4.3 SINAMICS position screen

The "SINAMICS position" screen shows the positioning status signals and positioning data,
such as position, block and override of the selected axis. The data, however, is available only
for those SINAMICS axes operated as positioning axes (EPOS).

1. Selection of the axis (selection window)

2. Positioning status signals
3. Display of the axis position
4. Number of the selected block
5. Override
6. Display of any pending fault/warning
"SINAMICS position" screen

Note

The "SINAMICS position" screen does not contain any information when a
SINAMICS S120 without positioning functionality is used.

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8.4.4 Configuring of the WinCC flexible screens

Configuring of the text list in WinCC flexible

The designations of the axes must be configured. The text items are stored in the
"SO_80_SinamicsAxis" WinCC flexible text list. A position in the text list must be present for
each configured axis. The text list that must be created for each drive group is displayed or
hidden depending on the selected CU.

The "SO_80_SinamicsAxis" text list has the following structure:

Text list SO_80_SinamicsAxis

Display Text
Format Decimal
Value 2 Designation of the first axis (value = drive object number)
Value 3 Designation of the second axis (value = drive object number)
… … …
Text list for the axis designations

! Important

The designation text for missing axes must be deleted!

! Important

The value of the text list entry must match the drive object number of the drive
group.

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8.4.5 Runtime interface (FB_HMI_SINAMICSCU3x0)

The FB_HMI_SINAMICSCU3x0 supplies the WinCC flexible screens for the SINAMICS
diagnostic screens. The displayed data is fetched directly from the drive as parameter requests
using acyclical communications services.

The function block must be fetched once cyclically with the appropriate diagnostic address
("DRIVE_DIAGADDR" parameter) for each CU. The "DRIVE_ENABLE" parameter assigned to
the selected CU (drive group) must be used to enable the FB call. In addition, the text list with
the associated drive object numbers assigned to the drive group must be displayed.

Call interface of the FB_HMI_SINAMICSCU3x0 function

Name Type Default Example Description

HMI_DATA_DB INT 67 67 Number of the HMI runtime
data block
HMI_ INT 69 69 Number of the HMI
DIAGNOSTIC_DB diagnostic data block
DRIVE_DIAGADDR INT --- --- SINAMICS diagnostic address
(see HW Config)
DRIVE_ENABLE BOOL TRUE --- "TRUE" enables the
communication of the block
with the drive
BUSY BOOL TRUE --- "TRUE": communication with
the drive is running
STATUS WORD --- --- Block status (0x8001 =
SFB53 error, 0x8002 =
SFB52 error)
Parameters of the FB_HMI_SINAMICSCU3x0 function

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9. System screens

9.1 System screen

9.1.1 Layout of the screen and functionality

The "System" screen contains general system functions, such as password and user
administration, the language setting for the user interface, lamp test, clear alarm history and
message archive.

"System" screen

Import/export password

This function can be used to export the password list to a memory card or import the password
list from a memory card. This makes it possible to specify the password list for only one
machine and then transfer it to the other machines.

User logoff

This function is used to reset the current password level to level 0 (user without any special
rights).

Delete message buffer

This function is used to clear the message buffer. This includes all messages that have
occurred until this time.

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Lamptest
The DB_HMI_DATA.GLOBAL.LAMPTEST variable has the 1-signal while the key or button
remains pressed.

This variable must be further processed by the machine manufacturer.

Address: DB_HMI_DATA.GLOBAL.LAMPTEST
Format: BOOL
Range of values: 1-signal when the "Lamp test" key on the operator panel
remains pressed.
Default setting: False

Changing the language

The "Change language" button can be used to switch between the languages installed on the
operator panel.
A maximum of three languages can be loaded onto the operator panel. The standard project for
SICAR is delivered in two languages:
German
English (United States)

Other languages can be implemented for specific projects.

F-Program Signature
If a Failsafe-PLC is in use the CRC-checksum of the failsafe program has to be shown here.
It must be programmed in FC984.

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PLC-cycle time
The current PLC cycle time has to be shown here.
It´s programmed in OB1.

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9.2 Panel Control screen

9.2.1 Layout of the screen and functionality

"Panel Control" screen

Increase/reduce contrast

These function keys are used to set the contrast of the operator panel.

System control

Pressing this function key opens the window for the system control of the operating system.

Clean screen (only for touchscreen operator panels)

After pressing the "Clean screen" function key, the operator panel user interface switches for a
parameterizable time to an empty screen page on which the touch function is deactivated.
During this time, it is possible to clean the screen without the danger of inadvertently initiating
some function.

Touch calibration (only for touch screen operator panels)

Pressing the "Touch calibration" button starts the calibration of the touch screen.

Exit runtime

Pressing this button exits the WinCC flexible runtime environment and switches to the operating
system level.

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9.3 Status Variable screen

9.3.1 Layout of the screen and functionality

"Status Variable" screen

The user can use this screen to monitor the control variables for diagnostic or maintenance
purposes.

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