Application Example  03/2015

Connecting SIMATIC HMI

Panel with SIMATIC S7-400H
WinCC (TIA Portal) V13 SP1 and STEP 7 V5.5

https://support.industry.siemens.com/cs/ww/de/96837136
 Warranty and Liability

Warranty and Liability

Note The Application Examples are not binding and do not claim to be complete with
regard to configuration, equipment or any contingencies. The Application
Examples do not represent customer-specific solutions. They are only intended
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described in this Application Example will be excluded. Such an exclusion will not
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 Table of Contents

Table of Contents
Warranty and Liability ................................................................................................. 2
1 Task ..................................................................................................................... 4
2 Solutions ............................................................................................................ 5
2.1 Connecting redundant panels .............................................................. 5
2.2 Connecting a script-capable panel with a “software solution”
with two H CPUs .................................................................................. 6
2.3 Connecting a non-script-capable panel with a “software
solution” with two H CPUs .................................................................... 7
2.4 Comparing the solutions....................................................................... 8
3 Software Solution with Scripts ......................................................................... 9
3.1 Components used ................................................................................ 9
3.2 Mode of operation ................................................................................ 9
3.3 Configuration ...................................................................................... 11
3.3.1 STEP 7 configuration ......................................................................... 11
3.3.2 WinCC configuration .......................................................................... 12
3.4 Example scenarios ............................................................................. 15
4 Software Solution without Scripts ................................................................. 17
4.1 Components used .............................................................................. 17
4.2 Mode of operation .............................................................................. 17
4.3 Configuration ...................................................................................... 18
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4.3.1 STEP 7 configuration ......................................................................... 18

4.3.2 WinCC configuration .......................................................................... 18
4.4 Example scenarios ............................................................................. 22
5 References ....................................................................................................... 23
6 History............................................................................................................... 23

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 1 Task

1 Task
Introduction
You would like to connect SIMATIC HMI Panel with a SIMATIC H station.

Overview of the automation task

The figure below provides an overview of the automation task.
Figure 1-1
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 2 Solutions
2.1 Connecting redundant panels

2 Solutions
2.1 Connecting redundant panels
Connect a panel to each H CPU.
Figure 2-1
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 2 Solutions
2.2 Connecting a script-capable panel with a “software solution” with two H CPUs

2.2 Connecting a script-capable panel with a “software

solution” with two H CPUs
Connect an operator panel with two H CPUs.
With scripts it is specified with which H CPU the operator panel is connected.
In the event of an error, the connection is automatically switched over:
• STOP of the addressed CPU
• CP failure
• Cable fault
• EMC
Figure 2-2
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A precise description of this solution can be found in chapter Software Solution with
Scripts.

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 2 Solutions
2.3 Connecting a non-script-capable panel with a “software solution” with two H CPUs

2.3 Connecting a non-script-capable panel with a

“software solution” with two H CPUs
Connect an operator panel with two H CPUs.
With the status of the H CPU (master/reserve) it is specified with which H CPU the
operator panel is connected.
Figure 2-3

PROFINET IE
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A precise description of this solution can be found in chapter Software Solution

without Scripts.

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 2 Solutions
2.4 Comparing the solutions

2.4 Comparing the solutions

Table 2-1
Solution Advantage Disadvantage
2.1 Connecting redundant High availability Higher hardware costs
panels
2.2 Connecting a script- Lower hardware costs Longer response times
capable panel with a
“software solution” with two
H CPUs
2.3 Connecting a non-script- Lower hardware costs No switchover in the event
capable panel with a of communication errors
“software solution” with two
H CPUs
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 3 Software Solution with Scripts
3.1 Components used

3 Software Solution with Scripts

3.1 Components used

Hardware components
Table 3-1
Component No. Article number Note
PS 407 10A 2 6ES7407-0KA02-0AA0
CPU 416-5H PN/DP 2 6ES7416-5HS06-0AB0
TP1200 Comfort 1 6AV2124-0MC01-0AX0
SCALANCE X204-2 1 6GK5204-2BB10-2AA3

Software components
Table 3-2
Component No. Article number Note
STEP 7 V5.5 + SP4 1 6ES7810-4CC10-0YA5
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WinCC Comfort V13 SP1 1 6AV2101-0AA03-0AA5

Example files and projects

Table 3-3
Component Note
96837136_WinCC_TIA_redundant_communication_en.pdf This document
96837136_Panel_H-PLC_Library.zip This zip file includes a
WinCC (TIA Portal) library

3.2 Mode of operation

The operator panel is connected with the two H CPUs. Scripts are used in the
operator panel in order to check which of the controllers are accessible. If the
connected H CPU or the communication to the H CPU fails, the connection is
automatically switched to the other H CPU.
The following script templates can be found in the library “96837136_Panel_H-
PLC_Library.zip”:
• connection_PLC1
• connection_PLC2
• connection_lost

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 3 Software Solution with Scripts
3.2 Mode of operation

Connection_PLC1 and connection_PLC2

The two scripts are functionally identical and only differ in terms of the connection
parameters.
The following functions are performed in the scripts “connection_PLC1” and
“connection_PLC2”:
1. Initializing:
The connection that reaches the trigger describes the tag for the connection
memory of the data connection with the connection name.
2. Resetting:
The connection status tag is set to 1 in order to get the “OK” state.
3. Fault detection:
The connection status tag of the other connection is increased. This process
discovers an existing fault of the other connection after some cycles and
checks a required switchover of the data connection.
4. Switchover:
If the other connection cannot reset the connection status tag, it will reach a
limit value. As a result, it will be checked whether the data connection in this
failed connection is available.
If this is the case, the connection is switched over.
5. Reentry:
This section deals with the reentry after a complete disconnection. The first
active connection switches the data connection to itself.
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Connection_lost
In the event of a complete disconnection, there is no fast trigger available on the
panel for the execution of scripts.
In order to be able to detect and display a total failure, the scheduler is used with a
cycle of one minute. The script (connection_lost) used in the scheduler includes the
following functions:
1. Fault marking:
The connection status tag is set to 5 for both connections. If both connections
are active, the access that is every minute, will have no effect. 5 corresponds
to connection status “OK”.
2. Deactivating:
If the connection status tags of the two connections are 5 or higher, they will be
set to 100. 100 corresponds to connection status “deactivated”.
“connection_lost” is written in the connection memory of the data connection.
Status of the connection status tags:
Table 3-4
Values Status
0 Initialization, waiting for the first trigger
1 to 5 OK
6 to 10 Faulty
11 to 20 Failed
100 Deactivated

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 3 Software Solution with Scripts
3.3 Configuration

3.3 Configuration
3.3.1 STEP 7 configuration

Table 3-5
No. Action
1. Configure your H system as usual with STEP7 V5.x
2. Open the properties of the H CPU.
3. Enable the clock memory in the “Cycle/Clock Memory” tab and enter the desired
memory byte.
In the example the memory byte 0 is used.
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To connect the operator panel to the H CPU, the proxy PLC is used in WinCC (TIA
Portal). This is why no further steps are required in the STEP 7 project.
Prerequisite for the use of the proxy PLC is a consistent STEP 7 V5.x project. More
detailed information on the use of the proxy PLC can be found in entry \3\.

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 3 Software Solution with Scripts
3.3 Configuration

3.3.2 WinCC configuration

Table 3-6
No. Action
4. Open the WinCC (TIA Portal) project with the comfort panel which you would like
to connect to the H CPU.
5. Add a new device from the “device proxy” type.
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6. Right click the proxy PLC and select “Initialize device proxy”.

7. Select the STEP 7 V 5.x project.

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 3 Software Solution with Scripts
3.3 Configuration

No. Action
8. Open the network view and create an HMI connection between the operator
panel and the proxy PLC.

9. Open the “Connections” editor and rename the created connection to

“PLC_Changer_12”.
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The panel communicates via this connection with the H CPU.

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 3 Software Solution with Scripts
3.3 Configuration

No. Action
10. Create two further connections “PLC_1” and “PLC_2”.
Set the connection settings (IP address, racks and slot number) of the two H
CPUs.
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11. Open the “96837136_Panel_H-PLC_library” global library that you can download
from the download page of this entry.
https://support.industry.siemens.com/cs/ww/de/96837136
12. Drag the “H-System_Connection” tag table and the VB scripts via drag & drop
into your project.
13. Open the “H-System_Connection” tag table.
Change the addresses of the tags “trigger_PLC1”, “trigger_PLC2” and
“Clock_memory” if you do not wish to use the clock memory as memory byte 0.

14. Open the “connection_PLC1” script.

Change the address parameter of the “PLC_Changer_12” connection in line 40
and line 54 to the address parameter of your “PLC1”.

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 3 Software Solution with Scripts
3.4 Example scenarios

No. Action
15. Open the “connection_PLC2” script.
Change the address parameters of the “PLC_Changer_12” connection in line 40
and line 54 to the address parameters of your “PLC2”.

16. Open the scheduler.

Add a new task with the trigger “1 Minute”.

Add the “connection_lost” script in “Events > Update”.

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Calling the scripts “connection_PLC1” and “connection_PLC2” is already

configured in the “value change” of the tags “trigger_PLC1” and “trigger_PLC2”.
17. Download the project into your operator panel.

3.4 Example scenarios

Initialization
The connections “PLC_1” and “PLC_2” are both active.
According to the assignment, the connection “PLC_Changer_12” is switched to
“PLC_1” (“connected_to” = PLC_1)

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 3 Software Solution with Scripts
3.4 Example scenarios

Fault detection and resetting

The scripts “connection_PLC1” and “connection_PLC2” are triggered by reading
the triggers (“trigger_PLC1” and “trigger_PLC2”).
• “connection_PLC1” increments the connection status tag by 1 with each
execution of the connection to PLC_2 and sets its own connection status tag to
1.
– con_state_PLC2 = con_state_PLC2 + 1
– con_state_PLC1 = 1
• “connection_PLC2” increments the connection status tag by 1 with each
execution of the connection to PLC_1 and sets its own connection status tag to
1.
– con_state_PLC1 = con_state_PLC1 + 1
– con_state_PLC2 = 1

Scenario 1
The PLC_1 connection fails due to an error.
• The trigger can no longer be read through this connection
• The “connection_PLC1” script is not executed.
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• The “connection_PLC2” script is still executed cyclically.

The connection status tag of the connection PLC_1 (“con_state_PLC1”) is no
longer reset, this is why the connection status tag reaches the limit value 11 (see
Table 3-4).
The “connection_PLC2” script checks the connection memory “connected_to”.
Since this memory is set to PLC_1, the “ChangeConnection” function switches the
data connection to the parameters of connection PLC_2. The connection memory
is set to PLC_2.
• connected_to = PLC_2

Scenario 2
The connection PLC_2 also fails due to an error, therefore the “connection_PLC2”
script can no longer be executed.
The “connection_lost” script is executed once every minute by the scheduler.
Both connection status tags are set to 5 in the first cycle.
• con_state_PLC1 = 5
• con_state_PLC2 = 5
Both connection status tags are set to 100 in the second cycle. The connection
memory is set to “connection_lost”.
• con_state_PLC1 = 100
• con_state_PLC2 = 100
• connected_to = connection_lost
 The connection is totally disconnected.

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 4 Software Solution without Scripts
4.1 Components used

4 Software Solution without Scripts

4.1 Components used
Hardware components
Table 4-1
Component No. Article number Note
PS 407 10A 2 6ES7407-0KA02-0AA0
CPU 416-5H PN/DP 2 6ES7416-5HS06-0AB0
KTP400 Basic PN 1 6AV2123-2DB03-0AX0
SCALANCE X204-2 1 6GK5204-2BB00-2AA3

Software components
Table 4-2
Component No. Article number Note
STEP 7 V5.5 + SP4 1 6ES7810-4CC10-0YA5
WinCC Comfort V13 SP1 1 6AV2101-0AA03-0AA5 As of WinCC Basic
V13 SP1
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4.2 Mode of operation

Through the evaluation of the status of the H CPU (master/reserve) as well as the
internal system function “ChangeConnection” there is the option to connect a panel
to an H CPU.
For this purpose, you have to set different addresses for the H CPUs.
If the SIMATIC H Station detects the failure of an H CPU (e.g. H-CPU_1), a
connection to a different H CPU is created with the help of the “ChangeConnection”
function.
The “ChangeConnection” function terminates the connection to the controller
currently in use and establishes a new connection with the specified controller.
You have two options to use the “ChangeConnection” function:
• Manual switchover with a function button: Configure the “ChangeConnection”
system function on the “Press” event.
• Automatic switchover: Automated call of “ChangeConnection”, e.g. on the “On
exceeding” event of a process tag.

Note Please note that no switchover takes place for this solution in the event of
communication errors.

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 4 Software Solution without Scripts
4.3 Configuration

4.3 Configuration
4.3.1 STEP 7 configuration

The FB523 function block allows the output of the modes “RUN/STOP” and of the
status “Master/Reserve” of an H system.
Table 4-3
No. Action
1. Download the library from the link \4\ and add it to your project as described in
the entry.
2. Define tags for the outputs “R0_MSTR” and “R1_MSTR” (in this example:
DB1.DBX4.0 and DB1.DBX5.0)

To connect the operator panel to the H CPU, the proxy PLC is used in WinCC (TIA
Portal). This is why no further steps are required in the STEP 7 project.
Prerequisite for the use of the proxy PLC is a consistent STEP 7 V5.x project. More
detailed information on the use of the proxy PLC can be found in entry \3\.

4.3.2 WinCC configuration

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Table 4-4
No. Action
1. Open the WinCC (TIA Portal) project with the operator panel that you would like
to connect to the H CPU.
2. Add a new device from the “device proxy” type.

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 4 Software Solution without Scripts
4.3 Configuration

No. Action
3. Right click the proxy PLC and select “Initialize device proxy”.

4. Select the STEP 7 V 5.x project.

5. Open the network view and create an HMI connection between the operator
panel and the proxy PLC.
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 4 Software Solution without Scripts
4.3 Configuration

No. Action
6. Open the “Connections” editor and rename the created connection to
“PLC_Changer_12”.
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The panel communicates via this connection with the H CPU.

7. Create two further connections “PLC_1” and “PLC_2”.
Set the connection settings (IP address, racks and slot number) of the two
H CPUs.

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4.3 Configuration

No. Action
8. Open an HMI tag table and add the following tags.

• Status_Connection_PLC1_Master: Data type: Byte, connection: PLC_1,

address: DB1.DBB4, acquisition mode: Cyclic continuous, maximum: 0

• Status_Connection_PLC2_Master: Data type: Byte, connection: PLC_2,

address: DB1.DBB5, acquisition mode: Cyclic continuous, maximum: 0

• Connected_PLC: Data type: WString, connection: Internal tag

Length: 15

9. Configure the “ChangeConnection” system function for the tags

“Status_Connection_PLC1_Master” and “Status_Connection_PLC2_Master” in
“Events > On exceeding”. Enter the connection parameters for the respective
connection “PLC_1” or “PLC_2” for the “PLC_Changer_12” connection.
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10. In addition, configure the “SetTag” system function on the “On exceeding” event
of the two tags. Describe the “connected_PLC” tag with the name of the
respective controller.

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 4 Software Solution without Scripts
4.4 Example scenarios

4.4 Example scenarios

Table 4-5
H CPU: Address Bit status Result
PLC_1 DB1.DBX4.0 1 Master
PLC_2 DB1.DBX5.0 0 Reserve
PLC_1 DB1.DBX4.0 0 Reserve
PLC_2 DB1.DBX5.0 1 Master

PLC_1 is master
The operator panel evaluates the upper limit value of the “DB1.DBB4” tag (limit
value: 0). If the “DB1.DBX4.0” bit is set, the limit value is exceeded and the
“ChangeConnection” function is executed.
The connection changes from the specified connection of the “PLC_Changer_12”
to the configured connection parameters of the “PLC_1”.
The connection to the PLC_1 is established.

PLC_2 is master
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The operator panel evaluates the upper limit value of the “DB1.DBB5” tag (limit
value: 0). If the “DB1.DBX5.0” bit is set, the limit value is exceeded and the
“ChangeConnection” function is executed.
The connection changes from the specified connection of the “PLC_Changer_12”
to the configured connection parameters of the “PLC_2”.
The connection to the PLC_2 is established.

Note You can switch the master CPU manually to STOP mode in order to test the
function.

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 5 References

5 References
Table 5-1
Topic Title
\1\ Siemens Industry http://support.automation.siemens.com
Online Support
\2\ Download page of the https://support.industry.siemens.com/cs/ww/de/96837136
entry
\3\ Combined configuration http://support.automation.siemens.com/WW/view/en/73502293
with WinCC (TIA Portal)
and STEP 7 V5.x
\4\ How do you read out http://support.automation.siemens.com/WW/view/en/19537149
the operating state and
status of an H system?

6 History
Table 6-1
Version Date Modifications
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V1.0 02/2015 First version

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