PLC-ANALYZER pro 5
Contents
1. BLACKBOX for PLC ANALYZER pro 5 BLACKBOX A for PLC ANALYZER pro Long term PLC process data recording and remote maintenance with PLC ANALYZER pro 5 Mini PC for integration in a switching cabinet BLACKBOX for PLC ANALYZER pro 5 User Manual Copyright 1995 2005 AUTEM GmbH All rights reserved No part of this user manual including excerpts may be reproduced photocopied or electronically stored without express written permission by AUTEM The software described in this manual is subject of a software licensing agreement and may be used only according to the terms of this agreement AUTEM GmbH Dithmarscher StraBe 29 D 26723 Emden Germany Telephone 49 4921 9610 0 Telefax 49 4921 9610 96 eMail info autem de http www autem de AUTEM issues no guarantee for this manual This includes both expressly given or tacit guarantees for commer cially accepted quality and suitability for a particular use AUTEM accepts no liability for errors in the manual or for damages that may occur as a result of using or applying this material The names of particular software and hardware products mentioned in this book are mostly registered trademarks whose usage is subject to the terms of appropriate law We are thankful for any comments suggestions or ideas you care to write to us 1 Edition 2005 SIMATIC SIMATIC NET S7 300 CP5611 are trademarks of Siemens AG Table of Contents Table of Contents2. The BLACKBOX from AUTEM provides an ultra compact data acquisition computer for the long term recording of PLC signals and external electrical values PLC process data archiving and also remote maintenance using the PLC ANALYZER pro 5 Due to its small dimensions the system can be integrated in a switching cabinet without any problem The BLACKBOX can continuously record and archive PLC signals over a longer period of time typically in excess of 3 years WARNING Errors that can occur in the automated facility endangering humans or causing large scale material damage must be prevented by additional external measures These measures e g independent limit monitors mechanical interlocks must guarantee safe operation even in the case of dangerous errors WARNING If you use the BLACKBOX within an unprotected network you should install S Windows security updates regularly Revocation of guarantee The warranty BLACKBOX is 12 months The warranty no longer applies if the product is tampered with or if the product is not handled properly or if the prod uct is stored under adverse conditions The warranty also no longer applies if the device is used in a fashion that does not correspond to the manufacturer s intended use or if used after wear and tear has taken effect or if used with incorrect cur rent or voltage or if used after damage by surge lightning fire water dampness The warranty no longer applies if the guaranty s
3. 1 INTRODUCTION Overview Field of application Performance characteristics Typical operation Help Support 2 INSTALLATION oa wN 2 1 Installation 2 2 Floating contact for external operating status signals 2 3 Installation of additional hardware 2 4 Installing the software 3 STARTING UP AND OPERATION S31 Operation using keyboard mouse and screen 3 2 Remote operation using a cross over direct connection LAN Oro Further options for remote operation 3 3 1 Remote operation via Intranet LAN 3 3 2 Remote operation via Internet VPN 3 3 3 Remote operation using remote data transmission via modem 3 4 Watchdog 4 OPERATION WITH PLC ANALYZER PRO 5 4 1 Creating the project for signal recording 4 2 Start signal recording 4 3 Start parameters tor PLC ANALYZER pro 5 4 4 Reading out recorded signal files 5 APPENDIX A MOUNTING BLACKBOX DC CONNECTOR Table of Diagrams Fig 2 1 BLACKBOX dimensions Fig 2 2 Pinout Power Supply Fig 2 3 Floating contact connection luster terminal on rear side of housing Fig 3 1 LAN cross over direct connection tor remote operation Fig 3 2 Structure of the Remote Desktop Connection Fig 3 3 Enable access to the local drives of the external PC Fig 4 1 Lite Indicator LED on the rear side of the housing Fig 4 2 Changing the PLC ANALYZER pro 5 start parameters Abb 5 1 Pin assignment DC Connector AAA WWWNN NN a0 TR GOs IRI ROI Introduction 1 1 1 Introduction 1 1 Overview
4. 5 watchdog Activates the Watchdog feature when the PLC ANALYZER pro 5 is started also refer to Section 3 4 d lt days gt Specifies the size of the ring buffer Signal files which are older than the number of days specified are being deleted For this PLC ANALYZER pro 5 only cares for those signal files which were cre ated during the current session also refer to Section 4 1 Operation with PLC ANALYZER pro 5 4 3 Parameter Description cip lt client IP gt Specifies the IP address of the PC for remote operation If a PC as signed this IP address is available in the network on starting the PLC ANALYZER pro Watchdog is not activated also refer to Sec tion 3 4 lt projectfile gt Project file with predefined settings for recording signals Table 4 1 PLC ANALYZER pro 4 start parameters for BLACKBOX The start parameters can be changed by opening Start All Programs Startup Position the mouse on PLC ANALYZER pro 5 and click the right mouse The start parameters can then be modified in the Properties Shortcut Target menu PLC ANALY ER pro 4 Properties General Shortcut Compatibility DAA PLC ANALYZER pro 4 Target type Application Target location PLC ANALYZER pro Target HC Program Files 4UTEMSPLC ANALYZER pro s Stark ir Comment Fig 4 2 Changing the PLC ANALYZER pro 4 start parameters 4 4 Reading out recorded signal files Signal files can be copied at any time from the c b
5. is normally sufficient for over 3 years Software is completely installed preconfigured and ready for operation Can only be supplied in conjunction with first license PLC ANALYZER pro 5 for BLACKBOX Operating temperature range 0 40 C 48 hour burn in CE certificate Warranty 12 months Introduction 1 3 1 4 Typical operation Create a project with PLC ANALYZER pro 5 and save it in the BLACKBOX directory Switch off BLACKBOX Connect BLACKBOX with the PLC Switch on BLACKBOX Check Life Indicator LED Process data recording is running V 1 5 Help Support Should problems occur when using the BLACKBOX for the PLC ANALYZER pro 5 please read this user manual thoroughly for assistance There is an FAQ list at our Web site http www autem de containing answers to frequently asked questions Please contact our technical support if you cannot solve the problem Technical Support AUTEM Tel 49 0 4921 9610 0 Fax 49 0 4921 9610 96 eMail support autem de Please have the following information at hand in addition to an exact error description Version and serial number of PLC ANALYZER pro Serial number of the BLACKBOX PLC model and CPU type e g SIMATIC S7 300 CPU 314 and release number Installation 2 1 2 Installation 2 1 Installation Due to the small dimensions the BLACKBOX can be installed directly in a switching cabinet Please refer to Fig 2 for the exact dimensions During installation pay attention
6. that the air vents on the left right rear sides of the housing remain free to ensure sufficient ventilation It can be installed either horizontally or vertically The BLACKBOX should be protected against vibration and impacts If necessary use rubber shock absorption pads during installation to protect the BLACKBOX from ambient vibration t gt t gt lt gt DA A O Q a q O Oy oO CO oO O N N N O or 0 2 y A BLACKBOX i for PLC ANALYZER pro AUTEN amg Fe a y Fig 2 1 BLACKBOX dimensions Connect the BLACKBOX to power supply The BLACKBOX requires a power supply of 16 24 Volt DC 2 5 A An appropriate DC connector is part of the material supplied Fehler Installation 2 2 Verweisquelle konnte nicht gefunden werden provides instructions for mounting the DC con nector ____ 6 24vce 2 5 A Fig 2 2 Pinout Power Supply Alternatively the power adapter supplied can be used in order to operate the BLACKBOX with 100 240 Volt AC 50 60 Hz Connect the data cable between the BLACKBOX and the PLC 2 2 Floating contact for external operating status signals A floating contact located on a luster terminal on the rear of the BLACKBOX provides the op tion of externally monitoring the operating st
7. LACKBOX is connected to an Ethernet hub by means of a patch cable in order to be available in the network NOTE IEY Use a standard patch cable to connect the BLACKBOX to a hub The cross over cable supplied is a crossed cable which can only be used for the direct connection of two computers Ensure that the corresponding LAN connection of the BLACKBOX is assigned to an IP address appropriate to the network address scheme 3 3 2 Remote operation via Internet VPN Remote operation of the BLACKBOX can also be performed via Internet Normally a VPN Virtual Private Network is set up for this purpose Modern Windows versions e g Win dows XP are already prepared for this Define the necessary settings under Start Control Panel Network Connections XP More detailed information on network parameter settings in Windows is available in the Win dows Help 3 3 3 Remote operation using remote data transmission via modem Remote operation of the BLACKBOX can also be performed via a modem DFU Rempte data transmission To do this a modem or an ISDN adapter must be connected to the BLACKBOX Define the necessary settings under Start Control Panel Network Connections XP More detailed information on network parameter settings in Windows is available in the Win dows Help 3 3 3 1 Settings BLACKBOX Click Create a new connection Select assistant Set up an advanced connection Next Select Accept incoming connecti
8. al Display Local Resources Programs Experience Remote computer sound QE Bring to thie computer s Keyboard ees Appl Windows key combinations ey for example 4ALT TAB In full screen mode only Local devices Comect automatically to these local devices when logged on GP to the remote computer Disk drives Printers C Serial ports Fig 3 3 Enable access to the local drives of the external PC Then press the Connect button The remote desktop connection is established The BLACKBOX can then be controlled by remote operation NOTE L If necessary the individual LAN connections of the BLACKBOX can also be as signed any other IP addresses Note down any change made to the IP address of the middle LAN connection clearly because it is essential for establishing a con nection for remote operation More detailed information on network parameter settings in Windows is available in the Windows Help NOTE IE If necessary the user name and password of the BLACKBOX Default Black box can be modified under Start Control Panel User Accounts Note down any changes to the settings clearly More information is available in the Windows Help Starting up and operation 3 4 3 3 Further options for remote operation 3 3 1 Remote operation via Intranet LAN Remote operation via Intranet is in principle identical to remote operation using a cross over cable refer to Section 3 2 In this case the B
9. atus of the BLACKBOX When signal recording is operating properly the contact is closed In the case of an interruption of the recording or the computer malfunctions or crashes the contact opens Electrical load max 15 W 200 VDC NAA ares a 2 Fig 2 3 Floating contact connection luster terminal on rear side of housing 2 3 Installation of additional hardware Other hardware components may need to be connected depending on the purpose for which the BLACKBOX is being used Examples of this are a modem for remote maintenance via remote data transmission or an external CD writer 2 4 Installing the software The BLACKBOX is supplied with the requested software configuration ready installed Other software components may need to be installed depending on the purpose for which it is being used Starting up and operation 3 1 3 Starting up and operation There are two methods with which to start up the BLACKBOX for the first time for configura tion purposes These are explained in the following sections NOTE is The BLACKBOX is equipped with a Watchdog which monitors the signal re cording In the case of an unforeseen interruption of the recording or a computer crash the Watchdog causes a RESET to be triggered so that the BLACKBOX is automatically rebooted The precise way in which the Watchdog functions and possibilities to deactivate it are described in detail in Section 3 4 3 1 Operation using keyboard mouse an
10. chdog which monitors the signal recording In the case of an unforeseen interruption of the recording or a computer crash the Watchdog causes a RESET to be triggered so that the BLACKBOX is automatically rebooted Watchdog is always activated when the PLC ANALYZER pro 5 is started with the watchdog parameter active setting in Startup There are three ways in which to deactivate the BLACKBOX Watchdog function for mainte nance work and remote operation Hold the lt Ctrl gt key pressed during the boot routine only with a keyboard which is connected directly Manual termination of signal recording in PLC ANALYZER pro 5 Availability of a PC for remote operation of the BLACKBOX in the network whose IP address network address was made known to the PLC ANALYZER pro 5 during startup with the cip lt ip address gt parameter refer to Section 4 3 l Jf you use an ISDN adapter choose PPP over ISDN PPP PPPoE as DFU device Operation with PLC ANALYZER pro 5 4 1 4 Operation with PLC ANALYZER pro 5 Before beginning long term data acquisition the PLC ANALYZER pro 5 must be appropriately configured The most important steps are described briefly below More information on the PLC ANALYZER pro 5 is available in PLC ANALYZER pro 5 User Manual NOTE IEY The BLACKBOX requires a special version of the PLC ANALYZER pro 5 This is supplied together with the BLACKBOX and is already installed 4 1 Creating the proj
11. d screen Connect the keyboard mouse and screen to the corresponding connections on the BLACKBOX Switch on the BLACKBOX Press and hold the lt Ctrl gt key during the entire boot routine so that the PLC ANALYZER pro 5 is not automatically started and activation of the Watchdog is prevented also refer to Section 3 4 The BLACKBOX can then be operated as a normal PC running under Windows 3 2 Remote operation using a cross over direct connection LAN I Define IP 192 168 0 2 BLACKBOX rear side 000R ooe OO OO ene O Q Q O m LAN LAN LAN ane PTC Default IP 192 168 0 1 LAN middle connection ana a a a a a u a a a ss ss ss ee Cross over network cable External PC for remote operation Fig 3 1 LAN cross over direct connection for remote operation Starting up and operation 3 2 For remote operation of the BLACKBOX a PC or Notebook running under Win9x NT 2000 XP is required Connect the middle LAN connection on the BLACKBOX to the external PC using the cross over network cable supplied Set the IP address for the network connection of the PC to 192 168 0 2 Since the hard disk C of the BLACKBOX is enabled in the network access is already available to the drive Explorer Network Neighborhood e g to copy PLC ANALYZER pro 5 signal or project files If Windows XP H
12. eal is removed or rendered un readable The BLACKBOX is connected to the PLC by means supported by the PLC ANALYZER pro 5 1 e via connection to the PU interface or an automation network MPI PROFIBUS Industrial Ethernet TCP IP Modbus The recording of any electrical signal outside the PLC is also possible by means of the AD_USB Box optional Introduction 1 2 The BLACKBOX automatically begins recording signals after being switched on and then op erates autarkical 1 2 Field of application Long term PLC process data recording Failure diagnosis Determine cause of production loss Preventive maintenance Documentation QA TPM QEE PLC Remote Service 1 3 Performance characteristics Massive steel case Housing dimensions WxDxH 17 7 x 22 8 x 5 1 cm Connections PS 2 keyboard mouse VGA 2 x USB 1 x RS232 3 x RJ45 LAN 10 100 Base TX Watchdog monitoring Life Indicator LED Free floating contact for external operating status signals Power supply 16 24 Volt DC 2 5 A Incl external power adapter 100 240 Volt AC 50 60 Hz Siemens CP 5611 SIMATIC NET PROFIBUS MPI connection PCI card or other PLC Adapter optional Remote maintenance software and TP RJ45 cross over network cable to remote PLC and signal file access via external PC Win9x NT 2000 XP Remote control via modem or Internet VPN possible remote maintenance Windows XP Pro operating system The BLACKBOX signal recording capacity
13. ect for signal recording Start the PLC ANALYZER pro 5 and create a project file for recording the signals The PLC ANALYZER pro 5 is configured in such a way that the signal recording defined in the project begins automatically after starting the BLACKBOX Information on the PLC ANALYZER pro 5 start parameters 1s provided in Section 4 3 For reasons of data integrity it is recommended to limit the size of the signal files created for long term recording We recommend a size of 60 minutes Select Project Project Options Acquisition Mode and set Signalfile Size to 60 minutes If not specified otherwise signal files are stored to the hard disk up to 300 MB free space Thereafter the oldest signal files are being automatically deleted step by step FIFO ring buffer With d you can specify a period of time in days after that the oldest signal file is being deleted gradually refer to Section 4 3 Save the project on the BLACKBOX hard disk in the c blackbox project folder under the name blackbox prj 4 2 Start signal recording Open c blackbox project and check whether a valid project file blackbox prj 1s available Terminate the Windows session and switch the BLACKBOX off Check that the connections to the PLC and power supply are correct If the BLACKBOX should operate autarkic disconnect the connections to the keyboard mouse and screen Switch on the BLACKBOX The system is booted and signal recording should start fully aut
14. lackbox signal folder even when sig nal recording is actually running For more information on operation refer to Section 3 Appendix A 5 Appendix A Mounting BLACKBOX DC Connector NOTE i Solder the cables to the appropriate contacts at the connector before mounting the connector x F 2 5 A eo 5 16 24VDC Abb 5 1 Pin assignment DC Connector Tabelle 5 1 Mounting BLACKBOX DC Connector
15. o matically after about 1 minute The green Life Indicator LED rear side of BLACKBOX housing see Fig 4 1 flashes at inter vals of one second when signal recording has been started successfully Operation with PLC ANALYZER pro 5 4 2 The system is now active Signal files are subsequently recorded according to the project set tings The BLACKBOX enables a practically continuous recording of signals over several years When the capacity has been reached the oldest signal file is automatically deleted to create space for new signal data Fig 4 1 Life Indicator LED on the rear side of the housing NOTE i If the green Life Indicator LED does not start to flash at intervals of one second after 2 minutes signal recording has not been started successfully Also perma nent rebooting of the BLACKBOX Beep indicates that signal recording has not been successfully started 4 3 Start parameters for PLC ANALYZER pro 5 The PLC ANALYZER pro 5 is started automatically through an entry in the Windows Startup folder after the BLACKBOX has been booted The syntax of the PLC ANALYZER pro 5 start parameters is explained below anawin run watchdog cip lt Client IP gt lt projectfile gt Example BLACKBOX default setting anawin run WacchdoGg Cip7 192 100 0422 Dlackbox pr Parameter Description run Signal recording in the project lt projectfile gt is started automatically after starting the PLC ANALYZER pro
16. ome or Professional is not installed on the PC the client for the remote op eration must be installed on the external PC first of all Otherwise skip the following instruc tion The client is located on drive C of the BLACKBOX under c blackbox client msrdpcli exe Start the file and follow the instructions in order to install the client Start the remote client It is located under Start Alle Programme Zubeh r Kommunikation Remotedesktopverbindung or Start All Programs Accessories Communications Remote Desktop Connection 2 Remote Desktop Connection General Display Local Resources Programs Experience Logon settings aj Type the name of the computer or choose a computer from the drop down list Computer 192 168 0 1 ke Username Blackbox Password Domain Save my password Connection settings ey oO E Save current settings or open saved connection Fig 3 2 Structure of the Remote Desktop Connection Enter the logon settings Computer 192 168 0 1 IP address of the BLACKBOX Benutzername User name Blackbox Kennwort Password Blackbox Starting up and operation 3 3 Select the Lokale Ressourcen Local Resources tab and click on the Laufwerke Disk drives checkbox This is useful because it enables access to the local drives of the external PC during remote operation of the BLACKBOX 3 Remote Desktop Connection lt _ _ O EE Gener
17. ons Next Select modem Next Select Do not allow virtual private connections Next l Jf you use an ISDN adapter choose PPP over ISDN PPP PPPoE as DFU device Starting up and operation 3 5 Select via Users allowed to connect BLACKBOX Next Open the properties of the TCP IP connection Set via Specify TCP IP address the TCP IP address from 192 168 0 1 to 192 168 0 10 Activate the control field Allow calling computer to specify its own IP address OK Next Finish 3 3 3 2 Settings PC which will be connected with the BLACKBOX for remote control Click via Control Panel Network Connections on Create a new connection Select via assistant Connect to the network at my workplace Next Select Dial up connection Next Enter name fort he connection e g BLACKBOX BMW USA Next Enter via Phone number the phone number of the BLACKBOX modem Next Activate Add a shortcut to this connection to my desktop Finish By double click on the new symbol of your desktop a window will open to enter user name Blackbox and pass word Blackbox Under Connect the phone number of the modem should be registered already Now press Connect The connection to the BLACKBOX starts After connection open Remote Desktop Connection via Start All programs Accessories Communications 3 4 Watchdog The BLACKBOX is equipped with a Wat
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