100843877.

doc

Commissioning Procedure for SIMATIC S7 Products/Systems 1. Visually inspect the PLC panels at site and check for any mechanical damage. Record the damages,if any, and inform the Site in Charge and Project Engineer. 2. Compare the panel layout drawings with the actual layout and mark any deviations in the drawing. 3. Compare the type number of all the hardware supplied with the type numbers in the Equipment List. Mark any deviation and report to Project Engineer. 4. Prepare a Site Report of the above three points.Send a fax to the Project Engineer and a copy to EFS. 5. Takeout the front connectors of all the I/O modules and also Function Modules, if any. 6. Perform a physical inspection of all internal wirings. Particularly check that high voltage lines are not shorted to low voltage lines and AC and DC voltage lines are not mixed up electrically.Physically check that the AC input wires to the Power Supply unit are coming from terminals as shown in the drawing. 7. Before switching ON any power supply from the Feeder Panels, switch OFF all mcbs inside the PLC panel and ensure that the voltage selector switch on the PS module is as per incoming voltage level .Check the feeder panels and ensure that the voltage levels are as required by the PLC panel.Then switch ON the feeder mcb/mcbs (only those which are required). 8. Switch ON the PS unit of the PLC and check that the 5V and 24V DC LEDs are glowing.If not,refer to the Fault/Error Messages list in the Module Specification Manual and analyse the cause. 9. Insert the Batteries of the PS unit and check their healthiness by putting the BATT INDIC switch at the appropriate position.If you select 1 BATT,then BATT.1 is used as the Backup Battery.If you select 2 BATT,then the system defines one of the Batteries as the Backup Batter and its voltage is monitored.When this battery is empty,the system switches to the reserve battery. The level of voltage should be between 2.7 volts to 3.6 volts.The voltage is monitored for the lower limit i.e. 2.7 volts. 10. Give an overall reset to the CPU and put it to Run Mode by the key switch.The Run LED should glow.If any other LED is glowing or flashing,analyse the fault as per Module Specification Manual. 11. Establish a link between the Programming Unit and the CPU through the MPI adapter or directly if you are using a PG740/etc.If a MPI adapter is used ensure that the interface cable from the PC to the adapter is earthed ( the online communication breaks sometimes if this is not done).Also check the settings in the PG/PC Interface Menu Page 1 of 5

100843877.doc

the Com port selected should be the same as the COM port used.Check also the settings of this COM port from the Control Panel Settings of Windows. 12. Download the Hardware Configuration to the CPU and give a Restart to the CPU.The CPU should go to the RUN mode.If it doesnt go to the RUN Mode inspite of the right settings in the Hardware Configuration,then try Uploading the Hardware Configuration and Downloading it to the CPU again.However pay attention to the addresses assigned by the Uploading method to see that the addresses are as per the User Software requirement. 13. Download the user program into the CPU Load Memory.If it doesnt fit into the CPU Memory,a Flash Eprom Card will be required ( Note: At this stage, as per this Commissioning Procedure,the front connectors of the I/O modules are open so that there wont be any accidental switching of outputs). 14. Switch OFF the incoming supply to the PS unit and check that the program in the CPU is retained when the power is switched ON again. 15. Digital Input checking:Before connecting the front connector of any digital input module check at the corresponding panel terminals that the voltage levels are as per the levels shown in drawings i.e. 110V AC should not come to terminals where 24V DC should come or 230V AC should not come where there should be 110VAC.Also actuate some of the switches/sensors and check that the voltage levels are as per requirement.It is recommended that you connect only one front connector at a time this will reduce the failure rate in case of serious voltage mix-ups.Then connect the front connector and check the i/ps. Caution: Pay attention to neutral/M-point connections;if these are not connected,the i/ps will not be registered. Before switching ON working supply to any field device eg. berros/encoders/sensors ensure that those devices are indeed rated for the supply you are switching ON. Caution: Dont switch on mcbs arbitrarily just because you have to check the auxiliary contact input to the PLC as this might lead to failure of the device being supplied power by these mcb if those devices are not rated for that supply level. 16. Digital Output checking:Before switching ON any o/p ensure that the devices which are being switched are of the correct rating eg. dont switch ON 110VAC to a 24VDC contactor. Also before switching ON, inform concerned people or isolate the final device viz. motors/fans/solenoids which may otherwise lead to accidents. Caution: Always think twice before switching ON any device.

Page 2 of 5

100843877.doc

17. Analog Input checking: Select the position of Measuring Range Modules on the side of the Analog Input module as per the table given below: Table 1.0 Position of the Measuring Range Module Position Sensor Type

Set the Static and Dynamic Parameters in the Step7 package as per the channel requirement.Check the Analog I/Ps by using a Simucal Simulator.The count value should be 27648 to +27648 in the Nominal Range. 18. Analog Output checking: Check the Analog o/ps by forcing counts ( -27648 to +27648 in the Nominal range) and measuring the corresponding current/voltage. 19. After completing the I/O checking load the S7 software to the CPU after putting a BEU statement at the beginning of OB1.Now check each of the plant function by calling the corresponding block in OB1. Caution: On calling a program in OB1 an o/p might get switched ON if all coditions are satisfied or there is an error in the program.Be careful about this. 20. If any Operation and Visualisation system is supplied,configure and load the software in these systems and check the communication with the PLC. 21. After checking that the user software is generally working inform the client about readiness to conduct NO-Load and Load Trials.

Page 3 of 5

100843877.doc

22. Prepare As Built Drawings.Keep one copy at site office,handover one copy to client and bring back one copy to office for preparing the final As Built Drawing. 23. Important: Take backup of user program everyday at the end of the day. 24. For handling the Simatic Manager package refer to Annexure-I

Commissioning Procedure For SIMATIC S7 Products/Systems

Page 4 of 5

100843877.doc

Please find enclosed along with this circular Commissioning Procedure For SIMATIC S7 Products/Systems. All Engineers are requested to follow this procedure for every commissioning job. Technical Report submitted should adhere to this proceudre.Problems faced,if any,should be clearly stated in the report.

Encl.: As above Distribution

Page 5 of 5