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Fifty-fifty after many years of TIA Portal evolution, every now so I come across another cool characteristic that I either was not enlightened of or have never had a take chances to attempt. Recently, I had an opportunity to utilise Configuration Command - a way to configure a single projection to use multiple different hardware configurations.

For OEM's who produce and sell standard machines with a number of customer-selectable options, Configuration Command can let a single projection to be developed and maintained that is capable of supporting multiple options and configurations. The really cool part is that the hardware configuration can even exist changed in the field without any program changes - even from an HMI.

The ability to change hardware configuration in the field allows an OEM to utilize a single program for every auto congenital while only using the hardware required for the options selected, which can assist to lower hardware costs while nevertheless allowing for expansion and upgrades. Hardware can exist added in the field, and options tin be turned on/off from either a configuration screen on the HMI or even a license key that can be provided and entered.

If you lot haven't worked with Configuration Control before, it's worth noting that there are several different Configuration Control features available.

I'm going to highlight two of them: Configuration Control at the Device Level and Configuration Command for IO Systems.

Configuration Control at the Device Level

Within TIA Portal, Siemens provides the ability to configure, at run-fourth dimension, the hardware modules used within an S7-1200, S7-1500, ET200SP Controller, or ET200SP (PN or DP) Remote I/O Rack. This ways a single projection tin can be created with a "Master Rack" configuration which defines a superset of all hardware that could be used and that a user can, at run-time, choose which modules to use and decide where in the rack they are located.

As a simple case, imagine a machine designed to batch and mix ingredients in a arrangement of tanks. As a machine builder, you provide an pick to your customers to add a temperature monitoring function. Some customers may experience this feature is worth the actress cost, but it is not a standard characteristic on every car built. With Configuration Control, you tin can add together a Thermocouple module to your rack and define the module as 'Optional.'

At present, you can develop a single program which includes the temperature monitoring functionality and build the auto according to your customers' selected options. If they cull to add temperature monitoring, you can include the Thermocouple module in your hardware rack and activate that option. If not, you leave information technology out. Either way, the software (and hardware configuration defined in information technology) are identical.

So how tin you prepare Configuration Control at the device level?

Permit's build a quick example. While we could utilise an S7-1200, S7-1500, or ET200SP I/O remote rack, I'thou going to use an ET200SP Controller  (S7-1510 1-PN) every bit I have one sitting on my desk. Additionally, I have i (1) DI 8x24VDC ST and 1 (1) DQ 8x24VDC/0.5A ST module. So, let'south assume I want to blueprint a system with four possible configurations:

• Option A: Both DI (Slot two) and DQ (Slot 3) Modules
• Option B: DI Module Merely (Slot 2)
• Option C: DQ Module Only (Slot 2)
• Pick D: No Modules

Stride 1 - Create a Master Rack
To kickoff with, I've created a "Primary Rack" in my hardware configuration containing all possible modules. The "Primary Rack" should contain the maximum options available. In my example, information technology volition include both the DI and DQ modules as shown below.

After adding the modules, become to the properties of the PLC and, nether Configuration Command, check the box for "Allow to reconfigure the device via the user plan."

Step 2 - Create a Configuration Control Record
Create a PLC Data Blazon (UDT) to define the hardware configuration. This UDT will be structured as follows:

Byte ane: Cake Length - the total number of bytes in the record. Header Length (4) + two * Number of Slots. In this case, in that location are iv slots: Slot one is the CPU, Slot 2 is the DI module, Slot three is the DQ module, and Slot 4 is the server module. Notation the default values I've given the UDT are the default positions assigned in the hardware configuration.

Byte two: Block ID - The data tape number being written. For configuring hardware in a rack, it is 196.

Byte 3: Version - This value is different depending on the type of hardware used. For the ET200SP, Version = ii. For an S7-1500, Version = 4. Additional documentation is bachelor for both with help and online examples.

Byte iv: Subversion - Nothing for the ET200SP.

Byte 5: Slot i - For the ET200SP Controller, the CPU is ever in slot i (where information technology is configured).

Byte 6: Additional Function for Slot ane - Cypher for the ET200SP CPU.

Byte vii: Slot ii - The value of this specifies where the module configured in the hardware configuration is installed. If the module is used in the station option, this will exist the slot in which it is installed. If a module is not used, put a 0 hither. If the module is configured to be empty, enter the slot number of the module + 128.

Byte viii: Additional Function for Slot two - If you supplant a dark colored base unit of measurement with a calorie-free colored base unit (new potential grouping), enter 1. Enter 0 if the base unit installed in this slot matches the hardware configuration.

Byte 9: Slot three

Byte x: Additional Function for Slot 3

Byte 11: Slot 4

- in this example, the Server Module

Byte 12: Additional Role for Slot 4

Step 3 - Create Configuration Options
For this example, I've created a Global DB with an array of four (four) of the command records we just created and set values corresponding to the four possible configurations listed above.

Note in the first that each module matches the configuration. The second removes the DQ module and moves the Server module upwards. The third option removes the DI module and moves the DQ and Server modules up. The terminal configuration eliminates both the DI and DQ modules and moves the Server module upwardly to Slot ii.

Pace four - Add in OB100 (Start-upward)
In the startup OB, you lot volition need to write the configuration option record to define the hardware used.

To do this, y'all can use the code beneath. Notice that I've created an "Alphabetize" tag to switch between the dissimilar options I've configured.

Step 5 - Configuration from HMI
There are many ways you could do this, but I've created a uncomplicated HMI screen to allow a user to select which hardware choice to apply.

It's very uncomplicated - a selection of a configuration sets the "Alphabetize," or a retained tag on the PLC, of the hardware option to be used.

Note that to switch hardware configurations, the PLC needs to be stopped and started and so that OB100 is executed.

If y'all're interested in learning more, Siemens provides a thorough organisation manual for the ET200SP Controller.

Configuration Command for I/O Systems

In improver to controlling the configuration (location and existence) of modules inside a PLC or Remote I/O Rack, TIA Portal also provides the ability to configure an I/O system dynamically. This means you tin can create a "Master Configuration" with multiple remote I/O racks. You can then programmatically (at run-time) define the apply and configuration of those racks.

As another simple example, consider a automobile with modular components such as a multi-cell vacuum press. As a machine builder, you can create and offer a organisation capable of controlling, for case, anywhere from two-8 cells. Each of those cells may accept their own control panel and remote I/O rack.

With Configuration Control, you tin can develop a single project capable of decision-making, for example, eight cells and define at runtime how many (and which) cells are in employ. Furthermore, because it's at runtime, your customer could choose to add an boosted cell at a later on appointment.

Considering of Configuration Control, yous could deliver the new cell, connect the I/O rack to the PLC, and then from the HMI activate the cell - all without making any software changes. By using a single project, the need for maintaining and supporting multiple versions of control code is eliminated allowing you to provide a flexible, modular, and scalable product without the demand for troubleshooting and testing of each combination.

So how can you ready Configuration Control for IO Systems?

Permit's look at how simple information technology can be.

First of all, there are a number of means in which we can set this up. The TIA Portal Help Files comprise some excellent application examples.

Siemens product support also has application examples for the different options. Just I'yard going to configure an ET200SP Profinet I/O rack (IM155-6 PN HF) to be an optional I/O device. While elementary to configure the hardware, it is slightly more complex from a programming perspective.

Step 1: Add an IM155-6 Rack to the Network Configuration
I added an ET200SP I/O rack with a single DI module. Under the properties of the interface module, expand the Profinet interface options and look nether Advanced Options. Select "Optional IO-Device. This will define this device as optional and will only be used if programmatically added to the Profinet network.

Note that if booting a PLC without any special code to activate this network device, it will non be automatically added to the I/O network.

Step ii: Configure Topology
While we could do this in other means, I've used Topology to simplify management of the Profinet network configuration for our Configuration Control demonstration. If you oasis't used Topology in the past, it is similar to your network configuration, but it defines specific port-to-port connections betwixt devices.

These connections must match the verbal ports used when the hardware is networked together. While adding some complexity, there are a lot of cool things yous can do with Topology - including automatic assignment of Profinet name and IP Address. Here, it will allow us to create a simpler configuration record in the side by side few steps.

In this demo, I've divers a connection between P2 on the PLC and P1 on the IM155-6. I've left the others undefined - meaning they can use whatever network connexion bachelor.

Step 3: Create Network Configuration Options
In this instance, I only accept 1 optional device. So I will define ii options: 1 with the IM155-half dozen and i without. The Control Records needed to reconfigure the I/O network are structured as follows:

Word 1 - Version: For reconfiguring the I/O organisation, this is xvi#0100.

Word 2 - Number of Optional Devices to be used: The total number of optional devices that will be used in this configuration pick.

Word iii - Optional Device to Actuate: the hardware identifier of the device to be activated (HW_DEVICE). You can notice this in the arrangement constants of the default tag table. For this example, it is 262.

Word 4 -> Word N-1: Optional Devices to Actuate

Give-and-take Due north - Number of port interconnections: Since we already defined the network topology, this is 0.

For the 2 options (with and without the rack), my configuration records are shown beneath.

Note that I've used a generic struct to define the configurations. Also, note that I've added an empty discussion to the end of the second configuration (WithoutRack) even though information technology isn't needed. It will be apparent why a lilliputian afterwards.

Step 4: Write Logic to Reconfigure the I/O
The I/O network tin can be configured at any betoken without restarting the PLC, unlike the previous example of configuring hardware inside a rack. It just requires three steps:

a) Call "ReconfigIOSystem" with Mode 1 to Deactivate all Optional I/O Devices.

b) Call "ReconfigIOSystem" with Fashion ii (and the configuration record) to Reconfigure/Activate the used I/O Devices.

c) Call "ReconfigIOSystem" with Mode 3 to Restart the I/O.

For this demo, I wrote a simple state machine to sequence through the three steps off of a start command (from the HMI). The user can select a configuration and restart as needed.

A Few Tricks Worth Nothing...

Then I'll go out you with some demo code.

First, the "ReconfigIOSystem" organization part block requires writing the command record equally an array of words.

Nosotros could take defined our Configuration Records as an array, but I liked the Struct better. However, nosotros exercise need to take the selected configuration and movement it into an array.

To do this, I created a static Array [0-3] of Words and a Struct CTRL_REC using an AT construct for the Array. Now I can move my Struct into CTRL_REC and still apply the array of Words as the input to the block.

exist foundSecond, the Logical Address used (LADDR) on the "ReconfigureIOSystem" telephone call is the Hardware Identifier of the PROFINET interface of the IO controller. Again,this tinbe constitute inthe system constants tab of the default tag list .

Finally, I played around with a few options (defining port connections vs. configured topology) and establish the topology method easier to demonstrate. The other cool thing about this is that because the topology is defined, the IM155-6 PN does not need to be commissioned (Profinet name, IP Accost assignment) in advance.

The PLC will automatically assign a Profinet name and IP Accost and autoconfigure the rack wWhen the I/O system configurationis updated with the rack activated! You can examination this be resetting the rack to factory default and then reconfiguring the network to actuate it. You'll notice that since the topology matches what was defined, the IP Address and Profinet Name will be automatically assigned and the rack will be auto commissioned and activated.

The Code

Here'southward the code I used for my quick test. I am running this FB from OB1 and accept buttons on the HMI for Starting/Resetting and selecting which configuration to use. This allows a user to, while the organization is running, add together or remove the remote I/O rack from the Profinet network.

I hope this is helpful! Thank you for reading!

For those of you who made it this far, I've attached a sample project for you lot if yous'd like to attempt information technology yourself!

Learn more about DMC'southward TIA Portal programming expertise or Contact Usa to go started on a project today.

gillispieprign1979.blogspot.com

Source: https://www.dmcinfo.com/latest-thinking/blog/id/9380/optional-hardware-configuration-control-in-tia-portal

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