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1 Utilization of RFID systems in the PCS 7 environment SIMATIC PCS 7 Siemens Industry Online Support

2 Siemens AG Copyright-2018 All rights reserved Warranty and liability Warranty and liability Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These Application Examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Application Examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of the Siemens AG. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement and continuously maintain a holistic, state-of-the-art industrial security concept. Siemens products and solutions only form one element of such a concept. Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place. Additionally, Siemens guidance on appropriate security measures should be taken into account. For more information about industrial security, please visit Siemens products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer s exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under Entry ID: , V3.0, 05/2018 2

3 Siemens AG Copyright-2018 All rights reserved Table of contents Table of contents Warranty and liability Introduction Overview Mode of operation Components used Abbreviations Solution Core functionality Hardware configuration Basics Quality assurance RFID system RFID Transponders RFID reader Preparation Configuration Creating the hardware configuration Configuring the CFC RFID_Ident Using the faceplate Initializing the reader Reading of transponder data Writing of transponder data Appendix Service and Support Contact Links and Literature Change documentation Entry ID: , V3.0, 05/2018 3

4 Siemens AG Copyright-2018 All rights reserved 1 Introduction 1 Introduction 1.1 Overview In today's world, the pharmaceutical industry is determined by standards, guidelines and legislation. Definitions of the requirements for the product manufacturing process and quality assurance lie at the basic principles of these regulations. The combination of automation technology and RFID technology offers a reliable and efficient solution for fulfilling these requirements. As a result of the use of mobile data storage devices (MDS) in the manufacturing process, identification information can be written and read contact-free and reliably using the RFID system. The automation system captures and uses this information in continuing process steps. Due to the RFID technology, products can be made that meet specifications and quality standards. Strict monitoring and identification of facilities, process actions and the operating and process materials is required for these products. During the manufacturing process, intermediate and finished products are continuously filled into mobile containers and temporarily stored. One element of process validation is the monitoring of these mobile containers. Any mixing up of the containers, whether during refilling or during material use, can have serious consequences. With this application, the focus is directed towards monitoring mobile containers that are integrated into the process control system by means of an RFID system. The RFID components used for this can be integrated into SIMATIC PCS 7 and STEP 7 and are specifically designed for applications in an industrial environment. 1.2 Mode of operation In the framework of this Application Example, the SIMATIC RF300 RFID system will be connected to a SIMATIC S7-400 controller. The following figure shows by way of example a container monitoring system with RFID technology as a potential application area for this Application Example in the pharmaceuticals industry. Figure 1-1 The existing labeling (e.g., labels, barcodes) on the containers is replaced or supplemented by RFID transponders (mobile data storage devices). In a CIP (Cleaning In Place) installation, the mobile containers undergo a cleaning process and the RFID transponders are then written with process-related data such as date, time and cleaning state. The RFID transponders are read out in a production Entry ID: , V3.0, 05/2018 4

5 Siemens AG Copyright-2018 All rights reserved 1 Introduction process. During this process, a check is carried out, for example, as to whether the correct container is present or the intensive cleaning has been properly carried out and was not carried out too long ago. Core contents of this Application Example This document describes all the steps relating to the commissioning, configuration and operation of the example project. Hardware configuration of the components Using the RFID block library Configuration in the PCS 7 environment Benefits Backtracking the containers over several production cycles Variable application areas Fulfilling prescribed rules Validity Note The project has been created with the following software: SIMATIC PCS 7 V8.2 STEP 7 V5.5 SP4 HF2 with CFC V8.2 (integrated into PCS 7) This example project cannot be used if an RF310R type reader is to be connected to PCS 7 via PROFINET or PROFIBUS. In this case, the Ident profile should be used. The Ident profile can be found here: Required knowledge Basic knowledge and experience of dealing with PCS 7 are required. Entry ID: , V3.0, 05/2018 5

6 Siemens AG Copyright-2018 All rights reserved 1 Introduction 1.3 Components used The following hardware and software components were used to create this Application Example: Table 1-1 Component SIMATIC S7-400, CPU 410-5H Numbe r Article number Note 1 6ES HX08-0AB0 Automation system SIMATIC RF 180C 1 6GT JD00 Connecting Module RFID Read/Write device 1 6GT2801-1BA10 RFID Read/Write device MOBY MDS D GT2600-4AH00 RFID transponder SIMATIC PCS 7 V ES7651-5AA18-0YA0 This Application Example consists of the following components: Table 1-2 Component File name Note Function blocks, CFC and image files RFID_Connection_PCS7_ Abbreviations The following abbreviations are used in this document: Table 1-3 Abbreviation ASM CFC CIP FB RFID Full designation Connecting Module Continuous Function Chart Cleaning in Place Function block Radio Frequency Identification Entry ID: , V3.0, 05/2018 6

7 Siemens AG Copyright-2018 All rights reserved 2 Solution 2 Solution 2.1 Core functionality This Application Example will show you how to integrate a SIMATIC RFID system into a PCS 7 landscape. For this, the blocks Ident16 and FbIdent from the supplied library must be used. The block Ident16 serves as a driver block for connecting an RFID/reader RF200/ 300 or 600 to PCS 7 via PROFINET. The functions of the Ident16 block are essentially identical to those of the Ident_Profile (FB2900) and can be found at The block FbIdent is used as an interface block between the driver block Ident16 of the RFID reader and the user program. The block FbIdent transfers process and status data of a RFID reader for further use in the user program and for visualization. Data entered in the faceplate or via the block inputs is transferred from Ident16 to the RFID reader via the driver block FbIdent. 2.2 Hardware configuration The Application Example has been created with the following configuration: S7-400 with RF180C and RF310R. Further configurations to which the example can be applied are possible, with only the hardware needing to be configured accordingly. Installation with SIMATIC S7-400 and RF180C Figure 2-1 Entry ID: , V3.0, 05/2018 7

8 Siemens AG Copyright-2018 All rights reserved 3 Basics 3 Basics 3.1 Quality assurance Quality Assurance must ensure that the organizational and technical requirements are observed in all phases of production. The production processes are checked and optimized. One focus is on safely running processes and guaranteeing communication between the individual installations. The optimizations resulting from RFID technology lead to increases in efficiency and safety and to the simplification of complex procedures. The benefits mentioned above result in higher product quality and adherence to the regulations prescribed for the pharmaceutical industry sector. 3.2 RFID system In a pharmaceutical process, containers are sometimes subjected to extreme conditions. To guarantee that the process runs smoothly, the transponders (mobile data storage devices) and readers must meet the following requirements. Heat-resistant The temperature of the container rises during cleaning to approx. 130 C and maintains this temperature for 30 minutes. During cleaning, the container may even be heated up to 200 C for brief periods. Since the transponder is not directly exposed to these temperatures, it must be heat-resistant up to a maximum of 80 C. The selected transponder D426 can withstand constant temperatures of up to 85 C during operation. Cold-resistant During temporary storage of the containers in cold-storage rooms, the transponders must withstand an ambient temperature of -25 C and enable the reading or writing of data. Mounting on metal One of the most important requirements is direct mounting on the stainless steel housing. Since the large metal surface partially absorbs the radio waves and thus affects the functioning, a transponder must be selected specifically for mounting on containers. For the selected transponder, a special spacer is available for metal mounting (Article Number: 6GT2690-0AL00). Data security The transponder data must be protected from unauthorized access and tampering. Alkali and acid resistant Caustic and corrosive chemicals are used to kill bacteria and micro-organisms during cleaning processes. Use in these applications requires that the transponders have a certain resistance to alkalis and acids. The concentration of the chemicals is dependent on the process. Storing user data A further important element is the storage of process-relevant data. The security of the process is guaranteed by the retrieval of this data. Degree of protection (IP) Protection from the ingress of dust, from pressurized water for indefinite periods and complete protection from contact and foreign objects must be selected regardless of the location of use. The transponder meets the criteria of protection class IP 68. Unlike the transponder, the reader is not exposed directly to the adverse conditions and therefore meets the criteria of protection class IP 65. Entry ID: , V3.0, 05/2018 8

9 Siemens AG Copyright-2018 All rights reserved 3 Basics EMC (Industry standard) The limiting values stipulated in the guidelines must be observed. This includes resistance to internal electrical interference, external electromagnetic interference, the radiation of noise and the influence on the electrical environment. 3.3 RFID Transponders Series Moby D transponders are basically designed for use in small assembly lines, as they can withstand the high stresses of production. The following table shows the technical data for the MDS D426 transponder which is used in this application: Table 3-1 Article number Memory size Read/write distance Property 6GT2600-4AH bytes FRAM Operating temperature C Degree of protection Operation on metal Dimensions Variable 113 mm with RF310R (130 mm with RF380R) IP68 With optional spacer 3.6 x 50 mm 3.4 RFID reader The RFID reader has an RS 422 interface for connecting to the ASM 456, ASM 475 and RF180 RFID communications modules. Thanks to the high degree of protection and the use of high quality materials, problem-free operation is guaranteed even under the toughest industrial conditions. The following table shows the technical data for the RF310R Read/Write device which is used in this application: Table 3-2 Read/Write device Cable length (shielded) SLG ASM Read (RF300 tags / ISO tags) Write (RF300 tags / ISO tags) Max. range 1000 m 310R 8 KByte/s / 600 Byte/s 8 KByte/s / 400 Byte/s 60 mm Degree of protection IP 67 Multitag capability Distance between two readers (side by side / face to face) Baud rate max. No 100 mm / 200 mm baud Temperature max. +70 C Temperature min. -25 C Frequency Standard MHz Entry ID: , V3.0, 05/2018 9

10 Siemens AG Copyright-2018 All rights reserved 4 Preparation 4 Preparation Project Library OS GSD file 1. For configuration, create a new multiproject with a AS H single station without CP with an OS. 2. Create a system bus and a field bus. 1. Inserting the supplied library into the multiproject. 2. Insert all the blocks from the library into your S7 program. 3. Instance the CFC template RFID_Ident16. Copy the WinCC images from the GraCS subdirectory which can be found in the supplied library into the GraCS directory of your WinCC project. (e.g.: /<PCS 7 Project name>/wincproj/<os-project name>/gracs). To use the RF180C V2.2, you need to install a GSD file. You will find the installation data in the article: Entry ID: , V3.0, 05/

11 Siemens AG Copyright-2018 All rights reserved 5 Configuration 5 Configuration 5.1 Creating the hardware configuration Procedure 1. Open the hardware configuration for the automation system. 2. Add a Master System to the PROFIBUS interface. Select the PN-IO-X8 interface. Open the relevant context menu with the right mouse button and click on Insert PROFINET IO System. Figure Add an RF180C to the PROFINET IO system. Figure Entry ID: , V3.0, 05/

12 Siemens AG Copyright-2018 All rights reserved 5 Configuration 4. Select the RF180C. 5. Open the relevant context menu by right clicking on it. 6. Click on Object Properties. Figure In the properties, click on the Parameters tab. 8. Set the parameters as shown in the image. Figure Save and compile your hardware configuration and download it to the automation system. 5.2 Configuring the CFC RFID_Ident Open the instance of CFC RFID_Ident Parameterize the FbIdent block. Entry ID: , V3.0, 05/

13 Siemens AG Copyright-2018 All rights reserved 5 Configuration LADDR: Input address of the 2x RS422 channels RFID from the hardware configuration (in this Application Example, the address is 512 (see Figure 5-3). CM_CHANNEL: Channel on which your RF310R is connected to the RF180C (the RF180C has two channels. In this Application Example, only Channel 1 is used, to which the reader is connected) Figure 5-5 Entry ID: , V3.0, 05/

14 Siemens AG Copyright-2018 All rights reserved 5 Configuration 3. Parameterize the Ident16 block. ReaderType: Your RFID reader type (an RF300 is used in this Application Example) RfPower : Output performance of your RFID reader from 0.5 W to 10 W in increments of 0.25 W. The value range is from 0x02 to 0x28 (in this Application Example, the RF310R has an output of 1W). CfgRx01 16: Types of data which you want to read from your transponder or write to it. Figure 5-6 Note If you enter the data type String1...5 for CfgRx01 16m you must parametrize the input LenS1 5. LenS1 5 defines the string length. 4. Compile the CFC and load it into the automation system. 5. Compile and download the OS. 6. Open the OS and start the runtime. Entry ID: , V3.0, 05/

15 Siemens AG Copyright-2018 All rights reserved 6 Using the faceplate 6 Using the faceplate 6.1 Initializing the reader 1. Click on Initialize Reader. 2. Click on Initialize Reader and OK. Figure 6-1 Entry ID: , V3.0, 05/

16 Siemens AG Copyright-2018 All rights reserved 6 Using the faceplate 6.2 Reading of transponder data 1. Click the Parameters tab. 2. Click on Read. 3. Click on Read Data and OK. Figure 6-2 Entry ID: , V3.0, 05/

17 Siemens AG Copyright-2018 All rights reserved 6 Using the faceplate 6.3 Writing of transponder data 1. Click the Parameters tab. 2. Click on Edit. 3. Click on Write. 4. Enter the data you wish to write to the transponder into the fields provided. 5. Click on Write Data and OK. Figure 6-3 Entry ID: , V3.0, 05/

18 Siemens AG Copyright-2018 All rights reserved 7 Appendix 7 Appendix 7.1 Service and Support Industry Online Support Technical Support Do you have any questions or need assistance? Siemens Industry Online Support offers round the clock access to our entire service and support know-how and portfolio. The Industry Online Support is the central address for information about our products, solutions and services. Product information, manuals, downloads, FAQs, application examples and videos all information is accessible with just a few mouse clicks at: The Technical Support of Siemens Industry provides you fast and competent support regarding all technical queries with numerous tailor-made offers ranging from basic support to individual support contracts. You send queries to Technical Support via Web form: Service offer Our range of services includes, inter alia, the following: Product trainings Plant data services Spare parts services Repair services On-site and maintenance services Retrofitting and modernization services Service programs and contracts You can find detailed information on our range of services in the service catalog: Industry Online Support app You will receive optimum support wherever you are with the "Siemens Industry Online Support" app. The app is available for Apple ios, Android and Windows Phone: Entry ID: , V3.0, 05/

19 Siemens AG Copyright-2018 All rights reserved 7 Appendix 7.2 Contact Siemens AG Digital Factory Division Factory Automation Production Machines DF FA PMA APC Frauenauracher Str Erlangen, Germany mailto: tech.team.motioncontrol@siemens.com 7.3 Links and Literature Table 7-1 No. Topic \1\ Siemens Industry Online Support \2\ Link to this entry page of this application example \3\ 7.4 Change documentation Table 7-2 Version Date Modifications V1.0 05/2008 First version V1.1 03/2013 Updated HW and SW components, new structure and new design V2.0 07/2014 Second Edition, complete reworking V2.1 09/2015 Revision to PCS 7 V8.1 MOBY ASM 456 replaced with SIMATIC RF180C V3.0 05/2018 Revision to PCS 7 V8.2 New Blocks Entry ID: , V3.0, 05/