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A digitally operating electronic system, designed for use in an industrial environment, whishes uses a programmable memory for the internal storage of user oriented instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to control, through digital or analog inputs and outputs and various types of machines or processes. Both the PC and its associated peripherals are designed so that they can be easily integrated into an industrial control system and easily used in all their integrated functions.
Processing section
K1 K2
Lamp
output section
RELAY CONTROL
1. 2. 3.
The relay control can be divided in to three parts : Input section switches & sensors ( A/D ). Processing section Relay coils and contacts. Output section solenoids, lamps or motors (A/D).
PLC replaces the function of the relay portion of the hard wired control .
+ 24 v dc PBPB-1 PBPB-2 TO PG UNIT
Q1 + _ Lamp
TYPES OF PLC
1. FIXED I/P AND O/P TYPE 2. MODULAR DESIGN (PLC/CPU SPECIFIC) ANALOG MODULE DIGITAL MODULE
MAKES : Allen Bradley, Siemens, Mitsubishi, Genera Electric , Omron , ABB, Fanuc etc.
COMPARISION
CHARACTERISTIC CONSTRUCTION CAPABLE OF COMPLICATED OPERATION EASE OF CHANGING THE COMTROL PROGRAM PHYSICAL SIZE MAINTENANCE PLC EASY TO PROGRAM YES RELAY TIME CONSUMING NO
VERY SIMPLE
VERY DIFFICULT
STRUCTURE OF PLC A PLC is essentially a micro computer with hardware, firmware and software. Bus system : Address Bus, Data Bus, Control Bus.
Hardware : Actual devices-PCBs , ICs , Battery , Housing etc. devicesFirmware : software supplied and installed by manufacturer-OS manufacturer(ROM/EPROM) Software : User program written by PLC user (RAM )
Data bus
ROM
Microprocessor CPU
Control Bus
SYSTEM COMPONENTS
BLOCK DIAGRAM :
Programming Devices
PLC
Power supply
Program Memory
Acknowledge Ments (Limits Switches,& sensor) Control Element (Push Buttons & switches )
Input modules
Output Modules
POWER SUPPLY
120/230 V AC
POWER SUPPLY
The power supply can be a separate unit or an integral part the processor depending on the manufacturer. PS307---2A/5A/10A---24 VDC---120VAC/230VAC PS307---2A/5A/10A---24 VDC---120VAC/230VAC
Input Module
Output Module
(120(120-240 V AC) or 24 V DC
INPUT MODULE
INPUT SIGNAL
SIGNAL DELAY
Opto -coupler
OUTPUT MODULE
Opto- coupler
Amplifier
Short-circuit monitoring
Output signal
DATA BUS
ALU
Program counter
Control unit
MEMORY
RAM ( Ram Access Memory ): Read/write, Volatile ( back up by battery/accumulator ) EPROM (Erasable Programmable Read Only Memory ): Readable only. nonnon-volatile ,ultra-violet eraser, reprogrammable ,ultraEEPROM (Electrically Erasable Programmable Read Only Memory ) :Erased electrically by the proper signal at erase pin, it is used primarily as a non-volatile back up for user program RAM, used as nonapplication memory in PLCs. Flash RAM : It s can be erased more quickly. WORD : 8/16/32 Bits PLC specific, stored binary data in form of BITS (Binary digiTS ) 0/1.
MODULAR PLCs Requirement of inputs/outputs/program memory compact modules or as plug in electronic card (8/16-Inputs/Outputs) (8/16Power supply To PG Unit Processor SM SM SM SM
Power supply
Processor
SM
SM
SM
SM
SOFTWARE
The user program can be written with the programming software suitable for the specific PLC. For example STEP 5 & STEP 7--------Siemens PLCs 7--------Siemens RS LOGIX 500 -------Allen Bradley PLCs -------Allen STEP 7 Three method of representation can be used to translate a program in to user program. Ladder Diagram (LAD) Graphical representation of control task using relay Symbology. Function Block Diagram (FBD) : Graphical representation of control task using logic boxes familiar from Boolean algebra. Statement List (STL): Textual representation of control task using mnemonic abbreviations
PLC STANDARD
Since 1992, an international standard IEC 1131 exists for programming logic controllers and associated peripheral devices. The purpose of the new standard was to define and standardize the design and functionality of a PLC and the languages required for programming to the extent where users were able to operate using different PLC system without any difficulties. IEC 1131 standard consists of 5 parts: Part 1: General Information Part 2: Equipment requirement & test Part 3: Programming Languages Part 4: User guidelines Part 5: Messaging service specification
SIEMENS PLCs
SIMATIC HARDWARE+SOGTWARE SIEMENS PROGRAMMING CONTROLLER OF S5 FAMILY.
SIMATIC S7:--THREE TYPES OF PROGRAMMING LOGIC CONTROLLER S7:--THREE SIMATIC S7 200 : Compact micro plc for lowest performance range. SIMATIC S7 300 : Modular mini controller for intermediate performance range. SIMATIC S7 400 : For high performance range.
SIMATIC S 7 300 CONFIGURATION IM 365-Up to o1 meter between racks 365IM 360 and IM 361-Up to 10 meter between racks 361Allotted 08 nos.
Rack 0
(IT MAY BE IN NCU )
PS CPU IM SM SM
Slot 2 Slot 1 SLOT 3
SM
SM SM
SM
SM
SM
Rack 1
PS
IM SM SM SM SM SM SM SM SM
Slot 1
Slot 2
IM(R)
DATA TYPES
Type & size Description (bits)
BOOL BYTE 1 8
format options
BOOLIAN TEXT TRUE/FALSE HEXADECIMAL B16#0 to b16#FF NUMBER WORD 16 HEXADECIMAL W#16#0 to W#16#FFFF NUMBER DWORD 32 HEXADECIMAL DW#16#0000DW#16#0000-0000 to NUMBER DW#16#FFFFDW#16#FFFF-FFFF CHAR 8 ASCII CHARACTER A , B etc TIME-OFTIME-OF-DAY 32 TIME IN STEP OF 1ms TOD#0:0:0:0 to TOD#23:59:59:999 S5TIME 16 S7 TIME IN STEP OF 10 ms S5T#0H-0M-OS-10MS to S5T#0H-0M-OSS5T#2H-46M-30SS5T#2H-46M-30S-OMS ABBREVIATION: INPUTS---I, OUTPUTS---Q, BIT MEMORY---M, TIMERS---T, INPUTS---I, OUTPUTS---Q, MEMORY---M, TIMERS---T, COUNTER---C, COUNTER---C, TEMPORARY LOCAL DATA---L DATA---L
STEP 7 IS THE PROGRAMMING SOFTWARE FOR THE SIMATIC S7 STEP 7 PROVIDE THE ENTIRE FUNCTIONALITY REQUIRED FOR CONFIGURING,PROGRAMMING,AND ASSIGNING PARAMETERS TO S7-300 S7STEP 7 RUNS UNDER MICROSOFT WINDOWS 95 OR HIGHER STEP 7 WORKS WITH OBJECT-ORIENTED CONCEPT. THE STEP 7 OBJECTS OBJECTINCLUDE STATIONS,MODULES,AND PROGRAMS.ALL OBJECT ARE REPRESENTED BY SYMBOLE ON THE GRAPHICAL USER INTERFACE. STEP 7 HAS A USER FRIENDLY,CONTEXT-SENSITIVE ONLINE HELP FUNCTION FRIENDLY,CONTEXTTHAT GIVES VALUABLE INFORMATION AND TIPS. THE SIMATIC MANAGER IS THE CENTRAL WINDOW WHICH IS ACTIVE WHEN STEP 7 IS STARTED.
CREATING A PROGRAM IN OB1 Opening the LAD/STL/FBD Program Window Choosing Ladder logic, Statement List or Function Block Diagram
LADDER LOGIC :
+ 24 V DC I 2.0 I 2.1 RUNG Q 4.0 0V
&
BASIC FUNCTION Binary logic operation, Memory function, Move function , Timers , Counters.
1. 2. 3. 4. 5. 6. 7.
NO CONTACT NC CONTACT SINGLE COIL SERIAL AND PARALLEL CIRCUIT NEGATING THE RLO SET AND RESET COIL MEMORY BOX ( SR BOX )
NOT
S S R SR
,
Q
1.
EDGE EVALUATION
--- POSITIVE EDGE IN POWER FLOW _____(P)______ NEGATIVE EDGE IN POWER FLOW _____(N)______
TIMERS
WITH
SP S_PULSE
START TIMER AS
PULSE TIMER
SE S_PEXT
SD ON DELAY TIMER S_OD SF OFF DELAY TIMER S_OFFDT SS RETENTIVE ON DELAY S_ODTS TIMER
REPRESENTATION OF A TIMER
T1
S S_ODT Q
BI TV
BCD
S-- BOOL START INPUT TV S5TIME PRESET TIME VALU E R BOOL---RESET INPUT BOOL---RESET BI WORD---REMAINING TTIME WORD---REMAINING VALUE, INTEGER FORMAT BCD WORD REMAINING TIME VALUE IN BCD FORMAT Q--- BOOL---TIMER STATUS BOOL---TIMER
COUNTER
IT S LOCATED IN SYSTEM MEMORY,PLC SPECIFIC,
1. 2. 3. 4. 5. 6.
UPUP-DOWN COUNTER (S_CUD) UP COUNTER (S_CU) DOWN COUNTER (S_CD) SET COUNTER COIL UP COUNTER DOWN COUNTER COIL
REPRESENTATION OF A COUNTER
COUNTER OPERAND
CU S_C U D Q
CD
CV
CV BCD
PV
CU BOOL UP COUNT INPUT CD BOOL DN COUNT INPUT S-- BOOL SET INPUT PV WORD PRESET VALU E R BOOL---RESET INPU BOOL---RESET CV WORD---CURRENT VALUE IN WORD---CURRENT BINARY CV_BCD WORD---CURRENT VALUE WORD---CURRENT IN BCD Q--- BOOL---COUNTER STATUS BOOL---COUNTER
I 0.0
Q4.0
MW10 IN
OUT DBW12
The instruction is executed if I 0.0 is 1 .The content of MW10 is copied to the word 12 of the currently open DB. Q4.0 is 1 if the instruction is executed.
COMPARISON INSTRUCTIONS
IN1 AND IN2 ARE COMPARED ACCORDING TO THE TYPE OF COMPARISON WE CHOOSE.
== IN1 is equal to IN2 <> IN1 is not equal to IN2 > IN1 is greater than IN2 < IN1 is less than IN2 >= IN1 is greater than or equal to IN2 <= IN1 is less than or equal to IN2 If the comparison is true, the RLO of the function is 1 .It behave like a normally open contact. The following comparison instructions are available: CMP ? I Compare integer CMP ? D Compare Double integer CMP ? R Compare Real
EXAMPLE: IO.O I0.1 MW0 MW2 IN1 IN2 CMP >= I Q4.0
Output Q 4.0 is set if the following condition exist: There is a signal state of 1 at inputs I0.0 and at I0.1 AND MWO>=MW2
CONVERTER
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
BCD_I
BCD_I I _BCD BCD _DI DI_BCD I_DINT DI_REAL INV_I INV_DI NEG_I NEG_DI NEG_R ROUND TRUNC CEIL FLOOR
EN ENO BCD to Integer Integer to BCD MW10 IN MW12 OUT BCD to Double Integer Double Integer to BCD Integer to Double Integer Double Integer to Floating Point 1,s compliment Integer 1,s compliment Double Integer 2,s compliment Integer 2,s compliment Double Integer Negate Floating Point Number Round the Double Integer Turncate Double Integer number Floating point number to double integer Round to +infinity Floating point number to double integer Round to - infinity
Add integer Subtract integer Multiply Integer MW0 Divide integer MW2 Add double integer Subtract double integer Multiply Double Integer Divide double integer Return fraction Double Integer
EN
ENO
IN1
OUT
MW10
IN2
CPUs
CPUs are capable of handling 85 K statements and 256 K data the main memory up to 512 KB. Various CPUs provide up to 8192 bit memories,512 timers, and 512 counter. Smaller CPUs can be expanded up to 256 DI/DO or 64AI/AO. Larger CPUs can be expanded up to 1024 DI/DO or 256 AI/AO. UpUp-down counters acquire pulses up to 10 kHz. With a frequency measurement up to 10 kHz motor speed can be accurately measured. For application involving controller of pressure, temperature or flow rates the integrated PID controllers can e parameterized. The most powerful S7-300 CPU is also available with an S7integrated PROFIBUS-DP interface. PROFIBUS-
NUMBER OF INPUTS DIGITAL / ANALOG NUMBER OF OUTPUTS DIGITAL/ANALOG MEMORY PROCESSING SPEED OF CPU. CPU CAPABILITIES/SYSTEM FUNCTIONS/SYSTEM FUNCTION BLOCKS. NO. OF TIMERS,COUNTERS & SIZE OF BIT MEMORY,FLAGS(MARKERS). NEED OF SPECIAL FUNCTION MODULES SUCH AS HIGH SPEED COUNTERS,CLOSED LOOP CONTROL ETC. NEED OF INTERFACE MODULE. NETWORKING AND COMMUNICATION CAPABILITIES.
StartStart-up block (OB100) execute once. Start the cycle monitoring time. Reading the signal states from the modules and saving the data in the PII (Process Image Inputs). Execution of the program in OB1(cyclic execution) .events, time of the day, hardware interrupts etc., call others OBs , FBs , FCs / PBs etc. Writing the process image output (PIQ) to the output modules. PII OB1 PIQ
S5 STEP 5 PLC
S7 SERIES S-7 200 ----- 214,215,224,226 etc. S-7 300 ----- 314,315,317 etc. S-7 400 . SOFTWARE : S7 200---Microwin 32,Programming Tool 802. 200---Microwin S7 300---Simatic Manager version 5.0,5.1,5.2,5.3,5.4 300---Simatic S7 400--- ----do---400--- ----do----
ABBREVIATION
IFM--IFM--- INTEGRATED FUNCTION MODULES MPI--MPI--- MULTIPOINT INTERFACE (9-PINS)-SERIES (9-PINS)COMMUNICATION ,BAUD RATE-187.5 KBPS RATEOPI---BAUD RATE---1.5 OPI---BAUD RATE---1.5 MBPS IM(S)--IM(S)--- INTERFACE MODULES (SENDER) IN(R)--IN(R)--- INTERFACE MODULES (RECIEVER) PROFIBUS--PROFIBUS--- PROCESS FIELD BUS BAUD RATE 12 MBPS NCU--NCU--- NUMERICAL CONTROL UNIT (NC+PLC CPU+IM) IN 840D/810D STL--STL--- STATEMENT LIST---HIGH LEVEL LANGUAGE LIST---HIGH LAD--LAD--- LADDER LANGUAGE--- LOW LEVEL LANGUAGE LANGUAGE--INDUSTRIAL ETHERNET---BAUD RATE---100 MBPS ETHERNET---BAUD RATE---100 NMI---NONNMI---NON-MASKABLE INTERRUPT. PCU---PROCESS PCU---PROCESS CONTROL UNIT--PCU 20--NO HARD DISK-FLASH DRIVE UNIT--PCU 20--NO DISKPCU 50 WITH HARD DISK PCU 70 WITH HARD DISK OP---OPARATION OP---OPARATION PANEL OP10,OP10C,10S,OP12,OP15 TWISTED PAIR -TO PREVENT EXTERNAL INTERFERENCE
STEP 7
1.
BLOCKS
2.FUNCTIONS (FCs) 3.FUNCTION BLOCK (FBs)
USER PROGRAMMABLE BLOCK-----1.ORGANISATION BLOCK (OB) BLOCKDATA BLOCK(DB) ----1. SHARED BLOCK
2. INSTANT BLOCK
2.
3.
NOTE:
USER CAN CALL FC & FB THROUGH PROGRAM OB1 ONLY CALLED BY CPU
BE
FC1
BE FC3
BE
SENSOR
ELECTRICAL SIGNAL
D/A
CPU