Lecture 19 and 20

Course Computer Based Automation WS 06/07 1 Stephan Simons
Computer Based Automation

Winter Term 06/07
Prof. Dr. Stephan Simons
University of Applied Sciences Darmstadt
Master of Science in Electrical Engineering
Contents of the course
1. Introduction to automation systems
2. Fundamentals
a) numerical representations, b) logical functions and operations
3. Programmable Logic Controller (PLC)
a) basics, b) principle of operation, c) architecture, d) PLC family
4. PLC S7-300 with interface modules
5. Programming of a PLC
1. Overview PLC standard IEC 1131-3
2. Programming Languages for S7 family & program structure
3. Basic operations of STEP 7 in STL, LAD and FBD: Flags, Edge
evaluation, Result of logic operation & Status word, Set and reset
operations (flip flop), Timer instructions, Counter instructions,
Particular instructions
4. Program organization units
5. Sequential Control Language (S7-Graph)
6. Structured Control Language (S7-SCL)
7. Indirect Addressing
6. PLC standard IEC 1131-3

today


Repetition of last lecture
Timer functions
On delay timer, retentive on delay timer, off delay timer, pulse timer, extended pulse
timer (symbols, example programs, timing diagrams, differences FBD, LAD, STL)
Setting the timer value as S5-Time or as hexadecimal value
Unused inputs and outputs
Example for timer functions (oscillator)
S7 Counter
Up counter, Down counter, Up and down counter (Symbols an program example for
LAD, FBD and STL)
Overview over counter operations
Signal state chart
Example for counter usage (frequency divider)
Standard data types and their internal representation
Load and transfer commands
Load and transfer commands in STL; MOVE blocks in LAD & FBD
Examples for load and transfer instructions
Example loading and transfering an analog value (AI & AO)
Instruction contents of lecture
Bit logic instructions
Bit logic instructions with expressions in parenthesize
Edge triggered instructions
Memory functions: Setting / Resetting bit addresses
Timer instructions
Counter instructions
Load and transfer instructions
Comparison instructions
Integer and floating-point arithmetic instructions
Floating point mathematical instructions
Jump instructions

S_ODT

S BI

TV BCD

R Q
T1
I0.0
S5T#2S
I0.1
MW0
MW2
Q 4.0
A I 0.0
L S5T#2S Load time (2s) in ACCU 1
SD T1 Start timer T1 as a pulse
A I 0.1
R T1 Reset timer T1
L T1 Load timer T1 DUAL-coded
T MW0
LC T1 Load timer T1 BCD-coded
T MW2
A T1 Query of the timer T1
= Q 4.0
S_ODT

S Q

TV BI

R BCD
T1
I0.0
S5T#2S MW0
MW2
Q 4.0

( )
I0.1

On-delay Timer
FBD
LAD
STL
S5-Time
If a delay time of 2 hours, 35 minutes, 24 seconds and 60 milliseconds shall be
set use the S5 Time:
S5T#2h35m24s60ms
The possible time range is from 10ms to 2h46m30s with a resolution of 10ms.
The S5 time is transferred to the ACCU 1 with the load instruction L. The time is
stored into the ACCU 1 as a 16 bit word with the following format:
15 14 13 12 11 8 7 4 3 0
Bit
10
2
10
1
10
0
time
base
factor for time base in BCD Irrelevant
00
(2)
0
(16)
0,01sec
01
(2)
1
(16)
0,1sec
10
(2)
2
(16)
1sec
11
(2)
3
(16)
10sec
Time base:
Examples:
S5T#3s 2003
(16)
or 0300
(16)
S5T#100ms 1001
(16)
or 0010
(16)
S5T#2h46m30s 9990s 3999
(16)
As a rule the smallest possible time base is used to achieve a better precision.
No. STL
Comments
1 L 16#1350
// Load time (35s) as hex literal (const.)
2 T MW10
// Transfer to MW 10
3 A I2.1
// Start delay time with positive edge of I2.1
4 L MW10
// Transfer time into ACCU 1.
5 SD T4
// Start timer T4 as an on-delay timer.
6 NOP 0
// Reset
7 L T4
// Load current time value of T4 as binary.
8 T QW4
// Transfer binary current time value to QW4.
9 NOP 0
// Current time value as BCD not used.
10 A T4
// Check signal state (binary output) of timer T4.
11 = Q4.0
// Transfer to Q4.0.
Changing the on-delay program:
The instructions no. 7 and 8 transfer the current time value of T4 as binary to
the output word QW4.
The output word QW4 consists of the two bytes QB4 and QB5
QB4 holds the more significant value:
QW4 [ QB4, QB5 ]
Choosing
the right
timer
S7 Counter

S_CUD
CU

CD

S CV

PV CV_BCD

R Q
C1
I0.0
C#5
I0.3
QW2
QW4
Q 0.0
FBD
STL
A I 0.7 Release (only in STL)
FR C1
A I 0.0
CU C1 Count up
A I 0.1
CD C1 Count down
A I 0.2
L C#5 Load counter with default value
S C1 Set counter with default value
A I 0.3
R C1 Reset counter C1
L C1 Load counter C1 DUAL-coded
T QW2
LC C1 Load counter C1 BCD-coded
T QW4
A C1 Query of the counter C1
= Q 0.0
S_CUD
CU Q

CD

S

PV CV

R CV_BCD
C1
I0.0
C#5
I0.2
QW2
QW4
Q 0.0
LAD

( )
I0.1
I0.1
I0.3
I0.2
Counter limits: 0 999
S7 Counter: Signal state chart

FR
CU
CD
S
R
Q 0.0
1
2
3
4
5
0
Load and transfer commands in STL
Load function consists of operation L(load) and an operand.
Operand is Byte, Word, DWord.
Operand is loaded into ACCU 1.
Examples for types of Operands:
L 16#F8A4 Load a constant value (Immediate addressing)
L IW16 Load an operand (Direct adrdressing)
L ActValue Load a variable (Symbolic addressing)
Loading takes place in two steps:
Step 1: The content of ACCU 1 is moved into ACCU 2.
Step 2: The operand of the load instruction is loaded into ACCU 1.
Both Accumulators ACCU 1 and ACCU 3 have 32 bits each (Width of
DWORD data type).
Examples for loading of binary operands in STL
Loading of inputs:
L IBn // Byte
L IWn // Word
L IDn // Doubleword
Loading of outputs:
L QBn // Byte
L QWn // Word
L QDn // Doubleword
Laden fromperiphery:
L PIBn // Byte
L PIWn // Word
L PIDn // Doubleword
Loading of flags:
L MBn // Byte
L MWn // Word
L MDn // Doubleword
n : Address parameter e.g. 4 or 32
Transfer instruction T in STL
T: Transfers contents of ACCU 1 to the operand
Operand: Byte, Word or Doubleword
T MW120 Contents ACCU 1 Flag (absolute addressing)
T RefValue Contents ACCU 1 Variable (symbolic addressing)
This function also works with Twisting (Exchanging byte positions).
QW10 = [QB11, QB10]
QW10 consists of the two bytes QB10 and QB11.
The lower byte of ACCU 1 is stored as the most significant byte QB11.
The higher byte of ACCU 1 is stored as the least significant byte QB10.
Examples for transfer instructions:
T QB15 // Transfers ACCU 1 to output byte 15.
T IW20 // Transfers ACCU 1 to process image of the inputs at
// word address 20.
T MD30 // Transfers ACCU 1 to flag doubleword at address 30.
T PQW320 // Transfers ACCU 1 to the periphery output word 320,
// e.g. to an analog output.
MOVE function in FBD and LAD
LAD
FBD
Input at IN and output at OUT can be of any elementary data type except BOOL.
Variables at input IN and output OUT may be of different data types.
Comparison functions in STL
Comparison
function
INT DINT REAL
Equal ==I ==D ==R
Not equal <>I <>D <>R
Greater >I >D >R
Greater or equal >=I >=D >=R
Less <I <D <R
Less or equal <=I <=D <=R
INT: Integer DINT: Doubleinteger REAL: floating point
Comparison functions in FBD and LAD
Comparison
function
INT DINT REAL
Equal CMP ==I CMP ==D CMP ==R
Not equal CMP <>I CMP <>D CMP <>R
Greater CMP >I CMP >D CMP >R
Greater or equal CMP >=I CMP >=D CMP >=R
Less CMP <I CMP <D CMP <R
Less or equal CMP <=I CMP <=D CMP <=R
INT: Integer DINT: Doubleinteger REAL: floating point
Example: Comparison functions in STL
The input word IW0 is compared with the literal 120
(10)
. If both values are
equal Bit Q4.0 shall be set to 1 , otherwise Q4.0 shall be 0.
No. STL Comments
1 A Q4.0
Q4.0
IW0
120
Q4.0
2 R // Q4.0 is set to 0
3 L // load IW0 into ACCU 1
4 L // transfer IW0 from ACCU 1 into ACCU 2 and load 120
// into ACCU 1
5 ==I // Compare ACCU 1 with ACCU 2 to be equal
6 S // Set Q4.0 to 1 if ACCU 1 = ACCU 2
Example: Comparison functions in STL
(10)
No. STL Comments
1 A Q4.0
Q4.0
IW0
120
Q4.0
2 R // Q4.0 is set to 0
3 L // load IW0 into ACCU 1
4 L // transfer IW0 from ACCU 1 into ACCU 2 and load 120
// into ACCU 1
5 ==I // Compare ACCU 1 with ACCU 2 to be equal
6 S // Set Q4.0 to 1 if ACCU 1 = ACCU 2
Example comparison function in FBD
(10)
Example comparison function in LAD
(10)
Arithmetic functions
Additional: DEC n (Decrements ACCU 1 by the value of n)
INC n (Increments ACCU 1 by the value of n)
Arithmetic function INT DINT REAL
Addition +I +D +R
Subtraction -I -D -R
Multiplication *I *D *R
Division with quotient as
result
/I /D /R
Division with remainder as
result
- MOD -
Arithmetic functions in FBD and LAD
No DEC or INC functions in FBD and LAD
Arithmetic function INT DINT REAL
Addition ADD_I ADD_DI ADD_R
Subtraction SUB_I SUB_DI SUB_R
Multiplication MUL_I MUL_DI MUL_R
Division with quotient as
result
DIV_I DIV_DI DIV_R
Division with remainder as
result
- MOD_DI -
Examples for arithmetic functions
L MW0
L MW2
+I
T MW10
L MD0
L MD2
-D
T MD10
L MD0
L MD2
*R
T MD10
L MD0
L MD2
/R
T MD10
Fct. LAD FBD STL
I1-I2
I1+I2
I1*I2
I1/I2
Meaning of EN and ENO within functions
EN Explanation ENO
EN = FALSE If EN is FALSE when calling the function, the
code-part of the function may not be executed.
In this case output ENO will be set to FALSE
upon exiting in order to indicate that the function
has not been executed.
ENO = FALSE
EN = TRUE If EN is TRUE when calling the function, the
code-part of the function can be executed nor-
mally. In this case ENO will initially be set to
TRUE before starting the execution.
ENO = TRUE
ENO can afterwards be set to TRUE or FALSE
by instructions executed within the function
body.
ENO = individual
value
If a program or system error (as described in
Appendix E) occurs while executing the function
ENO will be reset to FALSE by the PLC.
ENO = FALSE
(error occurred)
a TRUE = logical 1, FALSE = logical 0
Example: Two-step controller (two-position
controller, bang-bang servo)
(e.g. for temperature control)
Voltage range 0 10 V
16 bit integer value in the range 0 27648
1,5 V is equivalent to 4147 (= 1,5V * 27648) / 10V
(PIW288)
(PIW290)
(Q4.0)
w: reference value (010V)
X: actual value (010V)
Y: control variable (bit)
X
d
: control deviation
X
d
= w - x
Two-step controller:
FBD program
(PIW288)
(PIW290)
(Q4.0)
y
Mathematical functions
Square, square-root
Sine, cosine, tangent
Arc sine, arc cosine, arc tangent
Exponential function to base e, natural logarithm
All these mathematical functions only work with values of the data type
REAL!
Mathematical functions
Square, square-root
Sine, cosine, tangent
Arc sine, arc cosine, arc tangent
Exponential function to base e, natural logarithm
All these mathematical functions only work with values of the data type
REAL!
Conversion functions for REAL INTEGER (in STL):
lTD Conversion of INT to DINT
ITB Conversion of INT to BCD
DTR Conversion of DINT to REAL
RND Conversion of REAL to DINT with rounding to the next higher
integer number
Conversion
16 bit Integer
to
32 bit Integer
Conversion
32 bit Integer
to
REAL
Input Data
Integer
16 Bit
Program
algorithms
using REAL
Conversion functions INT DINT REAL
LAD FBD STL
MW12
MD20
MD20
MD28
L MW12
ITD
T MD20
L MD20
DTR
T MD28
MW12
MD20
MD20
MD28
Conversion function: Example
(PIW288) (PQW320)
Analog Input: PIW288 (16 bit Integer)
Analog Output: PQW320 (16 bit Integer)
Realize the following function f(x) with a PLC:
x * . y 16 3 =
with: 0V <= x <= 10V, 0V <= y <= 10V
0V 10 V 0 27648
(10)
Normalization (Scaling)
x y * 16 , 3 =
V 10 27648
int
=
8 , 2764 *
int
y y =
8 , 2764 *
int
x x =
8 , 2764
* 16 , 3
8 , 2764
int int
x y
=
int int
* 8 , 2764 * 16 , 3 x y =
int int
* 157 , 166 x y =
7)
1)
2)
3)
4)
5)
6)
Realizing a square root extraction (I)
Realizing a square root extraction (II)
Conversion fromReal 32 bit DINT
Round (FBD & LAD) / RND (STL): Rounds to the next integer. When the fraction
of the number is exactly between an even and uneven result, the operation chooses
the even result. Examples: +1.49 +1; 1.5 2; 2.5 2; 2.51 3
Trunc: Round with truncation of the fraction part. The result is only the integer part
of the real data. Examples: 1.6 1.
Ceil / RND+: Round to the next highest integer. This operation rounds the
converted number to the smallest integer, that is greater than or equal to the
converted integer. Examples: +1.2 +2; -1.5 -1.
Floor / RND-: Round to the next lowest integer. This operation rounds the
converted number to the largest integer, that is smaller or equal to the converted
integer. Examples: +1.5 +1; -1.5 -2.
Rounding Modes for the Conversion of REAL numbers
Revolution measurement: transducer
10 V, 20 mA, 16 mA
1000 U/min
365
500 865
1500 rpm
0 10 V
0 20 mA
4 20 mA
10 V : 1000 rpm = 0,01 V/U/rpm
365 U/min 3,65 V
Internal representation of analog value in case of
bipolar measurement range
Increments Voltage
measurement range
Current
measurement range
Range
dec. hex. 10 V 20 mA
32767 7FFF 11,851 V 23,70 mA
32512 7F00
32511 7EFF 11,759 V 23,52 mA
27649 6C01
27648 6C00 10 V 20 mA
20736 5100 7,5 V 15 mA
1 1 361,7 V 723,4 nA
0 0 0 V 0 mA
1 FFFF -361,7 V -723,4 nA
20736 AF00 7,5 V 15 mA
27648 9400 10 V 20 mA
27649 93FF
32512 8100 11,759 V 23,52 mA
32513 80FF
32768 8000 11,851 V 23,70 mA
Underflow
Underrange
Rated range
Overange
Overflow
Internal representation of analog value in case of
unipolar measurement range
System Voltage
measurement range
Current measurement range Range
dez. hex. 0..10 V 0..20 mA 4..20 mA
32767 7FFF 11,851 V 23,70 mA 22,96 mA
32512 7F00
32511 7EFF 11,759 V 23,52 mA 22,81 mA
27649 6C01
27648 6C00 10 V 20 mA 20 mA
20736 5100 7,5 V 15 mA 16 mA
1 1 361,7 V 723,4 nA 4 mA + 578,7 nA
0 0 0 V 0 mA 4 mA
1 FFFF
4864 ED00 3,52 mA 1,185 mA
4865 ECFF
32768 8000
Negative
values not
possible
Negative values
not possible
Underflow
Underrange
N
e
g
a
t
i
v
e

v
a
l
u
e
s
n
o
t
p
o
s
s
i
b
l
e
Rated
range
Overrange
Overflow
Revolution measurement AD converter
0 27648
0 10 V
0 20 mA
4 20 mA
13824
12
10
5
Revolution measurement: transducer
10 V, 20 mA, 16 mA
1000 U/min
365
500 865
1500 rpm
0 27648 Incr. 13824
1000
10092
Table for normalization
System Voltage
measurement
range
Current measurement range Range
dez. hex. 10 V 0..10 V 20 mA 0..20 mA 4..20 mA
27648 6C00 10 V 10 V 20 mA 20 mA 20 mA
0 0 0 V 0 V 0 mA 0 mA 4 mA
27648 9400 10 V 20 mA
Rated
range
Task: Reading and normalizing of an analog value
Acquire an analog value in the range of 0V to 10V with an analog input
module in rack 0 (central unit), slot 6 (PIW288), map it onto the range 100 to
1000 as a REAL value and store the result as MD10!
L PIW 288 // Analog value input 0 to 10 V contains 0 to 27648 integers (16 Bit)
ITD // Value of integer (16 Bit) converted into integer (32 Bit)
DTR // Value of integer (32 Bit) converted into a real number
L 2.7648e+4
/R // Division with real number 27648 mapping value to range 0 to 1
L 9.000e+2
*R // Multiplication with real number 900 (1000-100) -> range 0 to 900
L 1.000e+2
+R // Addition with real number 100 (Offset) range 100 to 1000
T MD10 // Normalized value 100 to 1000 in real format
Analog value conversion and processing
835 rpm 3,65 V 10092 Incr
10092
(INT)
10092
(DINT)
10092,0
10092,0 *2,2 22202,4
22202,4 22202
(DINT)
22202 Incr
22202 Incr 8,03 V 1303 rpm
Transducer
A/D-Converter
L PIWn
ITD DTR
Programmed algortihm
RND T PQWn
Actuator
D/A-Converter
J ump instructions
Unconditionally jumps: Are executed always no matter of a condition.
Conditionally jumps: Are executed only if the condition is fullfiled.
LOOP: instruction to call a program segment multiple times (only in STL)
J ump unconditional
LAD FBD STL
J umps conditional
LAD FBD STL
All jump instructions in STL
Unconditionally jumps:
JU label J ump Unconditional
JL label J ump to Labels
J umps based on RLO:
JC label J ump if RLO = 1
JCN label J ump if RLO = 0
JCB label J ump if RLO = 1 with BR
JNB label J ump if RLO = 0 with BR
J umps based on another bit in the status
word:
JBI label J ump if BR = 1
JNBI label J ump if BR = 0
JO label J ump if OV = 1
JOS label J ump if OS = 1
J umps based on the result of a
calculation:
JZ label J ump if Zero
JN label J ump if Not Zero
JP label J ump if Plus
JM label J ump if Minus
JPZ label J ump if Plus or Zero
JMZ label J ump if Minus or Zero
JUO label J ump if Unordered
Loop instruction
LOOP label call a program
segment multiple
times
J ump distributor: J L
The jump distributor allows specific (calculated) jumping to a
program section in the block conditional on a number of positions.
It works in conjunction with a list of J U jump functions following
immediately the J L instruction.
The list can contain up to 255 entries.
The label of the J L instruction points to the end of the list.
L Number_of_jump;
J L End; // jump label points to the first statement after the list
J U L0; // jump to L0 if Number_of_jump = 0
J U L1; // jump to L1 if Number_of_jump = 1
J U Lx; // jump to Lx if Number_of_jump = x

End:
LOOP J ump
L NumberOffLoops;
Next: T ActLoopCountNo;
L ActLoopCountNo;
LOOP Next;
The loop jump LOOP allows a simplified programming of program loops.

When processed, LOOP first decrements the contents of ACCU 1 by 1.
If the value is not zero afterwards, the jump is executed to the jump label
specified.
If the value is zero, the jump is not executed and the next statement is
processed.
The start value in ACCU 1 thus corresponds to the number of program loops
to be passed. This value has to be stored in a loop counter.
Example: Using the jump instruction to
restrict an analog value
(PIW288) (PQW320)
Internal representation of the limits:
Lower limit: 0V 0
Upper limit: 8V (8V * 27648) / 10 V = 22118
Restriction of an analog value: STL program
(PIW288) (PQW320)
Restriction of an analog value: FBD program(I)
Restriction of an analog value: FBD program(II)
Instruction contents of lecture
Bit logic instructions
Bit logic instructions with expressions in parenthesize
Edge triggered instructions
Memory functions: Setting / Resetting bit addresses
Timer instructions
Counter instructions
Load and transfer instructions
Comparison instructions
Integer and floating-point arithmetic instructions
Floating point mathematical instructions
Jump instructions

Lecture 19 and 20

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Course Computer Based Automation WS 06/07 1 Stephan Simons

Computer Based Automation

Course Computer Based Automation WS 06/07 3 Stephan Simons

Course Computer Based Automation WS 06/07 5 Stephan Simons

J U Lx; // jump to Lx if Number_of_jump = x

The loop jump LOOP allows a simplified programming of program loops.

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