Basic PLC (Siemens S7) Presentation Manual

WELCOME TO OUR
TRAINING
ON
N BASIC
PROGRAMMABLE
LOGIC CONTROLLER
T
(PLC)
SIEMENS S7
APPLIED ENGINEERING TECHNOLOGY INITIATIVE
OBJECTIVES
At the end of this course, participants will be able to:
1. Identify and explain the advantages of a
programmable logic control compared to
conventional controls;
2. Install and Operate
p programmable
p g logic
g
controller;
3. Identify and describe the functions of the
system components of a programmable logic
control;
4. Make a program in ladder diagram and
statement list programming;
1
OBJECTIVES Cont…
Cont
55. Translate a ladder diagram
g p
program
g into
statement list program;
6. Translate a ladder diagram program into
electrical and logic circuits equivalent;
7
7. Connect/Wire discrete input and output
PLC control systems;
8
8. C
Carry outt basic
b i Maintenance
M i t &
Troubleshooting of a PLC system
9. Observe safe practices in dealing with PLC
controls systems.
CONTENT
y Introduction to PLC and IEC 61131 Standard
y Introduction to Siemens PLC Hardware
y Types of PLCs – Micro and Modular PLCs
y Parts of a PLC
y The Power Supply Unit
y The PLC Central Processing Unit
y The PLC Memory
y types
yp
y Input and Output Modules
y Special Modules and Peripheral devices
y PLC System Components, Installation, and Field
device Connections
y Introduction
I d i to Si
Siemens S7
S Software
S f
y S7 Simatic Manager and MicroWin
y Creating a project and Software/Hardware configurations
y PLC Number Systems and I/O Addressing
2
CONTENT cont…
y Introduction to Siemens PLC programming
languages:
y LAD,
LAD STL
STL, and FBD
FBD.
y Commonly used instructions and Programming Logics
y Writing, Addressing And Commenting a program
y Uploading,
Uploading Downloading and Running a Program
y Use of Timers & Counters
y Basic PLC system Troubleshooting and Maintenance
y Hands‐on
d practicall exercises & simulations
l
WHAT IS PLC?
A Programmable Logic Controller (PLC) or
programmable controller is a digital (programmable
electronic device) computer used for automation of
electromechanical p processes,, such as control of
machinery on factory assembly lines, amusement rides,
or lighting fixtures. PLCs are used in many industries
and machines. Unlike general‐purpose computers, the
PLC is designed for multiple inputs and output
arrangements, extendedd d temperature ranges, immunity
to electrical noise, and resistance to vibration and
i
impact.
t All PLCs
PLC monitorit inputs
i t andd other
th variable
i bl
values, make decisions based on a stored program in its
memory and control outputs to automate a process or
memory,
machine. 3
OUTPUTS
OPRATION
&
MONITORING
PLC
INTPUTS
HARD‐WIRED
HARD WIRED CONTROL
Prior to PLCs, many control tasks were performed by
contactors control relays and other electromechanical
contactors,
devices. This is often referred to as hard‐wired control.
Circuit diagrams had to be designed, electrical
components specified and installed, and wiring lists
created.
A change in function
or system expansion
required extensive
component changes g
and rewiring.
4
A BRIEF HISTORY OF PLC
Before the PLC, control, sequencing, and safety interlock logic for
manufacturing automobiles was accomplished using hundreds or
thousands of relays, cam timers, and drum sequencers and dedicated
closed-loop controllers. The process for updating such facilities for the
yearly model change-over was very time consuming and expensive,
expensive
as electricians needed to individually rewire each and every relay.
In 1968 GM Hydramatic (the automatic transmission division of
General Motors) issued a request for proposal for an electronic
replacement for hard-wired relay systems. The winning proposal came
from Bedford Associates of Bedford,
Bedford Massachusetts.
Massachusetts The first PLC,
PLC
designated the 084 because it was Bedford Associates' eighty-fourth
project, was the result. Bedford Associates started a new company
d di t d to
dedicated t developing,
d l i manufacturing,
f t i selling,
lli and
d servicing
i i thi
this
new product: Modicon, which stood for MOdular DIgital CONtroller.
One of the people who worked on that project was Dick Morley, who
is considered to be the "father" of the PLC.
IEC 61131 STANDARD

IEC 61131 is the International Electrotechnical
C
Commission
i i (IEC) standardd d for
f Programmable
P bl logic
l i
controllers (PLCs). It was known as IEC 1131 before
the
h change
h i numbering
in b i system by
b IEC.
IEC It
I was
developed with the input of vendors, end‐users and
academics;
d i IEC 61131
6 consists
i off five
fi parts:
1. General information
2. Equipment and test requirements
3 PLC programming languages
3.
4. User guidelines
5. Communications
C i i
5
IEC 61131 STANDARD cont..
cont
Thus, IEC 61131‐3 is the international standard for
programmablebl controller
t ll programming i l
languages. A
As
such, it specifies the syntax, semantics and display for
the following suite of PLC programming languages:
1. Ladder diagram (LAD)
2. Sequential
S i l Function
F i Charts
Ch (SFC)
3. Function Block Diagram (FBD)
4. Structured Text (ST)
5. Instruction List (IL) or Statement List (STL)
One of the primary benefits of the standard is that it
p languages
allows multiple g g to be used within the same
programmable controller.
ADVANTAGES OF PLCs
PLCs not only are capable of performing the same tasks as
hard‐wired control,, but are also capablep of manyy more
complex applications.
Some of the additional advantages of PLCs are as follows:
y Smaller physical size than hard‐wire solutions.
y Designed
D i d for
f industrial
i d t i l environment
i t
y Easier and faster to make changes.
y PLCs have integrated diagnostics and override functions.
y Diagnostics
g are centrallyy available.
y Applications can be immediately documented.
y Applications can be duplicated faster and less
expensively. 6
SOME PLC APPLICATION AREAS
y Conveyors
y System
y y Paper Mills
y Fillers, Package, Labeler y Motor Control
y Heat Treating Metal Products y Power House/Plant
y Oil & Gas Management
y Pharmaceuticals y Product Assembly
y Plastics Manufacturing Machines
y Warehouse Automation y Food

F d Processing
P i
y Water treatment Systems
PLC BRANDS
BRANDS…
There are several manufacturers/brands of PLCs within the
automation industry.
industry However,
However three brands that are very
common in the Nigerian industrial system are mentioned
here below:
y Siemens
y Allen
All Bradley
B dl
y Omron
7
THE SIEMENS S7 PLCs
Siemens makes several PLC product lines in the SIMATIC®
S7 family.
family They are: S7-200,
S7-200 S7-300
S7-300, and S7-400
S7-400.
THE S7 PLC TYPES/CATEGORIES

1. The Micro or Compact PLC
2. The Modular PLC
1. Integrated PLC Micro/Compact PLC
The S7-200 is referred to as a

micro PLC because of its small
size. The S7-200 has a “brick”
design, with the CPU, power
supply, and some inputs/outputs
((I/O)) all included in a compact
p
brick-like structure.S7-200
models has the following CPU
series: CPU221 CPU222 CPU224
CPU224XP CPU226 8
M d l PLCs
Modular PLC
S7-300 and S7-400 PLCs use
a modular design
g with a wide
range of modules available.
They are usually for flexible
and
d high
hi h end
d applications
li ti th t
that
require varied and greater
number of I/O points or that
require more advanced
features. Here are some S7 S7-
300, 400 CPU series: CPU312,
CPU313, CPU315F-2DP,
CPU412-2, CPU414-2,
CPU414F-3 PN/DP
IIntegrated
t t d PLCs
PLC are special
i l Integrated PLCs
kind of Modular PLCs that
are manufactured with an
integrated I/O or dedicated
signal/function modules
modules.
They are built to bridge the
gap between a Micro &
Modular PLCs. Some S7-300
series such as CPU315T
CPU315T-
2DP, CPU313C, CPU 314C-
2 PtP,
PtP CPU 317TF
317TF-2
2 DP etc.
etc
belong to this group of PLCs,
they are also compact in
nature. 9
PARTS OF THE PLC
The PLC system is essentially made up of the following units:
The Power supply, Central Processing Unit, Memory unit,
I
Input/Output
/O units,
i Communication
C i i unit/ports.
i/
Input Output
Devices Devices
THE POWER SUPPLY UNIT

The power supply unit essentially does the work of providing a rectified,
rectified
regulated & filtered electrical power for the operation of the PLC system. It
can be in-built or comes in a modular unit and in various capacities as shown
b l
below. N
Note that
h in i some cases, an externall power supplyl unit
i that
h meet the h
required capacity can also be used External Power
Supply Unit
For Compact/S7 200 PLCs
AC Power
Internal Supply Unit
10
S7 300 & 400 PLCs HAVE MODULAR POWER SUPPLY UNIT
CPU
120/230v AC
LINE
24v DC LINE
The Central Processing

g Unit(CPU)
The central processing unit as the name signifies doe all the
work of processing/coordinating the control function of the PLC.
It is
i the
th heart
h t off the
th system
t andd it usually
ll consist
i t off ICs,
IC
Microprocessor, Registers & back-up battery etc. It’s processing
capacity defines the power of a PLC and each PLC model has
various CPU capacities/units number.
11
GENERAL S7 CPU FEATURES
MEMORY SLOT
STATUS
INDICATORS
MODE SELECTOR
BATTERY
COMPATMENT
COMMUNICATION
PORTS
GENERAL S7 CPU FEATURES…
12
THE PLC MEMORY UNIT
THE PLC MEMORY UNIT cont…
13
ACCESSIBLE MEMORY PACKAGES
• Flash Memory Card, FEPROM, Micro Memory Card
• Non- Battery Backed RAM Memory Cartridge
• Battery Backed RAM Memory Cartridge
THE MEMORY SIZE

PLC Memory unit is essentially its data storage location. The smallest
piece of the memory unit is called a Bit and can only hold a bit size data
which is a 1 or 0. to accommodate lager
g data size the memory y locations
are increased to byte, word length sizes etc. However, Memory devices
are generally quantified in BYTES e.g. b: Kilo, abbreviated K, normally
refers to 1000 units. When talking about computer or PLC memory,
however, K means 1024.This is because of the binary number system
(210=1024).
14
THE INPUT MODULE
The input Module connects all the input devices such as
Switches, Sensors to the PLC. And can either be DIGITAL
(DCV/ACV) Module
M d l or ANALOG Module.
M d l
INPUT MODULE ISOLATION SYSTEM
15
INPUT DEVICES
The input devices comprise of all electro-mechanical devices that send
electrical signal to the PLC Input Modules. They are either DISCRETE
or ANALOG depending on the type of signal they send to the PLC.
PLC
Example: Classification:
• Pushbuttons • Digital/Discrete
• Thermocouple • 120/230 VAC
• Transmitter • 24 VDC
• Level
L lSSwitches
it h • Analog
A l
• Photoelectric Sensors • Current 4-20mA
• Voltage 0-10v
• Proximity Sensors
• Motor Starter Contacts
y Contacts
• Relay
Etc.
DIGITAL/DISCRETE
/ INPUTS
A discrete input, also referred
to as a digital input, is an
input that is either on or off.
Pushbuttons, toggle switches,
limit switches
switches, proximity
switches, and contact closures
are examples of discrete
sensors which are connected
to the PLCs discrete or
digital inputs. In the ON
condition a discrete input may
be referred to as a logic 1 or a
logic high. In the OFF condition
a discrete input may be
referred to as a logic 0 or a
16
logic low. APPLIED ENGINEERING TECHNOLOGY INITIATIVE
ANALOG INPUTS
An Analog input is a
continuous, variable signal.
Typical analog inputs may vary
from 4 to 20 milliamps, or 0 to
10 volts.
volts In the following
example, a level transmitter
monitors the level of liquid in a
tank. Depending on the level
transmitter, the signal to the
PLC can either increase or
decrease as the level in the
tank increases.
increases These inputs
are connected to Analog input
Module of the PLC.
THE OUTPUT MODULE

The output module is the interface Classifications:
where the PLC transfers its electrical • Digital/Discrete Module
controll signal
i l to the
h out devices.
d i • 120/230 VAC
• 24 VDC
• Relay(24VDC/230VAC)
• Analog
A l M Module
d l
1L 24vdc • Current
OUT1 N • Voltage
OUT2
OUT3
2L
OUT4 N
OUT5
OUT6
OUT7
3L
OUT8
OUT9
17
OUTPUT MODULE ISOLATION SYSTEM
OUTPUT DEVICES
The Output devices comprise of all Actuator devices that
receive/transmit/convert the PLC electrical control signal to other form of
signal in order to do an automated
a tomated work
ork . They
The are either DISCRETE or
ANALOG depending on the type of signal they receive from the PLC.
Examples: Classification:
• Valves • Digital/Discrete
• Solenoids • 120/230 VAC
• C t l Relays
Control R l • 24 VDC
• Analog meter • Analog
• Lamps • Current
• Fans • Voltage
• Relays
¾ 240 VAC
¾ 24 VAC/VDC
• Transistor MOSFET
¾ 24 VDC
18
DIGITAL/DISCRETE OUTPUTS
A Discrete Output is an
output that is either ON or
OFF. Solenoids, contactor
coils
coils, and lamps are
examples of actuator
devices connected to
discrete outputs. Discrete
outputs may also be referred
to as digital outputs. In the
following example, a lamp
can be turned on or off by
the PLC output it is
connected To.
ANALOG OUTPUTS
An Analog Output signal
is a continuous,
continuous variable
signal. The output may be
as simple as a 0-10 VDC
level that drives an analog
meter. Examples of analog
meter
t outputs
t t are speed, d
weight, and temperature.
The output signal may also
be used on more complex
applications such as a
current-to-pneumatic
transducer that controls an
air-operated
i t d fl
flow-control
t l
valve. 19
COMMUNICATION PORTS/INTERFACE
Siemens S7 uses RS232/RS485 communication ports standard which is
located on the CPU. It communicate from the port to peripheral devices
through either a Point to Point Interface (PPI) cable or a Multi-Point
Multi Point
Interface (MPI) cable or Distributed Peripheral (DP) cable. Furthermore,
the PLC can also communicate to peripheral devices through special
C
Communication
i ti Processor
P (CP) Modules.
M d l
S7-300/400
RS232/485 port for
COMMUNICATION
CABLE MPI/DP CABLE
S7-200 RS232/485
port
for PPI CABLE
SPECIAL MODULEs
Special Modules are modules that are designed for specific
pp
automated I/O application. These mayy be required
q for special
p
Communication purposes, motion control, and temperature
measurement etc. This includes also general I/O Expansion
modules. Examples are as show below:
CPU I/O Expansion

E i
Module
20
SPECIAL MODULEs cont
cont…
SPECIAL MODULEs cont…
21
PERIPHERAL DEVICES
Peripheral devices are secondary devices such as the
Programming device, HMIs, Printers etc which are only
connected for special use and occasions.
HMIs
S7 SYSTEM OVERVIEW
COMMUNICATION
SYSTEMS
PPI
INPUTS/OUTPUT
DEVICES
22
PLC OPERATION MODES
The S7 PLCs have Operation mode switch for various operation modes on
the CPU. When the mode switch is in the RUN position the CPU is in the
Run mode and can execute its program.
g When the mode switch is in the
STOP position the CPU is stopped. When the mode switch is in the TERM
position the programming device can select the operating mode. The MRES
position is used to rest the PLC memory. Note: that the modes and status
indicator may vary slightly depending on the PLC model. The analog
adjustment is used to increase or decrease values stored in special memory.
These values can be used to update the value of a timer or counter,
counter or can be
used to set limits
PLC OPERATION SCAN/CYCLE

/
The PLC program is executed as part
of a repetitive process referred to as
a Scan Cycle. A PLC scan starts
with the CPU reading the status of
inputs The application program is
inputs.
executed using the status of the
inputs. Once the program is
completed, the CPU performs
internal diagnostics and
communication tasks. The scan cycle
ends by updating the outputs, then
starts all-over
all over again.
again The cycle time
depends on the size of the program,
the number of I/Os, and the amount
of communication required.
23
PLC SYSTEM INSTALLATION GUIDE
All PLC hardware and software systems come with complete
installation manual/guide and material specifications which should be
properly implemented during system installations.
installations However,
However some
general guidelines are discussed here as follows:
y The PLC installation manual,, control system y specification
p and design
g
diagram should be at hand.
y PLC system units are generally installed in an electrical panel. PLC
panel should have:
y The appropriate power supply rating 120/240 VAC or 24VDC.
y Should be properly grounded and possibly with an earth failure,
low voltage protection (LVP) systems.
y The
Th PLC is i a computer t system, t th should
thus h ld nott be b allowed
ll d to
t
suffer abrupt power failure; a power back‐up/Uninterruptible
Power Supply
pp y ((UPS)) system
y should be p provided.
y The PLC proper mounting and modular arrangements should be
observed APPLIED ENGINEERING TECHNOLOGY INITIATIVE
MODULAR PLC HARDWARE ARRANGEMENT
24
HORIZONTAL/VERTICAL
HORI ONTA /V RTICA INSTALLATION
INSTA ATION
MULTI‐TIER/RACK INSTALLATION
ER
ER
EXPANSION
RACK (ER)
CENTRAL
RACK (CR)
25
RAIL/BUS CONNECTION MOUNTING TYPE
RACK/CHASIS CONNECTION MOUNTING TYPE
2
1.Chasis/Backplane
2.Tracks
3 Output module/card
3.
4. Input module/card
5. Processor
6 Memory card
6.
7. Power supply
26
PLC SYSTEM INSTALLATION cont..
y The panel should have adequate space for the PLC rack/rail installations and
cable trunks.
y Minimum clearance are required between the PLC modules and enclosure,
check the specs.
y Back‐up Battery should be installed if the PLC only has a RAM memory
y Proper ventilation
l is required
d but
b theh panell should
h ld be
b waterproof.
f
y Ensure proper Input/Output load sizing (Current/Voltage level) and use a
((Diode/RC)
/ )p protective circuit for inductive loads when necessary.
y
y The PLC system panel should have a properly labeled cable termination block.
y Power cables and signal cables should not be in the same cable trunk especially
when
h theh power cablebl is
i carrying
i a high
hi h voltage.
l
y Standard flexible cable of proper wire gauge size with crimp connectors are
generallyy used for basic PLC system
g y cabling.
g
y Simple I/O devices can be generally wired with flexible cables, but it is
recommended that shielded cable should be used for critical analog signal
devices; where there is much industrial noise and when the signal have to travel
through a long distance to minimize electrical/field interference.
FIELD DEVICE CONNECTION

SOURCING Vs SINCKING I/Os
27
SOURCING Vs SINCKING FIELD DEVICEs
AND THE PLC I/O MODULE

AND THE PLC INPUT MODULE
SOURCING + 24v DC
L
3 WIRE
PNP IN1
SENSOR IN1
PLC PLC
+ SINCKING + SOURCING
INPUT INPUT
POWER POWER
SUPPLY MODULE SUPPLY MODULE
- - 3 WIRE
NPN
SENSOR
COM COM
SINCKING
28
AND THE PLC OUTPUT MODULE
SOURCING
+
L SOURCING
OUT1 + SINCKING OUT1 OUTPUT
OUTPUT
FIELD COM - FIELD
DEVICE
DEVICE
PLC
PLC SINCKING
SOURCING OUTPUT SINCKING
OUTPUT MODULE
MODULE
N -
COM
COM
SOURCING Vs SINCKING RULEs
• Field devices on the positive side (+VDC) of the

field power supply are sourcing field devices.
devices
• Field devices on the negative side (DC COM) of the
field power supply are sinking field devices.
devices
• Sourcing field devices must be connected to sinking
I/O cards and vice versa.
versa
• Sinking field devices must be connected to sourcing
I/O cards and vice versa.
versa
29
PLC SYSTEM INSTALLATION cont..
y Manual Override, Special operational and emergency control
switches should be installed at easy access points.
points
y HMIs can be installed for easy operation, data parameter changes
aand
d for
o first
s hand
a d sys
system
e d diagnosis
ag os s aand
d troubleshooting.
oub es oo g.
y After proper hardware installations, then:
y Power the PLC system
y
y Connect and establish communication between the PLC and the
Programming device
y Configure
C fi and
d place
l th PLC in
the i the
th proper operation
ti moded
y Download the automation design control program to the PLC
y Test
Test‐run,
run, Debug and Commission the System.
y The PLC panel should have a tag‐out security system and have a
work‐order p
permit/Authorization system.
y
A TYPICAL PLC INSTALLATION PANEL
30
BASIC REQUIREMENT FOR PLC PROGRAMMING
In order to Program a PLC the following are the basic requirements:
• The PLC S7-200, 300, 400
• A Communication
C i i Cable
C bl PPI/MPI Cable
C bl
• A Programming Device PG/PC
• A Software (STEP 7 – SIMATIC Manager)
A COMPLETE PLC SYSTEM SET‐UP
31
INTRODUCTION TO SIEMENS S7 PLC PROGRAMMING
MICROWIN FOR S7-200 PLCs SOFTWARE
SIMATIC MANAGER FOR S7-300

S7 300 & 400 PLCs
32
CREATING A PROJECT
Before you create a project, you should know that STEP 7 projects can be
created in different orders. Two options are as shown below:
33
OPENING A PROJECT in Simatic Manager
g
y By ‘New Project Wizard’
y By
y Customised New Project
j
INSERTING A STATION by a Customised Project
34
HARDWARE CONFIGURATION
STARTING HW CONFIGURATION
35
HARDWARE SETPOINT CONFIGURATION
SAVING THE HW CONFIGURATION AND

DOWNLOADING INTO MODULE
36
CREAT A PROGRAM IN OB1 AFTER
HW CONFIGURATION
S7 PROGRAMMING LANGUAGES AND COMMONLY USED

INSTRUCTIONs
THE LADDER LOGIC DIAGRAM
37
FEATURES OF A LADDER DIAGRAM

POWER
RAIL
RUNG
38
ELECTRICAL CONTROL CCT. Vs PLC & LADDER DIAGRAM
I0.0 I0.1 Q0.0
I0.3 I0.4 Q0.5
I0.6
I0.2 I0.5 Q0.2
PLC NUMBER SYTEM

Since a PLC is a digital computer,
computer it stores information in the form of on or off
conditions (1 or 0), referred to as bits. Sometimes bits are used individually
and sometimes they are used in group to represent numerical values.
U d
Understanding
di h
how these
h bi can be
bits b used d to represent numerical
i l values
l
requires an understanding of the binary number system. The binary system
is the number system used by programmable controllers though values
can also be entered in decimal and hexadecimal values through the
programming software.
The binary y system
y has the following g characteristics:
Two digits: 0, 1
Base 2
Weights Powers of base 2 (1 (1, 2
2, 4
4, 8
8, 16
16, ...))
In the binary system 1s and 0s are arranged into columns.
39
PLC MEMORY AREAS/ADDRESSING
40
PLC I/O ADDRESSING/NUMBERING
The S7 PLCs inputs and outputs are labeled at the wiring terminations and next
to the status indicators. These alphanumeric symbols identify the I/O address to
which a device is connected
connected. This address is used by the CPU to determine
which input is present and which output needs to be turned on or off. I
designates a discrete input and Q designates a discrete output. The first
number identifies the byte,
byte the second number identifies the bit
bit. Input I0
I0.0,
0 for
example, is byte 0, bit 0.
I0.0 = Byte 0, Bit 0
I0 1 = B
I0.1 Byte
t 0
0, Bit 1
Q1.0 = Byte 1, Bit 0
Q1.1 = Byte 1, Bit 1
PLC MEMORY AREAS/PROCESS IMAGES
41
PLC MEMORY AREAS/PROCESS IMAGES
¾ Process‐Image Input Register: I
¾ Process
Process‐Image
Image Output Register: Q
¾ Analog Inputs: AI
¾ Analog Outputs: AQ
y Variable Memory Area: V
y Bit
Bi MMemory A
Area: M
y Timer: T
y Counter: C
y Special
p Memory:
y SM
¾ High‐Speed Counters: HC
y Accumulators: AC
y Local Memory Area: L
BASIC PROGRAMMING LOGICs:

LAD STL & FBD REPRESENTATION
LAD,
42
43
AUTOMATION TASK ILLUSTRATION
44
PLC PROGRAMMING EXERCISE
BEGINs
y CREATING
y ADDRESSING
y COMMENTING
y DOWNLOADING
y UPLOADING
y SIMULATION
y ACTUAL CONNETION OF A PROJECT & RUNNING
OF A PLC PROGRAM
y COMMISIONING OF THE PLC PROGRAM
ALL REFER TO YOUR PLC TRAINING SYSTEMs
PLC TIMERS
45
AN ON‐DELAY TIMER CONTOL EXAMPLE
46
REVERSE ON‐DELAY TIMER CONTOL FUNCTION
47
A TONR TIMER CONTOL EXAMPLE
48
SIMATIC MANAGER TIMERS
S_PULSE Pulse S5 Timer
If the signal state of input I0.0 changes from "0" to "1" (positive
edge in RLO), the timer T5 will be started. The timer will
continue
ti t run for
to f theth specified
ifi d time
ti off two
t seconds
d (2 s)) as
long as I0.0 is "1". If the signal state of I0.0 changes from "1" to
"0" before the timer has expired the timer will be stopped. If the
signal state of input I0.1 changes from "0" 0 to "1"
1 while the timer
is running, the time is reset. The output Q4.0 is logic "1" as long
as the timer is running and "0" if the time has elapsed or was
reset.
S_PEXT Extended Pulse S5 Timer

If the signal state of input I0.0 changes from "0" 0 to "1"
1
(positive edge in RLO), the timer T5 will be started. The
timer will continue to run for the specified time of two
seconds (2 s) without being affected by a negative edge at
i
inputt S.
S If the
th signal
i l state
t t off I0.0
I0 0 changes
h f
from "0" to
t "1"
before the timer has expired the timer will be re-triggered.
The output Q4.0 is logic "1" as long as the timer is running.
SIMATIC MANAGER TIMERS cont…

S_ODT On-Delay S5 Timer
If the signal state of I0.0 changes from "0" to "1" (positive
edgeg in RLO), ), the timer T5 will be started. If the time of two
seconds elapses and the signal state at input I0.0 is still "1",
the output Q4.0 will be "1". If the signal state of I0.0
changes from "1" to "0", the timer is stopped and Q4.0 will
be "0" (if the signal state of I0.1
I0 1 changes from "0" to "1",
"1" the
time is reset regardless of whether the timer is running or
not).
S_ODTS Retentive On-Delay S5 Timer

If the signal state of I0.0 changes from "0" to "1" (positive
edge in RLO),
RLO) the timer T5 will be started.
started The timer runs
without regard to a signal change at I0.0 from "1" to "0". If
the signal state at I0.0 changes from "0" to "1" before the
timer has expired, the timer will be re-triggered. The output
Q4.0 will be "1" if the
timer elapsed. (If the signal state of input I0.1 changes from
"0" to "1", the time will be reset irrespective of the RLO at S.)
49
SIMATIC MANAGER TIMERS cont…
S OFFDT Off
S_OFFDT Off-Delay
Delay S5 Timer
If the signal state of I0.0 changes

from "1"
1 to "0",
0 , the timer is started.
Q4.0 is "1" when I0.0 is "1" or the
timer is running. (if the signal state
at I0.1
I0 1 changes from "0"0 to "1"1 while
the time is running, the timer is
reset).
ON DELAY TIMER
50
STORE ON DELAY TIMER
PULSE TIMER
51
EXTENDED PULSE TIMER
OFF DELAY TIMER
52
TIMER BIT INSTRUCTION
COMPARISON INSTRUCTION
53
LOADING AND TRANSFERING OF DATA
INSTRUCTION
PLC COUNTERS
54
THE THREE TYPES OF COUNTERS
THE UP COUNTER
55
THE DOWN COUNTERS
THE UP/DOWN COUNTERS
56
SIMATIC MANAGER S7 COUNTER
COUNTER BIT INSTRUCTION
57
C48
PLC SYSTEM MAINTENANCE GUIDE

Preventive maintenance of programmable controller systems
includes only a few basic Procedures, which will greatly reduce the
f il
failure rate off system components. Preventive
P i maintenance
i f the
for h
PLC system should be scheduled with the regular machine or
equipment maintenance,
maintenance so that the equipment and controller are
down for a minimum amount of time. However, the schedule for
PLC p preventive maintenance depends
p on the controller’s
environment— the harsher the environment, the more frequent the
maintenance.
Th following
The f ll i are guidelines
id li f preventive
for i measures:
y Periodically clean or replace any filters that have been
installed in enclosures.
y Do not allow dirt and dust to accumulate on the PLC’s
components
58
PLC SYSTEM MAINTENANCE GUIDE cont..
y Periodically check the connections to the I/O modules to
ensure that all plugs,
plugs sockets
sockets, terminal strips
strips, and modules
have good connections.
y Ensure that Memory Back‐up
Back up Battery is changed as of when
due
y Ensure that heavy,
heavy noise‐generating
noise generating equipment is not located
too close to the PLC.
y Make sure that unnecessary items are kept away from the
equipment inside the enclosure. Leaving items, such as
drawings installation manuals
drawings, manuals, or other materials
materials, on top of
the CPU rack or other rack enclosures can obstruct the
airflow and create hot spots, which can cause system
malfunction.
PLC SYSTEM TROUBLESHOOTING GUIDE

To achieve a degree of success when troubleshooting a PLC
system, the Engineer/Technician must take a systematic
approach. There are always unique situations that dictate
troubleshooting steps; but all effective troubleshooting has
three
h steps in
i common. TheyTh are:
y System Observation and Symptom Recognition which
i l d Operators’
includes O ’ Report
R
y Problem Isolation
y Corrective action – Check, Repair and Test.
Three basic troubleshooting g tools are also required:
q
y An Electrical Multimeter
y An Electrical signal Tester or Signal Probe
y A Programming Device. 59
PLC
P C SYST
SYSTEM
M TROU
TROUBLESHOOTING
SHOOTING cont..
y The PLC Status lights/indicators are valuable sources of
information during a PLC system troubleshooting.
The status lights/indicators can help in the follow
situations:
y DC POWER STATUS:
y CPU OPERATION MODE STATUS: RUN, RUN STOP,
STOP and
FAULT:
y I/O STATUS:
STATUS
y BATTERY LOW STATUS:
y I/O FORCING:
REFER TO A SPECIAL TROUBLSHOOTING SOFTWARE

PLC SYSTEM TROUBLESHOOTING cont..

When the problem has been identified, proper repair or
replacement specification/procedures should be followed.
Th test‐run the
Then h repaired
i d system and d document
d accordingly,
di l
see a typical work‐order sheet below:
60
EVALUATIONS
TRAINING OBJECTIVES
At the end of this course, participants will be able to:
1. Identify and explain the advantages of a programmable logic control
compared to conventional controls;
2. Install and operate
p p
programmable
g logic
g controller;;
3. Identify and describe the functions of the system components of a
programmable logic control;
4
4. Make a program in ladder diagram and statement list programming;
5. Translate a ladder diagram program into statement list program;
6. Translate a ladder diagram program into electrical and logic circuits
equivalent;
i l
7. Connect/Wire discrete input and output PLC control systems;
8. Carry out basic Maintenance & Troubleshooting g of a PLC system
9. Observe safe practices in dealing with PLC controls systems.
SELF EVALUATION
END OF PROGRAM
THANK YOU
61

Basic PLC (Siemens S7) Presentation Manual

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WELCOME TO OUR

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

y Commonly used instructions and Programming Logics

y Writing, Addressing And Commenting a program

y Use of Timers & Counters

y Basic PLC system Troubleshooting and Maintenance

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

IEC 61131 STANDARD

y Pharmaceuticals y Product Assembly

y Plastics Manufacturing Machines

y Warehouse Automation y Food

y Water treatment Systems

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

THE S7 PLC TYPES/CATEGORIES

The S7-200 is referred to as a

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

THE POWER SUPPLY UNIT

For Compact/S7 200 PLCs

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

The Central Processing

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

GENERAL S7 CPU FEATURES…

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

THE PLC MEMORY UNIT cont…

• Non- Battery Backed RAM Memory Cartridge

• Battery Backed RAM Memory Cartridge

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

THE MEMORY SIZE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

INPUT MODULE ISOLATION SYSTEM

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

THE OUTPUT MODULE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

CPU I/O Expansion

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

SPECIAL MODULEs cont…

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

PLC OPERATION SCAN/CYCLE

MODULAR PLC HARDWARE ARRANGEMENT

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

RACK/CHASIS CONNECTION MOUNTING TYPE

FIELD DEVICE CONNECTION

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

SOURCING Vs SINCKING FIELD DEVICEs

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

SOURCING Vs SINCKING RULEs

• Field devices on the positive side (+VDC) of the

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

A TYPICAL PLC INSTALLATION PANEL

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

A COMPLETE PLC SYSTEM SET‐UP

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

SIMATIC MANAGER FOR S7-300

APPLIED ENGINEERING TECHNOLOGY INITIATIVE

INSERTING A STATION by a Customised Project

APPLIED ENGINEERING TECHNOLOGY INITIATIVE