(Basic Course)

Objectives

To understand the basic PLC theory including primary

elements, signal processing, scan time and
specifications

Identify the major components of a PLC, its functions

and performance characteristics

Design, test and troubleshoot a simple application

program
Outline

PLC Defined

Benefits and Applications of PLC

Parts of PLC

PLC Operation

PLC Programming

Hands-on Programming Exercises

 PLC Defined

“ A digitally operating electronic system, designed for use in

an industrial environment, which 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, various types of machines or
processes. Both the PLC and its peripherals are designed so
that they can be easily integrated into an industrial control
system and easily used in all their intended functions.”

- IEC 1131, Part1

 DIGITAL APPARATUS

PROGRAMMABLE
MEMORY

LOGIC
SEQUENCING
TIMING
ARITHMETIC
6-1

ANALOG OR DIGITAL I/O

assembly_arm_md_wht.gif

boiler_bursting_md_wht.gif

MACHINE OR PROCESS
 PLC Defined

A PLC is a specialized
computer, designed to
withstand the harshness
of industrial environment
and to perform a
specified task.
Benefits of PLC
Flexibility and Functionalities

Easier and faster system changes and error correction

Large number of contacts available

Lower cost

Simplicity on specifying system components

Safer pilot running

Benefits of PLC

Integrated visualization, diagnostics and override functions

Faster actuation response

Immediate documentation

Multiple programming method available

Simple security implementation

Reliability/Maintainability
 Applications of PLC
PLC
APPLICATIONS

MACHINE CONTROL or
FACTORY AUTOMATION
PROCESS CONTROL
Applications of PLC
 What PLC’s can Do

SUPERVISORY
• Process Monitoring
SOPHISTICATED and Alarm
• Fault Diagnostic and
SEQUENCE • Arithmetic
monitoring
• Conventional Operation
• Interfacing w/
Relay Logic • Information
Computer
Replacer Handling
• Printer / ASCII
• Timers / Counters • Analog Control
Interfacing
• PCB Card • PID Control
Controller • Factory Automation
• Servo motor
Replacer Networking
control
• Auto/ Semi-auto/ • LAN/WAN
• Stepper motor
Manual control of control
machine and
processes
Classification of PLC (no. of I/O’s)

Micro
Up to 32 I/O’s

Small
Up to 128 I/O’s

Medium
Up to 1024 I/O’s

Large
Up to 8192 I/O’s
 Classification of PLC (enclosure/ function)

Compact/
CPU, Power Supply, I/O Modules in an enclosure
Shoebox
Expandable but only handles limited I/O’s

Parts/functions are individually enclosed and inter- Modular

connectible with each other
Can handle huge amount of I/O’s

PLC is combined with other functions such as Human Hybrid

Machine Interface (HMI)
PLC ARCHITECTURE
 Parts of a PLC System
POWER SUPPLY

INPUT OUTPUT
MODULE MODULE

CPU
PROGRAMMING
DEVICE

HUMAN
MACHINE INTERFACE

SERIAL DEVICES
S7-200 PLC
 INPUT\OUTPUT MODULES

Categorized according to its signal associated

with its application:

▪ Discrete
▪ Analog
▪ High Speed Pulse
▪ Register (BCD)
Typical Discrete Input Module Circuit

com com
input1 input2 input3 input4 input5 input6
 Input Module
LIMIT
SWITCHES

ELECTRO-
MECHANICAL
SWITCHES LASER
PHOTOELECTRIC
SENSORS
SENSORS

PROXIMITY
SENSORS ON or OFF

FIBER OPTIC
SENSORS
LIGHT
CURTAINS
 Analog Input
TACHOGENERATORS
THERMOCOUPLE

LOAD CELL
PRESSURE SENSORS

4-20 mA
1-5 Vdc
RTD’s 0-10 Vdc
-10 to +10 Vdc
 Pulsed Input

High Speed Pulse

RELATIVE ROTARY
ENCODER
 REGISTERS (BCD) INPUT

800px-Rotatory_EnDat_Encoder
THUMBWHEEL
SWITCH

BCD, GRAY CODE

ABSOLUTE ROTARY
ENCODER
Typical Discrete Output Module Circuit

com
output1 output2 output3 output4

Transistorized Output
Typical Discrete Output Module Circuit

com
output1 output2 output3 output4

Relay Output
 DISCRETE OUTPUT
4-kuhnway

SOLENOID
VALVES
SSR
RELAY
COILS

LAMPS
ON or OFF

CONTACTOR
COILS
 Analog Outputs

4-20 mA
1-5 Vdc
0-10 Vdc
-10 to +10 Vdc

VARIABLE
FREQUENCY DRIVE PANEL
(ANALOG INPUT) METERS

VALVE
POSITIONER
 PULSED OUTPUT

ROBOCYLINDERS

SERVO/STEPPER
MOTORS High Speed Pulse
REGISTER (BCD) OUTPUT

BCD
Central Processing Unit
Central Processing Unit

CPU contains:

• Microprocessor

• Memory System

• supporting circuitry
Memory

SYSTEM
MEMORY

APPLICATION
MEMORY
 System Memory

• operating
system EXECUTIVE
• PLC
MEMORY
capabilities

SCRATCH
PAD • calculation
• control
DATA TABLE
AREA
USER
PROGRAM
AREA
 Application Memory

EXECUTIVE
MEMORY

SCRATCH
• stores all data PAD
associated
with the control DATA TABLE
program
AREA • provides storage
for programmed
USER instructions entered
PROGRAM by the user
AREA
Memory Map

EXECUTIVE
MEMORY

SCRATCH
PAD
INPUT TABLE
OUTPUT TABLE
INTERNAL BITS
REGISTERS/ WORDS
USER
PROGRAM
AREA
S7-200 Memory System
Program Block Program Block
Program Block
System Block System Block System Block
Data Block
V Memory Data Block

M Memory
M Memory
(permanent area)
Timer and Counter RAM Forced Values
Current Value

Forced Values EEPROM

Electrically Erasable
Programmable Read-
Program Block only
System Block Memory
Data Block
PLC OPERATION
 PLC Scan Cycle Diagram

Read
Inputs Execute
Programs

PLC Scan
Write Cycle
Outputs

Diagnostics/
Communications
 input
device converter opto-isolator input logic

“1”
“0”
power
supply

to CPU
 Opto-isolator
Opto-isolators act as a protection
mechanism, ensuring that harmful
electrical currents cannot flow across the
device. In simplest terms, an opto-isolator
works by taking an input electrical signal
and converting it into a light signal using a
light-emitting diode, generally operating in
the near-infrared spectrum.
 PLC memory
can be read
through word

PII

PIQ
 output
output logic opto-isolator switching device

relay
“0”
“1”
power
supply

from
CPU
Putting them together…
7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0

150 0 0 0 0 0 0 0
Process Image for
Output
I0.0 I0.1 Q0.0

7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Input
 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Output
I0.0 I0.1 Q0.0

7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 1
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Input
 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Output
I0.0 I0.1 Q0.0

7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 1 0
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Input
 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 1
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Output
I0.0 I0.1 Q0.0

7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 1 1
1 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0
.
150 0 0 0 0 0 0 0
Process Image for
Input
 PLC OPERATION
PROGRAM DOWNLOAD

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

Microprocessor

Power
Supply AC
 PLC OPERATION
READ INPUT
STATUS RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION

EXECUTE RUN MODE

PROGRAM

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
WRITE
OUTPUT RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 1 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
RUN MODE

USER PROGRAM
000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 1 1 0 0 0 0
1
PLC OPERATION

MicroProcessor

Power
Supply AC
 SIMATIC S7-200

SIMATIC S7-200
 Positioning within the SIMATIC family
Micro Automation Totally Integrated
Automation

▪ Small,compact systems ▪ Shared data management,

configuring and
▪ Easiest programming tools
communications
with Wizards
▪ Highest performance
▪ micro automation sets as
solution from one supplier ▪ Programming with
high-level languages

S7-200
S7-300
LOGO!

S7-400

SIMATIC S7-200
 S7-200 Second Generation Overview
CPU 221 CPU 222 CPU 224
(10 I/O Points) (14 I/O Points) (24 I/O Points)

CPU 224XP (24 I/O + 2AI/1AA) CPU 226 (40 I/O Points)

SIMATIC S7-200
 Features: CPUs (1/2)
Features CPU 221 CPU 222
Integrated Inputs/Outputs 6DE/4DA 8DE/6DA
Max. Expansion Modules - 2
Max. # of Dig. I/O Channels 10 78
Analogue Points In/Out/Max - 8/4/10
Program/Data Memory 4KB/2KB 4KB/2KB
Boolean Execution Time 0.22 µs 0.22 µs
Bit Relays/Counters/Timers 256/256/256 256/256/256
High Speed Counters 4 x 30 kHz 4 x 30 kHz
Real Time Clock optional optional
Pulse Outputs 2 x 20 kHz 2 x 20 kHz
Communication Interface 1x RS-485 1x RS-485
Analogue Potentiometers 1 1

SIMATIC S7-200
 Features: CPUs (2/2)
Features CPU 224 CPU 224XP CPU 226
Integrated Inputs/Outputs 14 DE/10 DA 14 DE/10 DA 24 DE/16 DA
Integrated Analogue In/Out - 2AE/1AA -
Max. Expansion Modules 7 7 7
Max. # of Dig. I/O Channels 168 168 248
Analogue Points In/Out/Max 28/14/35 30/15/38 28/14/35
Program/ 8/12 KB 12/16 KB 16/24 KB
Data Memory 8 KB 10 KB 10 KB
Boolean Execution Time 0.22 µs 0.22 µs 0.22 µs
Bit Relays/Counters/Timers 256/256/256 256/256/256 256/256/256
4 x 30 kHz
High Speed Counters 6 x 30 kHz 6 x 30 kHz
2 x 200 kHz
Real Time Clock Integrated Integrated Integrated
Pulse Outputs 2 x 20 kHz 2 x 100 kHz 2 x 20 kHz
Communication Interface 1 x RS-485 2 x RS-485 2 x RS-485
Analogue Potentiometers 2 2 2

SIMATIC S7-200
 Built-in Features
Cartridge Slot CPU Status I/O Point Internal:
LEDs Status LEDs - Power Supply
- Super Capacitor
- Clock (224(XP),226)

Communication
Port(s)

Removable Snap-On Clip 24V Sensor Mounting Holes for Panel

Terminal Blocks for DIN Rail Mounting Power Output Installation
(224(XP),226)

SIMATIC S7-200
 224XP Built-in Features
I/O Point Internal:
Status - Power Supply
LEDs - Super Capacitor
- Clock (for 224, 224XP, 226)

CPU Status
LEDs Mounting Holes
for Panel
Installation
Removable
Analogue
Terminals
Removable
Terminal Blocks
(224,226)
Cartridge Slot

Snap-On Clip
for DIN Rail Mounting
Communication 24V Sensor
Ports Power Output

SIMATIC S7-200
 SIMATIC S7-200 in detail ...
Clock and battery module
◼Real-time clock and calendar
(for 221, 222 CPU)
◼ Typically 200 days backup

Battery module
◼Backup of the internal data
(data block)
◼Typically 200 days backup

Flexible Memory Modules

◼For general program
transfer and backup
◼Data Logging Files, Recipes
Files, and General File
Storage

SIMATIC S7-200
 Diagnostic LED on
▪ All the new and improved CPUs
have a multi purpose Diagnostic LED
▪ The Diagnostic LED is combined with the System Fault LED
▪ The combined LED is either RED or YELLOW depending on the fault
▪ The Diagnostic LED is controlled by both the operating system and the user’s program by
means of the Diagnostic instruction
▪ The Diagnostic LED can be turned on when a value is FORCED or an I/O Error occurs or
the USER’s program commands it on

Diagnostic LED New Micro/Win Instruction

SIMATIC S7-200
 S7-200 Networking possibilities
S7-22X CP EM EM CP CP
243-2 277 241 243-1 243-1 IT

+ Email
+ HTML
+ FTP
Ethernet Network

Telefon Network

PROFIBUS Network (Slave)

AS Interface Field Bus

PPI/MPI Network

ASCII Protocol (FreePort)

SIMATIC S7-200
 STEP7-Micro/WIN 4.0
Setting THE Standard
in Micro PLC Programming

▪ Simple Installation and Configuration

▪ EASY to Learn, EASY to Use
▪ Comprehensive programming tool
▪ Find & Correct quickly fixes errors
▪ Tools to handle Running PLC Changes
▪ Documentation for easy maintenance
▪ Wizards simplify programming tasks
▪ Software tools
for easy commissioning

SIMATIC S7-200
 Your Choice of Editors
▪ Use the right tool for the job
▪ Ladder & FBD editors for graphic LADDER
languages (IEC 1131-3)
▪ STL for text programming
▪ Switch between editors as necessary
▪ Easy error identification
▪ Save project in any case

STL

FBD

SIMATIC S7-200
Function Block Diagram - FBD
STL- Statement List
PLC Ladder diagram
PLC PROGRAMMING
 Defining the Control Task

• Understand the function of the system

• Recognized the Sequence

• Identify the auxiliary conditions

Decide for the Control Strategy

Intuitive Method ( Conditions )

Pattern Method ( Sequence )

GRAFCET Method

Relay Pattern
 GRAFCET Method

GRAphe Fonctionnel de Commande Etape

Transition (GRAFCET) is a powerful graphical
means for the specification of controllers in
discrete event systems and an international
standard since 1988.
Elements of PLC Programming
 Addressing in Simatic Systems

I0.0 Bit addressing

TRODUCTION
PLC DEFINED
BENEFITS from PLC

PPLICATIONS IB0 Byte addressing

PARTS of PLC
LC OPERATION
PLC PROGRAMMING

IW0 Word addressing

 Addressing in Simatic Systems
Direct Addressing

Permissible Operands:

I Input 0.0 - n.7

Q Output 0.0 - n.7
M Bit Memory 0.0 - 31.7
T Timing 0 - 255
C Counter 0 - 255

n = dependent on CPU Type

S7-200 Features
Programming
 STEP SEQUENCE

▪ A drill motor is started clockwise with S1. After 3s, the feed is
activated.
▪ When the depth limit at I0.3 is reached, the feed is de-activated. A
spring returns the drill to the initial situation. In doing so, the drive turns
anti-clockwise (Q0.0 and Q0.1 are "1").
▪ When the initial situation I0.4 = "1" is reached, the drive continues to
operate for 1s until the drill is fully switched off.
▪ The drill can always be switched off with Stop (activation with I0.0 =
"0").
• A control method in which a task is broken down
into very small, usually sequential, subtasks (e.g.
Motor on, feed on, feed off, ...).
• The subtasks (functions) are called steps.
• Usually one step has to be completed before the
next one is started.
• A new step becomes active when the relevant
transition condition is active.
• A step is active when the associated step flag,
e.g. M0.1 = "1".
• Each step is started (activated) by a condition).
The condition is usually derived from the states of the machine.
These can include actuated limit switches, operator keys,
temperatures reached or timers.
• An active preceding step is almost always part of the
condition.
• If a new step flag is set, the step flag of the preceding step is
reset.
• If two or more processes must be controlled simultaneously and
independently, separate sequencers are used. This is shown in the
diagram below.
Thank You !