THE ULTIMATE GUIDE FOR PLC AND ITS

APLICATION
Table of Contents
1 Arrangement of a PLC..........................................................................................................6
1.1 Structure of a PLC .............................................................................................................................. 7
1.2 Structure of an automation unit .................................................................................................. 7
1.3 Hardware requirements .................................................................................................................... 7

Power supply unit (PS) ........................................................................................................ 8

Central processing unit (CPU) ......................................................................................... 8
Input and output module ................................................................................................... 8
MPI cable................................................................................................................................ 8
Personal computer (PC) ..................................................................................................... 8
Programming unit (PU) ..................................................................................................... 8
Hardware structure .............................................................................................................. 9
1.4 Software requirements ...................................................................................................................... 9
1.4.1 STEP 7 programming language ...................................................................... 9
1.4.2 Objects ..................................................................................................................... 9
1.4.3 Projects ................................................................................................................. 10
1.4.4 Configuring an S7-300 ...................................................................................... 11
1.4.5 Parameterization ............................................................................................. 11
2 Way of Functioning of a PLC.......................................................................................... 12
2.1 Modules of the PLC ........................................................................................................................ 12
2.1.1 Power supply unit ............................................................................................... 12
2.1.2 Program memory ................................................................................................. 13
2.1.3 Central processing unit (CPU) ........................................................................ 14
2.1.4 Bus system............................................................................................................. 17
2.1.5 Input and output modules................................................................................ 17
Program Processing and Programming ......................................................................................... 18
2.2 Linear program processing .......................................................................................................... 18
1.1 Structured programming ............................................................................................................... 19
High-speed inputs .............................................................................................................................. 46
High-speed outputs ........................................................................................................................... 46
PID control............................................................................................................................................ 46
Definition and Basic Functionality of PLCs
A Programmable Logic Controller (PLC) is a specialized industrial computer
used to control machines and processes. It is designed to withstand harsh
industrial environments and operate reliably for extended periods. The
basic functionality of a PLC includes the following key components:
Input Interface: PLCs receive signals from various input devices such as
sensors, switches, and analog devices. These inputs are used to monitor the
state of the controlled process.
CPU (Central Processing Unit): The CPU is the brain of the PLC. It executes
the control program stored in memory and processes inputs to determine
the appropriate outputs.
Memory: PLCs have two types of memory: RAM (Random Access Memory)
for storing the control program and data, and ROM (Read-Only Memory)
for storing the operating system and other firmware.
Programming Device: PLCs are programmed using specialized software on
a programming device such as a computer. The programming language
used is typically ladder logic, which resembles electrical relay logic
diagrams.
Output Interface: PLCs control output devices such as motors, valves, and
actuators based on the program's logic and input signals. The output
interface converts the signals from the CPU into commands for these
devices.
Power Supply: PLCs require a stable power supply to operate. They often
have built-in power supplies or require external power sources depending
on the application.
Communication Ports: PLCs may have communication ports for connecting
to other devices such as Human-Machine Interfaces (HMIs), SCADA
systems, or other PLCs for data exchange and control.

The basic functionality of a PLC involves continuously scanning inputs,

executing the control program, and updating outputs based on the
program's logic. PLCs are widely used in industries such as manufacturing,
automotive, and energy for automation and control applications due to
their reliability, flexibility, and ease of programming .

Relay-Based Control Systems

Relays: In the early days of industrial automation, control systems relied on
electromechanical relays. These relays were used to control electrical
circuits by opening or closing contacts in response to electrical signals.
Control Panels: Control panels consisted of numerous relays wired
together to perform logic functions. Wiring was complex and time-
consuming, and troubleshooting was difficult.
Limited Flexibility: Changes in the control logic required rewiring of the
relays, leading to downtime and increased maintenance costs. The systems
were also limited in terms of complexity and functionality.
Evolution to PLCs
Introduction of PLCs: The development of the PLC in the late 1960s
revolutionized industrial control. PLCs were designed to replace complex
relay-based control systems with a more flexible and programmable
solution.
Digital Logic: PLCs implemented digital logic using microprocessors,
memory, and input/output (I/O) interfaces. They could be programmed to
perform a wide range of control functions.
Programming: PLCs introduced programming languages such as ladder
logic, which made it easier for engineers and technicians to create and
modify control logic. Programming was done using a computer or a
dedicated programming device.
Modularity and Expandability: PLCs were modular in design, allowing for
easy expansion and modification. New I/O modules could be added without
rewiring the entire system.

Reliability and Maintenance: PLCs improved system reliability by reducing

the number of moving parts (compared to relays) and providing diagnostics
for troubleshooting. Maintenance was also simplified.

Integration with SCADA and HMIs: PLCs could be integrated with

Supervisory Control and Data Acquisition (SCADA) systems and Human-
Machine Interfaces (HMIs) for monitoring and control of industrial
processes.
Advantages of PLCs

Flexibility: PLCs can be easily reprogrammed to accommodate changes in

the control logic or process requirements.

Reliability: PLCs are more reliable than relay-based systems due to fewer
moving parts and built-in diagnostics.
Cost-Effectiveness: While initial costs may be higher, PLCs offer long-term
cost savings due to reduced downtime and maintenance.
Safety: PLCs can implement safety functions such as emergency stop and
interlocking, enhancing workplace safety.
Overall, the evolution from relay-based control systems to PLCs has
transformed industrial automation, making processes more efficient,
flexible, and reliable.
1 Arrangement of a PLC
PLCs are mass-produced. Initially, they do not yet have a task.
Manufacturers integrate all the components necessary for the
control engineering such as the logic elements, latching/unlatching
functions, times, counters, etc. and these components are linked to
form a functioning controller by means of programming. There are a
large number of different control units that differ from one another
by virtue of the following functional units:

 Inputs and outputs,

 Storage locations,
 Counters,
 Times,
 Bit memory functions,
 Special functions,
 Operating speed,
 Type of program processing.

Relatively large control units are assembled from individual

components on a modular basis. Using a modular system like this, it
is possible to start from a basic configuration and build up PLC
systems that you can customize for specific ap- plications. For
relatively small control tasks, manufacturers offer compact control
units. These are self-contained devices that have a fixed number of
inputs and out- puts.
1.1 Structure of a PLC
Automation unit Figure 2.1

Basic structure of a
programmable logic
controller

PLC

Signalling equipment Actuators or indicator lights

1.2 Structure of an automation unit

Central processing unit Program memory Figure 2.2

Basic structure of an
automation unit

Automation unit

Power supply unit Bus system

Input and output modules

 Signaling equipment supplies digital and analog signals for further processing
to the PLC,
 Actuators or indicator lights receive digital and analog signals from the PLC.

1.3 Hardware requirements

To be able to work with the examples below, you need the
following hardware components.
Power supply unit (PS)

The power supply unit converts the 120/230 V AC mains supply to

24 V DC to supply the S7-300 modules.

Central processing unit (CPU)

The central processing unit is for executing the user programs. It

communicates with other modules via the MPI interface.

Input and output module

The system inputs signal from the encoder via the input module into
the S7-300 or outputs them to the output module. An LED display
shows the signal state at the modules.

MPI cable

The MPI cable connects the computer to the central processing unit
(CPU). With- out this cable it is not possible to communicate with the
PC.

Personal computer (PC)

The PC is for configuring, parameterizing and programming the S7-300.

Programming unit (PU)

The PU is also for configuring, parameterizing and programming the S7-

300.
Hardware structure
When setting up an S7-300, you must observe slot rules. You plug in
the modules from left to right:
 You must always plug in the power supply unit (PS) as the first
module on the DIN rail,
 You must plug in the central processing unit (CPU) as the second
module,
 You plug in the input and output modules after the CPU,
 Next to the central processing unit (CPU), you may only plug in
at a maximum 8 signal modules,
 You can plug in the modules horizontally or vertically.

1.4 Software requirements

For programming the S7-300, we use the Windows XP operating
system as well as Version 3.xx of the STEP 7 software package. This
version integrates the following three methods of representation:
Statement List (STL), Ladder Diagram (LAD) and Function block
diagram (FBD). Previous versions, e.g. 2.xx did not contain the
Function block diagram (FBD) representation.
1.4.1 STEP 7 programming language
Following the replacement of SIMATIC S5 by SIMATIC S7 in the
Autumn of 1995, a new programming language (STEP 7) was
developed based on the IEC 1131 standard. This programming
language provides the entire functionality for parameterizing,
configuring and programming the S7-300 automation unit. STEP 7
runs under Windows XP and works on an object-oriented basis. The
symbols for the objects are mapped on the graphical user interface.
STEP 7 has an integrated online help system that provides valuable
hints and tips.
1.4.2 Objects
On the graphical user interface, the system represents objects with
symbols. A symbol is assigned to a specific object. STEP 7 objects offer
access to the following processing functions
1.4.3 Projects
STEP 7 allows you to divide a plant into projects. A project contains
all the data for an automation solution. You can consider a project to
be the most important object.

Figure 2.4 Task

Project
Project
structure
with SIMATIC
S7-300 Station
S7

CPU 314 Programmable module

S7 program 1 S7 program

Elevator program Modules

OB 1 FC 1 Existing modules
 The data for an automation solution is managed in a project. In
our example, the project is a lift controller. This project contains the
entire automation solution. The project includes, for example, the S7-
300 station as well as the programmable controller (PC) with the CPU
314. You enter the S7 program in this PC. The pro- gram is then broken
down into the corresponding blocks, such as, OB 1 and FC 1, for
example.

1.4.4 Configuring an S7-300

When configuring, the S7 modules are arranged in a configuration
table.
You can choose the modules from an electronic catalogue and enter
them in the configuration table to match the slot. The slot in the
configuration table corresponds to the slot on the sub rack. An
address is then automatically assigned to each module.

1.4.5 Parameterization
You can set the properties of the individual modules in various ways.
One of the parameters is, for example, cycle time monitoring with the
CPU S7-300. The parameter can be changed.
2 Way of Functioning of a PLC

2.1 Modules of the PLC

The various modules of a PLC are explained in Figure 3.1.

Power supply for signalling equipment

Signalling equipment

Power Central processing unit

Input Output
supply Program (CPU)
memory
unit module module

Processor

Actuators and indicator light

Figure 3.1 Interaction and arrangement of the modules of a PLC

2.1.1 Power supply unit

The power supply unit generates the voltage for the programmable
controller's electronic modules from the mains voltage. This voltage
is 24 V DC. The voltages for signalling equipment, actuators and
indicator lights, which are above 24 V (24 to 220 V), are supplied by
mains units or control-power transformers that are additionally
provided for this purpose.
2.1.2 Program memory
Storage elements are components in which information can be stored
in the form of binary signals. Semi-conductor components are mainly
used as program memo- ry.A memory comprises:

 512,
 1024,
 2048 etc. storage locations.

It is normal to state the capacity of program memory (i.e. the number

of storage locations) in multiples of 1 K (here, 1 K stands for 1024). In
each storage location, you can use a programming unit to write
(program) a control instruction. In this connection, each of the binary
elements of a storage location can take on a signal state of "1" or "0".

Program memory Figure 3.2

Schematic
of a
Free programmable Not free programmable program
(read-write memory)
memory

Alterable Not alterable

ROM - PROM

Erasable by ultraviolet light

EPROM - REPROM

Semi-conductor Semi-conductor

fuse memory mask memory

Semi-cond. memory Magnetic core Semi-cond. memory

RAM memory EEPROM - EAPROM

It is possible to write information to the storage locations as often as you
like.
The information is read out without its content being lost.
However, RAM is volatile memory, i.e., the information is lost when
the power supply fails or is switched off. RAM is deleted electrically.

ROM
Read-only memory contains information that cannot be deleted or
changed. ROM stands for Read-Only memory. Manufacturers enter
the information and they are the only ones who can change it.

EPROM
EPROM stands for erasable programmable read-only memory. You
can erase the entire content of the EPROM using UV light; after
this, you can reprogram it.
This makes it very suitable for transportation without data loss.

REPROM
REPROM stands for reprogrammable erasable read-only memory.
You can also only erase its contents using UV light.

EEPROM
EEPROM stands for electrically erasable programmable read-only
memory. In an EEPROM, it is possible to delete and write to each storage
location electrically.

EAPROM
EAPROM stands for electrically alterable programmable read-only
memory.

2.1.3 Central processing unit (CPU)

The voltage coming from the signals is switched to the terminal strip
of the input module. In the CPU (central processing unit, see Figure
3.3), the processor pro- cases the program in memory and when
doing this poll whether the individual inputs of the unit are carrying a
voltage or not. Depending on this status at the inputs and the
program in memory, the processor instructs the output module to
switch a voltage to the corresponding connections of the terminal
strip. Again, depending on the voltage status at the connections of
the output module, the system switches on or off the connected
actuators or indicator lights.
The address counter polls successively (on a serial basis) the
program memory instruction by instruction and brings about
program-dependent transfer of information from the program
memory to the statement register. All the memory in a processor is
normally referred to as registers.
The processor gets its instructions from the statement register. While
the processor is processing the current statement, the address
counter shifts the next statement into the statement register.
The status transfer of the inputs to the process input image (PII) is followed
by linking, application of the timers, counters, and accumulators and
transfer of the results of logic operations (RLO) to the process output image
(PIQ). If the system detects a block end (BE) after processing of the user
program, the respective status is transferred from the PIQ to the outputs.

AI 1.0
Processor Bit memories
AI 1.1

Internal timers
OI 2.0

Internal counters

OI 3.0
Process output
Statement
image for digital
register and analog
inputs and out-
puts

Peripheral bus (Bus module)

Input Output

digital and digital and

analog analog

Bild 3.3 Central processing unit (CPU)

The peripheral bus handles data exchange between the central
processing unit and the peripherals. Peripherals include the digital
input and output modules, the analog input and output modules as
well as the timer, counter and limit value modules.
2.1.4 Bus system
The bus system (see Figure 3.4) is a group line for transferring signals.
The system exchanges signals in the programmable controller (PC)
between the processor and the input and output modules across
what is known as a process bus system. The process bus consists of
three parallel signal lines:

Figure 3.4 Address bus

The bus system

Bus system

Data bus Control bus

 Using the address bus, the system addresses the addresses on

the individual modules,
 Using the data bus, the system transfers data, e.g. from the
input to the output modules,
 On the control bus, the system transfers the signals for
controlling and moni toring the function cycle within the
programmable controller.

2.1.5 Input and output modules

Using the input and output modules, the system exchanges data
with the process to be controlled.
Program Processing and Programming
You have the option of linear and structured program processing.

2.2 Linear program processing

Linear program processing (see Figure 4.1) is mostly used for simple,
not too comprehensive controllers and can be implemented in a
single organization block (OB). In this connection, the control unit
processes the statements in the order in which they are stored in the
program memory. When the end of program (BE) is reached, program
processing starts from the beginning again. The time that a con- trol
unit needs to carry out processing of all the statements once is called
the cycle time. This is why this type of processing is also referred to
as cyclical processing.

1. Statement

2. Statement

3. Statement

Figure 4.2 Linear program processing

1.1 Structured programming
With comprehensive control jobs, you divide the program into small
manageable program blocks that are arranged by function. This has
the advantage of allowing you to test program sections individually
and, if they function, to combine them into an overall function. STEP
7 provides the following user blocks for this:

1. 1. Global
Statement Statement
data
(all
FBs
Local data (FB1 only) FCs
OBs

1.
Statement

Figure 4.2 Structured programming using user blocks with: OB

organization block, FB function block, FC function, DB
data block
Organization bock (OB)
The operating system cyclically calls an OB which functions as the
interface be- tween the user program and the operating system. In
the OB, the system informs the processor of the programmable
controller (PLC) by means of block call com- mands about the
program blocks that it has to process.
Function block (FB)
FBs have an assigned memory area. When an FB is called, it is possible
to assign a data block (DB) to it. It is possible to access the data in this
instance DB by means of calls from the FB. An FB can be assigned to
different DBs. It is possible to call further FBs and FCs via block call
commands in a function block.
Because a PLC is a computer, it stores information in the form of on
and off conditions represented by ones and zeros, referred to as bits.
Sometimes bits are used individually and sometimes they are used to
represent numerical values. Understanding how these bits can be
used to represent numerical values requires an understanding of the
binary number system.

The binary system has a base of 2 and uses only two characters, 1 and
0. Each bit is associated with a power of 2 based on its position in the
number. The further to the left, the higher the power of 2. The
number in the far left-hand position is referred to as the most
significant bit or MSB, and the number in the far right-hand position is
referred to as the least significant bit or LSB. A 1 is placed in a position
if that power of 2 is used in the number. Otherwise, a 0 is placed in a
position.

The accompanying graphic shows an 8-bit binary number, but the

number of bits used varies.
Converting from Binary to Decimal

The process of converting a binary number to an equal decimal value is

as simple as adding the equivalent decimal value for each position in
the binary number where a 1 is shown. Positions with a 0 do not add to
the number value.
Logic 0 and 1

While PLCs are capable of sensing and generating analog values,

internally, PLCs use signals that are off or on.
These off and on conditions correspond to the binary values 0 and 1,
also referred to as logic 0 and logic 1.

For example, as shown in graphic 1, when an input to a PLC is off, a 0

is stored in the corresponding position in the CPU’s input process
image. And, as shown in graphic 2, when the input is on, a 1 is stored
in that position in the input process image. If that input is used in the
CPU program, the status or change in status of the input process
image bit can trigger other events.

As shown in graphics 3 and 4, the CPU program can cause an output

process image status bit to be a 0 or a 1. If the corresponding output
channel on an output signal module is wired to an output device, the
output device will be off when the status bit is a 0 and on when the
status bit is a 1.
Bits, Bytes, Words, and Double Words

Some operations performed by a PLC use individual binary bits. Other

PLC operations group binary bits to represent numerical values or
various conditions. The number of bits used by an operation depends
on the instruction.

Some instructions operate on 8 consecutive binary bits, referred to as

a byte. Other instructions operate on larger groups such as a word
(16 consecutive binary bits) or double word (32 consecutive binary
bits).
Hexadecimal

Hexadecimal is another number system used by PLCs. Each position in

a hexadecimal number represents a power of 16.

The hexadecimal system uses 16 characters. The ten digits of the

decimal system are used to represent the first ten characters of the
hexadecimal system. The first six letters of the alphabet are used for
the remaining six characters.

One of the reasons the hexadecimal system is used by PLCs is because

it allows the statuses of a large number of binary bits to be
represented in a small space such as on a computer screen or
programming device display.

Each hexadecimal character is equivalent to a four-bit binary value. If

you know the corresponding binary bits for each of the hexadecimal
characters, you can quickly convert a hexadecimal number of any
length to binary. The accompanying example, shows the equivalent
binary value for the hexadecimal number 3A2F.
Binary Coded Decimal (BCD)

While it is necessary for PLCs to use binary values, humans often

need to see values
represented in decimal. As a result, some input and output devices
provide a decimal display with each decimal digit corresponding to
four PLC digital inputs or outputs. The most common system used by
input and output devices of this type is referred to as Binary Coded
Decimal (BCD).

One example of a BCD device is a type of four-digit thumbwheel

switch. Each thumbwheel digit controls four PLC inputs. This means
that for a four-digit thumbwheel, 16 inputs are required. Because each
thumbwheel digit only needs to represent decimal values from 0
through 9, only ten corresponding binary values are required for each
digit.
Data Types

Binary bits can be used independently or as a group. When used as a group,

they are used to represent numerical values as well as other types of data.
In order to know how a bit or bit string will be interpreted by a PLC, you
must know the data type, which is the PLCs description of the data.

PLC data types of various lengths are specified for binary numbers,
integers (also called whole numbers), real numbers (also called
floating point numbers), date and time, characters, parameters,
system data, and other types of data.

Because the number of data types has increased overtime, not all data
types are available for all SIMATIC S7 PLCs.
The accompanying graphic shows the binary number, integer, and real
number data types available for S7-1200 PLCs.

Real numbers are numbers expressed in scientific notation, To convert

a decimal number to scientific notation move the decimal point to the
left or right to create a mantissa that is greater than or equal to 1, but
less than 10. Then multiply the mantissa by a power of ten to
compensate for the decimal point movement.
Page 1-22
Inputs and Outputs

Input devices are usually switching or sensors that send electrical

signals to the CPU

through input channels on input signal modules. Similarly, output

devices receive electrical signals from the CPU through output
channels on output signal modules. These output devices are
sometimes called actuators and are used to control a machine or
process.

PLCs have two broad categories of inputs and outputs (I/O), digital
I/O and analog I/O. Digital I/O devices, also called discrete I/O
devices, are either on or off and are connected to digital I/O
channels. Analog I/O devices use continuously variable voltage or
current signals and are connected to analog I/O channels.

Each analog input signal is converted by an analog input signal

module to a stream of numerical values represented in binary. This is
necessary for the CPU to process this information. Because each
analog output device requires a variable voltage or current signal, the
stream of numerical values provided from the CPU is converted by an
analog output signal module to an analog signal compatible with the
associated device.

Page 1-23
CPU

The central processing unit (CPU) is a microprocessor- based system

that contains the
system memory and is the PLC’s decision-making unit.

The CPU monitors the inputs, outputs, and other variables and makes
decisions based on instructions stored in its user program memory.

Some SIMATIC S7 CPUs have input and output points in the same
enclosure with the CPU. For example, the
S7-1200 CPU shown in the accompanying graphic has 14 digital
inputs,10 digital outputs, 2 analog inputs, and 2 analog outputs.

Page 1-24
CPU Scan

The PLC’s user program is executed by the CPU as part of a repetitive

process referred to as a scan. After startup, a typical CPU scan
includes the following steps.

• The CPU reads the statuses of inputs.

• The CPU executes the user program.
• The CPU performs internal diagnostic and
communication tasks.
• The CPU updates the statuses of outputs.

This process is repeated continuously as long as the PLC is in the run

mode.

The time required for a scan depends on the capabilities of the CPU,
the size of the user program, the number of inputs and outputs, and
the amount of communication required.
However, because PLC CPUs are very fast, this time is typically
measured in milliseconds. This means that the response time for a
PLC is also very fast.

Page 1-25
User Program

The first PLCs were designed for use in the automotive industry in the
late 1960s.

Prior to that time, control of an auto assembly line relied heavily on

electromechanical relays, contactors, timers, and related devices.

Because the hard-wired circuits replaced by PLCs used control circuit

diagrams referred to as ladder diagrams, early PLCs used ladder
diagram software programs, sometimes referred to as ladder logic, to
make it easier for someone familiar with control circuits to program a
PLC. Unfortunately, every PLC manufacturer had its own version of
ladder diagram programing. This variation in programming grew as
PLCs were developed to handle a wider range of tasks.

Today, most PLCs can still use ladder diagram (LAD) programing, but
the IEC 61131 international standard now defines this PLC
programming language. This same standard also defines other types
of programming languages available for PLCs, so that they can be
used for the even the most complex applications.

Page 1-26
PLC Communication

communication used is serial communication, where bits are sent and

received one at a time. Serial communication is still used with some
devices; however, more often, PLCs use network communication.

For example, Industrial Ethernet is a high-performance network that

uses industrial-grade switching technology. An Industrial Ethernet
switch is an active network component that allows multiple devices to
communicate simultaneously at high speeds.

PROFINET is an open Industrial Ethernet standard and the leading

Industrial Ethernet standard world-wide.
PROFINET IO, the most widely-used form of PROFINET, handles both
non-time-critical IT communications and the full range of real-time
control communications.

Another network type used is PROFIBUS, which is an open fieldbus

standard. A fieldbus is a multi-drop network that provides a
standardized approach for communication with devices commonly
used for factory automation or process control. The version of
PROFIBUS most widely used in factory automation applications is
PROFIBUS DP.

Page 1-27
Virtual Instructor-led Learning

Siemens virtual instructor-led courses offer students a live, classroom

experience

with the convenience and cost savings of online learning. These

courses provide hands-on instruction and live interaction, delivered
anywhere an internet connection is available.

Scheduled courses are typically 10-hour agendas presented Monday

through Friday in two-hour sessions. These sessions provide students
with lecture, demonstration, lab exercises, and Q&A sessions – all
presented by Siemens subject matter experts.

For the full course duration, students can complete assignments and
reinforce classroom instruction using a virtual cloud-based application
providing 24/7 access to fully functional Siemens software such as
SIMATIC STEP 7 and PLCSIM.

Page 1-28
S7-1200 PLC System Overview

SIMATIC S7-1200 basic controllers are part of the SIMATIC S7 family of

PLCs and are

designed to handle a wide variety of small to medium-sized

automation tasks.

Like more advanced S7 PLCs, S7-1200 controllers are configured and

programmed using TIA Portal software which allows efficient
engineering approaches to be employed for Siemens S7 PLCs, HMIs,
and other automation products.

Because automation tasks vary in complexity, Siemens offers other

controller options that allow common design concepts and
approaches to be employed over the full range of applications.

Page 2-29
 S7-1200 CPU Features

enclosure with the CPU. By flipping down the hinged doors, you can
easily gain access to removable input and output wiring connectors.
Status LEDs associated with the I/O points and CPU status LEDs are
visible on the front of the CPU.

A signal board can be installed in the CPU to add digital or analog input
or output channels. Alternatively, a battery board can be installed to
provide long term backup for the CPU’s real-time clock, or a
communications board can be installed to provide a serial
communication port.
S7-1200 CPUs are available in three versions, standard CPUs, failsafe
CPUs (described later in this course), and SIPLUS CPUs (for use in
extreme environmental conditions).
S7-1200 CPUs have internal memory for various functions including load
memory, which stores the user program, data, and configuration
information. Alternatively, load memory can be stored on a SIMATIC
memory card installed in a slot behind the upper hinged door.

S7-1200 CPUs have one or two PROFINET ports.

Page 2-3

S7-1200 CPUs have a small number of inputs and outputs in the same
S7-1200 Standard CPU Model

Key features of S7-1200 standard CPUs are shown in the accompanying

graphic. All

models are 100 millimeters (mm) high by 75 mm deep, but vary in

width from 90 mm for CPU 1211C and CPU 1212C to 150 mm for CPU
1217C.

Each CPU model, except CPU 1217C, is available in the following three
power configurations: DC/DC/DC, DC/DC/RLY, and AC/DC/RLY. CPU
1217C is available in the DC/DC/DC power configuration.

The first two letters designate the type of CPU power required. DC
indicates that 24 VDC is required, and AC indicates that 120 or 230 VAC
is required.

The second two letters indicate the type on-board digital input
channels provided. In all cases, 24 VDC input channels are provided.

The remaining letters indicate the type of on-board digital output

channels provided. DC indicates that 24 VDC output channels are
provided, and RLY indicates that relay output channels are provided.
Relay outputs can be used with AC or DC power.

Page 2-4
S7-1200 CPU Memory

S7-1200 CPUs have the following user memory types.

• Load memory is non-volatile memory for the user program,
program data, and configuration information. Load memory is
located either in in the CPU or on a SIMATIC memory card. SIMATIC
memory cards are available in a range of sizes, including sizes that
are greater than the internal load memory for any CPU. A SIMATIC
memory card can also be used to transfer load memory content to
another CPU.

• Work memory is volatile storage for some elements of the user

program. The CPU copies these elements from load memory into
work memory during program execution. This is volatile memory,
so the information is lost when CPU power is lost, but is restored
by the CPU when power resumes.

• Retentive memory is non-volatile storage for a limited quantity

of work memory content.

• Much of the data used by the user program is stored in data bocks
in the user program. However, CPUs also have global memory
areas that are accessible by the user program. These include bit
memory (M) and image tables for inputs (I) and outputs (Q).

Page 2-5
CPU Modes and CPU Status LEDs

The current mode for the CPU is indicated by the RUN/STOP CPU
status LED. S7-

1200 CPUs have the following three operating modes.

• In the STOP mode, the CPU is not executing the user program
and a new program can be downloaded to the CPU.
• In the STARTUP mode, the CPU executes any startup logic, if
present.
• In the RUN mode, the CPU executes the PLC scan repeatedly.

The CPU mode is determined by a software setting and whether or not

a critical CPU error has occurred. In the event of a critical error, the
CPU goes into the STOP mode.

Adjacent to the RUN/STOP status LED are the ERROR and MAINT
status LEDs .

Page 2-6
Module Installation

S7-1200 hardware has a compact design to save control panel space.

In addition,

for mounting flexibility, S7-1200 modules can be mounted in either

a horizontal or vertical position.

All SIMATIC S7-1200 modules have built-in clips that allow for easy
and convenient mounting on a standard 35 mm DIN rail. These clips
can also be snapped into an extended position to provide mounting
holes for panel mounting.

When additional I/O is required beyond what is available on-board,

all CPUs, except the CPU 1211C, allow signal
modules to be mounted to the right of the CPU. CPU 1212C permits the
addition of two signal modules, and the remaining CPUs permit the
addition of eight signal modules. Once the signal module is in place,
the bus connector on the front of the module is moved to the left to
allow the module to communicate with the CPU.

All S7-1200 CPUs have at least one built-in PROFINET port, CPU 1215C
and CPU 1217C have two PROFINET ports. For other types of
communication, all CPUs can be equipped with up to three
communication modules mounted to the left of the CPU.

Page 2-7
Signal Boards

Digital input devices provide an on or off signal to a PLC, and digital

output devices

turn on or off in response to a PLC signal.

Analog input devices provide a variable current or voltage, such as 4 to

20 milliamps or 0 to 10 volts, representing a condition in a machine or
process, and analog output devices require a similarly variable signal
from the PLC. In addition, analog input devices such as thermocouples
and resistance temperature detectors (RTDs) provide variable signals
that require special processing.

A digital I/O device connects to an S7-1200 PLC through to a digital I/O

channel on a CPU, digital signal board, or digital signal module.
Similarly, an analog I/O device connects to an S7-1200 PLC through an
analog I/O channel on a CPU, analog signal board, or analog signal
module.

A signal board can be added to the CPU to increase the CPUs I/O
channels without increasing the size of the CPU. As shown in the
accompanying graphic, various signal boards are available to add digital
or analog I/O channels.

Page 2-8
Signal Modules

Signal modules have channel status LEDs with numbers that match
the corresponding input or output terminals. The indicators are
numbered in groups with the first input or output per group
associated with terminal “.0” for that group.

A digital signal module I/O channel LED is green and turns on or off to
indicate the on or off state of the individual input or output. An analog
signal board or module channel LED is green when the channel has
been configured and is active. An analog channel LED is red when there
is an error condition.

In addition, all signal modules have a diagnostic (DIAG) LED that is

green when the module is operational and red when the module is
defective or non-operational.
The accompanying graphic shows a combination digital
input/output signal module and a combination analog
input/output signal module and lists the various standard signal
module types available. S7-1200 PLC signal modules have
removable terminal strips that speed module replacement by
allowing field wiring to remain in place when a module is
removed.

Page 2-9
Energy Meter Module

The accurate recording of energy consumption is essential for

enterprise energy

management. The SM 1238 Energy Meter module provides cost-

efficient, entry-level, machine- oriented energy management. At just
45 mm wide, this module is extremely compact and saves space in
the control cabinet.

The Energy Meter module enables energy management with up to

200 measured energy values. It records electrical values in a single or
three-phase network and measures voltages up to 480 VAC. External
current transformers (1 A or 5 A) with a conversion factor of up to
10,000 are used to sense the current.

The measured energy data can be processed directly in the CPU and
visualized on an HMI such as a SIMATIC HMI Basic or Comfort Panel.

Page 2-10
I/O Link Master Module

IO-Link is an open communication standard developed by the IO-Link

research group

of the PROFIBUS & PROFINET International organization in response to

the need for a simple, low-cost way to allow actuator and sensor
communication in a concentrated area, such as for a control panel or
individual machine. IO-Link is a point-to-point system, not a fieldbus. It
uses an unshielded, three-wire cable, a 24 VDC power supply, and an
IO-Link master.

The SM 1278 4 x IO-Link Master is a 4-port module that functions as

both a signal module and a communication module. Each port can
operate in the IO-Link mode, for connection to an IO-Link device, as a
24 VDC digital input, or as a 24 VDC digital output.

Page 2-11
Communication Board and Modules

All S7-1200 CPU models have one or two built-in PROFINET ports
and can also

have one CB 1241 communication board installed in the CPU to

provide an RS-485 serial communication port for point-to-point
communication. S7-1200 PLCs can have up to three
communication modules mounted to the left of the CPU.

S7-1200 PLC communication modules are available for PROFIBUS DP,

AS-Interface (AS-i), or other fieldbuses and for point-to-point serial
communication or wireless communication.

A CM1243-5 PROFIBUS DP Master module can be installed to allow an

S7-1200 PLC to function as a master device, or a CM 1242-5 PROFUS
DP Slave module can be installed, to allow an S7-1200 PLC to function
as a slave device.

AS-Interface (AS-i) is a fieldbus that simplifies the interconnection

of actuators and sensors. A CM 1243-2 AS-i Master module can be
installed to allow an S7-1200 PLC to function as an AS-i master.

Page 2-12
Communication Board and Modules

Telecontrol refers to the connection of control stations spread out over

a wide area to

one or more central control systems.

An S7-1200 PLC functioning as a remote station, also called a remote

terminal unit (RTU), requires a communication processor (CP) to
securely communicate with the central control system. The CP
incorporates a combination of security functions including a firewall
and protocols for data encryption.

GPRS CP 1242-7 communication processor supports Telecontrol

applications using general packet radio service (GPRS).

CP 1243-1 communication processor supports Telecontrol applications via an

Ethernet network or the Internet.

CP 1243-1 DNP3 and CP 1243-1 IEC communication processors support

Telecontrol with standardized remote-control protocols.

Page 2-13
Scalable and Flexible Design

Page 2-14
Chapter 2 - S7-1200 PLC

This chapter covers the following

topics:
• S7-1200 PLC Overview
• S7-1200 with Safety Integrated

Page 2-15
Functional Safety

Safety is a relative term because it is impossible to eliminate all risk

from a system

or operation. From a practical perspective, this means that a prime

objective of system design is to eliminate unacceptable risks to
people and property.

An important aspect of risk elimination is achieving functional safety,

which eliminates unacceptable risk by ensuring that all parts of a
machine or system function in a safe manner. Failsafe is another
term often used in this context. Even the best designed equipment
has some potential for failure, but a failsafe device or system is one
that will not cause injury or damage when a failure occurs.

Achieving functional safety requires that the safety-related parts of

the protection and control systems function correctly. In addition,
the systems must behave in such a way that either the plant remains
in a safe state, or it is put into a safe state if a fault occurs.

To accommodate the wide range of functional safety applications,

Siemens offers the full range of safety-related products from basic
components to the most innovative solutions.

Page 2-16
European Machinery Directive

Although safety standards vary throughout the world, you may need
to know about

the European Machinery Directive even if you do not work in a

European manufacturing plant. Compliance with this directive is
required for machinery operated in many European countries
regardless of where the machinery was designed and manufactured.
In addition, some international companies with factories in Europe
design machinery intended for use outside of Europe consistent with
the Machinery Directive to avoid the cost and complexity of multiple
machine designs.

Conforming to the Machinery Directive requires machine

manufacturers to perform a risk assessment of a machine design. This
risk assessment must identify and evaluate all hazards associated with
a machine. In addition, the machine manufacturer must take steps to
reduce the risks to an acceptable residual level and must document
proof of compliance.

To simplify the process of risk assessment, Siemens offers a free,

online Safety Evaluation Tool that guides the user step-by-step through
an evaluation of the safety functions of a machine and provides a
report that can be integrated in the machine’s documentation as proof
of functional safety.

Page 2-17
Safety Integrated for Factory Automation

While localized safety applications are common for individual

machines or factories

with limited automation, many factories require safety systems that

integrate with automation solutions. Siemens Safety Integrated for
Factory Automation solutions include automation systems, drive
technology, operator control and monitoring systems, safe industrial
controls, and the software to simplify component and system
engineering.

Safety Integrated products and systems permit the seamless

integration of safety technology with standard automation. This
integration of standard and safety technology offers considerable
benefits for enhanced competitiveness for both machine
manufacturers and the end users of their machines.

Machine manufacturers benefit from reduced hardware and

significantly simplified engineering that speeds the design of
machines and systems. End users benefit from the increased safety
and productivity provided by the use of safe machines and systems.

Page 2-18
S7-1200 Failsafe CPUs

S7-1200 failsafe CPU 1212FC, CPU 1214FC, and

CPU 1215FC are available in the following power configurations:

DC/DC/DC and DC/DC/RLY. This means that the CPU and on-board
input channel power must be 24 VDC for all models. The last two
letters designate the on-board output channel power requirements.
DC indicates that 24 VDC is required and RLY indicates that relay
output channels are provided. Relay outputs can be used with AC or
DC power.

An S7-1200 failsafe system requires a failsafe CPU and failsafe signal

modules. The CPU’s on-board I/O channels are not failsafe, but can be
used for other control functions.

S7-1200 failsafe CPUs can used for both standard and safety-related
applications. S7-1200 standard signal modules, communication
modules, and signal boards can be used in the same system to perform
functions that do not require a rated Safety Integrity Level. This
reduces the wiring required in comparison to conventional solutions
with separate safety systems.

Page 2-19
S7-1200 Failsafe Signal Modules

The accompanying graphic shows the available S7-1200 failsafe signal

modules.

SM 1226 F-DI 16 x 24 VDC has 16 input channels for connection to 24

VDC sensors or switches. The module has two sensor supplies that can
each power eight external inputs.

SM 1226 F-DQ 4 x 24 has four output channels that

are each rated for connection to 24 VDC at up to a 2.0 A.

SM 1226 F-DQ 2 x Relay has two output channels. Each channel has
two contacts in series controlled by independent relay coils.

S7-1200 failsafe signal modules have two processors. The processors

monitor each other and verify that they are executing the same code
at the same time, automatically test the I/O circuits, and set the
module to a safe state in the event of a fault.

Communication between the failsafe CPU and the failsafe signal

modules is verified using the PROFIsafe protocol.

Page 2-20
SIMATIC S7-1200 with Safety Integrated

Page 2-21
Chapter 3 - S7-1200 PLC Programming

This chapter covers the following

topics:
• Programming Concepts
• LAD Programming Basics
• LAD Timers and Counters

Page 3-1
TIA Portal

Siemens Totally Integrated Automation Portal (TIA Portal) is

engineering software

that is used in all phases of the design, operation, and maintenance

of systems that can include Siemens PLCs, HMIs, PCs, electronic
drives, and related devices.

TIA Portal combines the software editors needed for these various
tasks in one engineering tool with a common layout and navigation
design. This integrated, intuitive approach speeds the learning process
and also allows experienced users to function more efficiently.

At the start of a project, the user can choose between the portal
view, which guides the user through each engineering step, and the
project view, which offers fast access to all the relevant tools. With
one click a user can toggle between views.

The portal view is a good place to start for a new user or anyone who
wants to logically proceed with the development of a new project or
continue with the development of an existing project. The available
tasks are clearly identified, such as “Create new project,” Configure a
device,” or “Write PLC program.”

Page 3-2
STEP 7 Basic (TIA Portal)

STEP 7 Basic (TIA Portal) is used for the configuration and

programming of S7-1200

PLCs and related devices. This can also be done using STEP 7
Professional (TIA Portal); however, STEP 7 Basic (TIA Portal) is a more
economical approach when other PLC models are not being used. Both
STEP 7 Basic (TIA Portal) and STEP 7 Professional (TIA Portal) simplify
project design and allow for online diagnostics of operational systems.

STEP 7 Basic supports the following IEC 61131 PLC programming

languages:

• Ladder diagram (LAD), shown the accompanying figure, is a

graphical programming language originally derived from
electromechanical control circuit diagrams, but which has been
expanded to include much more advanced capabilities.
• Function block diagram (FBD), is a graphical programming
language similar in capabilities to LAD.
• Structured control language (SCL) is a high-level, text- based PLC
programming language. SCL is particularly suitable for the high-
speed programming of complex algorithms and arithmetic
functions.

Page 3-3
Security Integrated

Security functionalities are integrated in TIA Portal and S7-1200 to

provide know-

how protection, copy protection, access protection, and

manipulation protection.

Know-how protection - Algorithms can be protected against

unauthorized access and modifications. Machines are protected from
unauthorized replication.

Copy protection - Program blocks on the SIMATIC Memory card are

linked to the serial number of the memory card and will only run with
the intended memory card.

Access protection - Access protection functionality offers security

against unauthorized project changes. Permission levels can be used to
grant separate rights to different user groups.

Manipulation protection - The system helps to protect the data being

transmitted to the controller from unauthorized manipulation and
detects manipulated firmware updates.
The system provides protection from network attacks such as
infiltration of fake/recorded network communication.

Page 3-4
Modular Programming

A PLC program can be organized as a linear program or a modular

program. As

shown on the left in the accompanying graphic, a linear program has

all the instructions in one block and executes these instructions in
sequence in each PLC scan. A linear program works well when the
program is simple and does not need to vary from one PLC scan to
another.

As shown on the right in the accompanying graphic, a modular

program is composed of multiple program blocks. Some program
blocks are executed in each PLC scan and other program blocks are
executed under special circumstances, such as during startup, at
specific times, or when an error or interrupt occurs. An interrupt is a
special signal or condition that causes a PLC to immediately perform
a specific task.

In programming terminology, when a program block initiates another

program block, the initiating block is said call the other block. This
causes the calling program block to temporarily halt its execution until
the called program bock completes its execution. Then the calling block
resumes its execution.

Page 3-5
Nesting

As shown in the accompanying graphic, program blocks can also be

nested. This

means that one program block can call another program block which
can call another program bock. This provides additional flexibility in
programming.

As compared to a linear program, a modular program with program

blocks that perform functional tasks is easier to understand, develop,
and debug. In addition, a modular program often performs better
because it can vary the tasks from one PLC scan to another based on
the needs of the application.

Page 3-6
Program Blocks

An S7 PLC program can include data blocks (DBs) and three types of
program

blocks: organization blocks (OBs), function blocks (FBs), and functions

(FCs). Program blocks are blocks that include instructions.

Organization blocks (OBs) define the structure of the program. Every

program must have at least one OB. If it has only one OB, that block is
identified as OB 1. OB 1 is the main program block, and it controls the
execution of the user program. OB 1 is also called a program cycle OB
because it is executed each scan cycle while the CPU is in RUN mode.
A modular program can be composed of multiple OBs, each with a
unique number.

FCs and FBs are often referred to as subroutines. A subroutine is a

portion of a program that is executed when certain conditions are
met. FCs and FBs contain the program code that performs specific
tasks. An FB uses an associated data block, called an instance DB, that
stores data for that FB. Another type of data block, called a global
data block, contains data that is available to any program block. An FC
does not have an instance data block, and the output data values from
the FC must be written to a memory address or to a global DB.

Page 3-7
Assigning Memory Areas to Instructions

An S7 PLC CPU provides the following options for storing data associated
with a user program.

• Global memory is memory that is accessible by all program

blocks. Global memory includes a variety of specialized
memory areas, such as inputs (I), outputs (Q), and bit memory
(M).
• Data blocks (DBs) are used to store data. A global DB stores data
that can be used by any program block, while an instance DB stores
data for a specific function block (FB).

When you program instructions, you must specify which data values
the instruction will process. These values are referred to as operands.
An operand can be a constant, an operand which directly identifies a
memory location, or a tag.

Tags are symbolic alphanumeric operands that are useful because they
aid understanding of the program. Tags are listed in a PLC tag table,
which also identifies the associated memory location and other
information. Tags appear in the program in quotation marks when the
tag data is available to any program block and preceded by # when the
data is associated with an instance DB.
Page 3-8
Data Types

Data type is a short way of saying a description of the data. There are a
variety of data types, which are often represented by shorthand names
such as Word or Sint.
These shorthand names are useful to understand when developing a
program.

For example, the accompanying upper graphic shows a that the data type
for an instruction is selected during programming. When making this
selection, it is important to make sure that the data type is compatible
with the operands associated with the instruction.

The data type is also among the values that must be selected when a tag is
set up. The PLC tag table shows the data type and other important
information for PLC tags.
 STEP 7 Safety (TIA Portal)

(TIA Portal) are used for the configuration and programming of failsafe
applications. STEP 7 Safety Basic (TIA Portal) is used with either STEP 7
Basic (TIA Portal) or STEP 7 Professional (TIA Portal). STEP 7 Safety
Advanced (TIA Portal) requires STEP 7 Professional (TIA Portal).

All the configuration and programming tools needed for a safety

program are integrated into the STEP 7 user interface and use a
common project structure. You create a safety program using the
program editor and program failsafe FBs and FCs in FBD or LAD
programming languages using the instructions from the safety
package.

Safety checks are automatically performed and additional failsafe blocks

for error detection and error reaction are inserted when the safety
program is compiled. This ensures that failures and errors are detected
and appropriate reactions are triggered to keep the system in a safe
state.

A standard program can function with a safety program in a failsafe

CPU because the safety-related data is protected from being
unintentionally affected by data of the standard user program.
Page 3-10

SIMATIC STEP 7 Safety Basic (TIA Portal) or STEP 7 Safety Advanced

Classroom Learning

Studies indicate that when students practice what they have learned
in a classroom

setting they retain 75% of the lesson, as compared with lecture-only

settings where
they retain just 20% of the lesson.

Our learning content is reviewed and approved by Siemens technical

and operational experts to ensure compliance with the highest
industry, health, safety, and environmental standards. Siemens
simulator workstations provide a safe and risk-free platform for job
training, project testing, design engineering, and troubleshooting.

We combine technology and industry experience to deliver highly

effective, customized learning programs.
• Job targeted courses
• Hands-on learning and skill building
• System-level training approach
• Extensive schedule of classes
• Various media and course length options
• On-site and custom courses
• Multiple training center locations
• Packaged services and products

Page 3-11
Chapter 3 - S7-1200 PLC Programming
 Ladder Diagram (LAD) Programming

Ladder Diagram (LAD) programming is one of the programming

languages defined in

the IEC 61131 specification. LAD is a graphical programming language

originally derived from the diagrams used in electromechanical control
circuits, but which has been expanded to include much more advanced
capabilities.

A LAD program or program block is composed of networks. For

example, the accompanying graphic shows two completed networks
and one network yet to be programmed. The networks in a program
or program block are numbered consecutively beginning with network
1, the top network. Because the networks in a LAD program resemble
the rungs of a ladder, a network is sometimes referred to a rung.

Each network is made up of instructions that are interconnected both

graphically and in the order of execution of instructions. As a result,
when a network is scanned, it is scanned from left to right beginning
with the instructions closest to the power rail, which is the vertical
line shown on the left in each network.

Page 3-12
Instructions and Operands

PLCs store information as binary numbers. One of the ways that PLCs
use these binary

bits is to represent the on or off condition of inputs and outputs.

Input (I) and output (Q) bits in the process image along with a type of
memory called bit memory (M) are collectively called global memory
because these memory areas are available throughout the user
program.

Most instructions in a PLC program interact with one or more bits,

bytes, words, double words in the CPU memory. The amount of
memory used by an instruction depends on the type of instruction.
The specific memory location or locations used are identified by one
or more operands associated with an instruction.

For example, the instructions shown in the accompanying graphic

each use a one-bit memory location. The operand for the normally
open contact instruction indicates that this instruction is controlled
by the I3.2 status bit, and the operand for the output coil instruction
indicates that this instruction controls the Q4.1 status bit. Often
times only tags such as “jogMotor2” or “motor2” are displayed, but
tags also define memory locations and related information.

Page 3-13
Bit Logic Instructions

Because the LAD programing language includes many instructions,

STEP 7 groups

instructions into categories. As shown in the accompanying graphic,

there are a number of basic and extended instruction categories.

This lesson provides examples of some of the instructions in the bit

logic category. Bit logic instructions are so called because they
perform logical operations using single-bit memory locations.

Page 3-14
Power Flow

Because LAD programming was originally based on control circuit

diagrams, some

electrical terminology is used in describing a LAD program. For

example, even though a network in a LAD program is an arrangement
of computer instructions, each network in a LAD program is said to
control power flow from the power rail.

As the PLC scans the user program from top to bottom in a program
block, each network is scanned from left to right. Scanning a network
means that the PLC’s CPU is examining the logical conditions
described by the instructions to determine if power flows through the
network. In programming terminology, this examination of logical
conditions is called solving the logic and the solution of a
configuration of instructions is called the result of logic operation
(RLO).

Using the simple network shown in the accompany graphic as an

example, when the normally open contact instruction permits power
flow to the output coil instruction, output Q4.1 is on. When the
normally open contact instruction does not permit power flow,
output Q4.1 is off.

Page 3-15
Contact and Coil Instructions

The accompanying graphic shows four of the most often used LAD
instructions, the

normally open and normally closed contact instructions and the output
coil and inverted output coil instructions. It is important not to confuse
the names of these instructions with any electrical device.
Therefore, you should to memorize the following rules and use them
when interpreting a bit logic network.

• Normally open contact instruction: The contact is closed when

the status bit specified by the operand is 1. When the status bit
specified by the operand is a 0, the contact is open and will not
pass power flow.
• Normally closed contact instruction: The contact is closed when
the status bit specified by the operand is 0. When the status bit
specified by the operand is 1, the contact is open and will not pass
power flow.
• Output coil instruction: This instruction sets the status bit specified
by the operand to 1 when the instruction receives power flow.
When this instruction does not receive power flow, the status bit
specified by the operand is 0.
• Inverted output coil instruction: This instruction sets the status
bit specified by the operand to 1 when there is no power flow to
the instruction. When this instruction receives power flow, the
status bit specified by the operand is 0.

Page 3-16
Contact and Coil Instruction Examples

To understand how these rules work, consider the two networks

shown in the

accompanying graphic. For each network there is an associated truth

table shown to the right of the network. A truth table is one way to
show all the possible logical combinations associated with a network
and the resulting logic condition for each combination.

First, consider the truth table conditions for the top network. Note
that for both contacts to be closed at the same time I2.4 must be 1
and I3.5 must be 0. This is the only condition that will cause power
flow to the output coil instruction, resulting in Q3.2 being set to 1.

Next, consider the truth table conditions for the bottom network.
Because the final instruction is an inverted output coil instruction,
anytime there is no power flow to this instruction, output Q4.1 will be
set to 1. The only time that Q4.1 is 0 is when I2.4 is 1 and I3.5 is 0.

Page 3-17
AND, OR, and Exclusive OR Functions

Three of the most common Boolean logic functions are the AND, OR,
and Exclusive OR

(XOR) functions. These functions can be easily represented in a LAD

program.

For example, the top network in the accompanying graphic shows an

AND function. For this network, as the associated truth table shows,
the only condition that causes the output coil to turn on and the Q2.1
status bit to be set to 1 is when the I3.2 and I4.4 status bits are both 1.
The AND function can be easily expanded by adding additional
contacts in series.

The middle network shows an OR function. For this network, as the

associated truth table shows, if the status bits for either or both of the
normally open contact instructions are 1, the Q2.1 status bit is set to 1.
The OR function can be easily expanded by adding more contacts in
parallel.

Another common Boolean logic function is shown at the bottom. This is

called the Exclusive OR (XOR) function. As the truth table for this
function shows, Q2.1 is 1 if either I3.2 or I4.4 is 1. If I3.2 and I4.4 are in
the same state, Q2.1 is 0.

Page 3-18
Instructions that Set and Reset Bits

The term set is often used to mean causing a 1 to be written to the

operand, and the

term reset is often used to mean causing a 0 to be written to the

operand. There are a variety of LAD instructions that set and reset
bits.

For example, the accompanying graphic shows networks that include

the set and reset coil instructions. When there is power flow to the
set coil instruction, the bit specified by the instruction’s operand is
set to a 1.

In this example, when I4.3 goes from 0 to1, the corresponding normally
open contact instruction closes and provides power flow to the set coil
instruction. This causes output Q5.1 to be set to 1. Q5.1 remains a 1
even if I4.3 returns to 0.

When there is power flow to the reset coil instruction, Q5.1 resets to 0.
In this example, this happens when I4.5 goes to
1. There can be multiple networks in between the set and reset coil
networks, and the set and reset coil networks can each have multiple
contacts to establish the logical conditions for the set and reset
operations.

Page 3-19
Set Reset and Reset Set Flip-flops

Two other instructions that set and reset bits are the set reset and the
reset set flip-flops. Both networks perform a similar function. When there is
power flow to the set (S) input, the output (Q) and the memory bit
specified by the operand at the top of the instruction both go to 1. They
remain a 1, even if there is no power flow at the set input, until there is
power flow at the reset (R) input.

There is one important difference between these instructions. For the

reset set flip-flop, the set input is dominant. For the set reset flip-flow,
the resent input is dominant.

The significance is that, if there is power flow at both the set and reset
inputs, the dominant input controls the result. In other words, with
power flow at both the set and the reset inputs, the output and
memory operand for the set reset
flip-flop are both 0. For the reset set flip-flop, with power flow at
both the set and the reset inputs, the output and memory operand
are both 1.

In the examples shown, note that a bit memory (M) address is used as
an operand. Using a bit memory address avoids the problem of picking
an I or Q operand that could otherwise be associated with I/O devices.
Page 3-21
Motor Start-Stop Circuit

Three-phase AC motor start-stop control is a basic PLC application.

Consider how AC

motor control is often done using hard-wired circuits.

The upper portion of the diagram is called the power circuit, because
power to the motor flows through a circuit breaker and a motor
starter composed of a contactor and an overload relay.

Power to the control circuit is through a control transformer. The

pushbuttons are wired to control the flow of current to the starter
coil, which is part of the motor starter contactor. An auxiliary contact
that is part of the contactor is also wired into this circuit as is a
contact that is part of the motor starter overload relay.

Because the stop pushbutton and overload relay contacts in the control
circuit are normally closed, when the start pushbutton is pressed,
current flows through the starter coil, which closes both the motor
starter’s main contacts and the auxiliary contact in the control circuit,
and the motor starts. Because the auxiliary contact is now closed, even
when the start pushbutton is released, current continues to flow
through the starter coil and the motor continues to run.

Page 3-22
PLC Motor Control

Motor start-stop control is a common application for a PLC. Note that

the power

circuits are not wired to the PLC and the hard-wired control circuit has
been replaced by the PLC and the devices connected to it.

The input and output devices shown are not interconnected in the
same way as for the hardwired circuit. It is only after the PLC has been
configured and programmed that the inputs can be used to control the
starter coil.

Consider how the motor start-stop control should function. When the
start pushbutton is pressed, as long as the stop pushbutton is not also
pressed and the normally closed overload relay contact is closed, the
starter coil energizes, closing the contactor’s contacts and starting the
motor. The starter coil remains energized, allowing the motor to
continue to run, when the start pushbutton is released.

When the stop pushbutton is pressed, the starter coil de- energizes,
opening the contactor’s contacts and removing power from the motor.
The third input to the PLC is a normally closed contact that is part of
the overload relay. When the overload relay senses an overload, this
contact opens and the motor stops.

Page 3-23
PLC Motor Control Program

Consider how this could be programmed in a SIMATIC S7 PLC. For

simplicity, this

example has the three inputs wired to one input signal module that
has been set up so that the input addresses used are I4.0, I4.1, and
I4.2. These inputs could have been wired to separate input signal
modules or to integrated digital input signal channels, if available. The
output signal module has been set up so that the output address used
is Q2.0.

The I/O address assignments determine which process image status bit
is associated with each input and output. The operand for each
instruction determines which process image status bit is associated
with that instruction.

All the instructions needed are in one network. Recall that a normally
open contact instruction is open when the associated process image
status bit is 0 and closed when the associated process status bit is 1.
This means that, for the current state of the inputs, the I4.1 and I4.2
normally open contacts are closed, and the other two normally open
contacts are open. The output coil instruction controls the associated
output process image status bit, causing it to be 0 when there is no
power flow to the instruction, so output Q2.0 is off, and the motor is
not running.

Page 3-24
Starting the Motor

Note what happens when the start pushbutton is pressed. The I4.0
process image

status bit is set to 1, causing the I4.0 normally open contact to close,
and providing power flow to the output coil instruction. This sets the
Q2.0 process image status bit to 1 and turns on output Q2.0.
When output Q2.0 turns on, the starter coil for the motor energizes,
and the motor starts.

On the next scan of the PLC, with the Q2.0 process image status bit set
to 1, the Q2.0 normally open contact closes. With this contact closed,
there will still be power flow to the output coil instruction even after
the start pushbutton is released, and the motor will continue to run.

The motor will stop if the stop pushbutton is pressed or if a motor

overload occurs, causing the normally closed overload relay contact
to open.

Page 3-25
How-to Video Library

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Page 3-26
Timers and Counters

Timers and counters are extremely useful PLC instructions. Timers

allow PLCs to

control and monitor time-dependent aspects of machines and

processes. Counters allow PLCs to keep track of actions or events.

The IEC 61131 standard identifies PLC programming languages and

standardizes the instructions available. Some Siemens S7 PLCs were
already in use when the IEC 61131 specification was developed. This
is noticeable when reviewing the SIMATIC timer and SIMATIC
counter instructions available for S7-300 and S7-400 PLCs. While the
tasks performed by SIMATIC timers and counters are similar to those
performed by IEC timers and counters, there are noticeable
differences. Keep in mind that S7-300 and S7-400 PLCs also allow IEC
timers and IEC counters to be implemented through use of system
function blocks.

Because S7-1200 and S7-1500 PLCs were developed well after the
deployment of IEC 61131, these PLCs include IEC timers and counters
as basic instructions. Therefore, to minimize the complexity of this
lesson, the IEC timers and counters included are consistent with those
used with
S7-1200 PLCs.
Page 3-27
IEC Timers
For LAD programs, S7-1200 PLCs support the IEC box and coil timer
instructions

shown in the accompanying graphic.

Each timer uses a data block (DB) to store timer data.

For S7-1200 PLCs, the number of timers that you can use in program
is limited only by CPU memory size.

IEC timers in S7-1200 PLCs use the 32-bit Time data type for preset
time (PT) and elapsed time (ET) values. Time data is stored as a signed
double integer interpreted as milliseconds. However, negative time
values cannot be used with timer instructions. This means that the
range of values that can be represented by timer preset and elapsed
times is 0 to +2,147,483,647 milliseconds, which is equal to 24 days,
20 hours, 31 minutes, 23 seconds, and 647 milliseconds.

In STEP 7, preset time is entered using this format:

T#(days)d(hours)h(minutes)m(seconds)s(milliseconds)ms. For example,
T#12d10h30m21s253ms is a valid time, but it is not necessary to
specify all units of time. Therefore, T#5h10s and T#500h are also valid.

Page 3-28
 TP Timer Box Instruction

generates a pulse at output parameter (Q) when the input parameter (IN)
transitions from 0 to 1, unless the timer has already started timing. The pulse
duration is defined by the preset time parameter (PT). The elapsed time (ET)
increases from 0 to the present time during the pulse duration and is retained
until IN transitions from 1 to 0. The PT and ET values are stored in a data
block (DB).

The accompanying graphic shows a TP timer in a network and an

associated timing diagram. Note that PT is set to 10 seconds. When the
I1.0 contact closes at time T1, IN transitions from 0 to 1. This starts the
timer timing and causes Q and output Q2.3 to transition from 0 to 1. At
time T2, when ET reaches 10 seconds, the timer stops timing, and Q
and output Q2.3 are reset to 0. The 10 seconds elapsed time is
retained until time T3 when the I1.0 contact opens, and IN and ET are
reset to 0.

This sequence begins again at time T4 when the I1.0 contact closes.
However, the TP timer continues to time and Q, and output Q2.3
remain on when IN is reset to 0 during the preset time. At T5, the
elapsed time reaches 10 seconds and Q and output Q2.3 are reset to
0. Because IN is already at 0, ET is also reset to 0.
Page 3-30

A TP timer, also called a pulse timer, is an instruction that

TP Timer Coil Instruction

As shown in the accompanying graphic, a LAD program can also use a

TP timer coil

instruction to perform the same function as a TP timer box instruction.

Like the box instruction, a TP timer coil has an associated data block
that stores the PT and ET values.

Page 3-31
TON Timer Box Instruction

A TON timer, also called an on-delay timer, is an instruction that

begins timing when the input parameter (IN) transitions from 0 to 1.
When the elapsed time (ET) reaches the preset time (PT), the output
parameter (Q) transitions from 0 to 1. Q remains a 1 until IN
transitions from 1 to 0. If IN transitions from 1 to 0 before ET is equal
to PT, the timer stops timing, ET is reset to 0, and Q remains a 0. The
PT and ET values are stored in the data block (DB) associated with the
instruction.

The accompanying graphic shows a TON timer in a network and an

associated timing diagram. In this example, PT is equal to 15 seconds.
At time T1, when the I1.1 contact closes, IN transitions from 0 to 1.
This starts the timer timing. At time T2, when ET is equal to 15
seconds, the timer stops timing, and Q and output Q2.4 transition
from 0 to 1. At time T3, when the I1.1 contact opens, IN, ET, Q, and
output Q2.4 are reset to 0.

This sequence begins again at time T4 when the I1.1 contact closes
and IN transitions from 0 to 1. However, at time T5, the I1.1 contact
opens, and IN transitions from 1 to 0 before ET is equal to PT, so Q
and output Q2.4 remain off, and ET is reset to 0.

Page 3-32
TON Timer Coil Instruction

As shown in the accompanying graphic, a LAD program can also use

a TON timer

coil instruction to perform the same function as a TON timer box

instruction.

Like the box instruction, a TON timer coil has an associated data block
that stores the PT and ET values.

Page 3-33
 TOF Timer Box Instruction

the output parameter (Q) to 1 when input parameter (IN) transitions from 0
to 1. However, the TOF timer does not begin timing until IN transitions from
1 to 0. When the elapsed time (ET) reaches the preset time (PT), Q
transitions from 1 to 0. Q remains a 0 and the elapsed time is retained until
the next 0 to 1 transition of IN. The PT and ET values are stored in the data
block (DB) associated with the instruction.

The accompanying graphic shows a TOF timer in a network and an

associated timing diagram. In this example PT is equal to 5 seconds.
When the I1.2 contact closes at time T1, IN, Q, and output Q2.5
transition from 0 to 1. At time T2, when the I1.2 contact opens, IN
transitions from 1 to 0, and the timer starts timing. At time T3, when
ET is equal to 5 seconds, the timer stops timing, and Q and output
Q2.5 transition from 1 to 0.

At time T4, when the I1.2 contact closes and IN and Q transition from
0 to 1, ET is reset to 0. At time T5, when the I1.2 contact opens, IN
transitions from 1 to 0, and the timer starts timing. However, at time
T6, the I1.2 contact closes and IN transitions from 0 to 1 before ET is
equal to PT, so
Q and output Q2.5 remain on, and ET is reset to 0.
Page 3-34

A TOF timer, also called an off-delay timer, is an instruction that sets

TOF Timer Coil Instruction

As shown in the accompanying graphic, a LAD program can also use a

TOF timer

coil instruction to perform the same function as a TOF timer box

instruction.

Like the box instruction, a TOF timer coil has an associated data block
that stores the PT and ET values.

Page 3-35
TONR Timer Box Instruction

A TONR timer, also called an on-delay retentive timer, is an instruction

that begins timing when the input parameter (IN) transitions from 0 to
1. If IN transitions from 1 to 0, the elapsed time (ET) is retained. When
IN again transitions from 0 to 1, the timer resumes timing from the
retained ET value. When ET reaches the preset time (PT), the timer
stops timing, and the output parameter (Q) transitions from 0 to 1.
When the reset parameter (R) transitions from 0 to 1, ET and Q are
reset to 0, even if IN remains a 1. The PT and ET values are stored in
the data block (DB) associated with the instruction.

The accompanying graphic shows a TONR timer in a network and an

associated timing diagram. In this example PT is set to 10 seconds.
When the I1.3 contact closes at time T1, IN transitions from 0 to 1.
This starts the timer timing. At time T2, when the I1.3 contact opens,
the timer stops timing, but retains the 5 second ET value. At time T3,
when the I1.3 contact closes, IN transitions from 0 to 1, and the timer
resumes timing. At time T4, when ET is equal to 10 seconds, the timer
stops timing, and Q and output Q2.6 transition from 0 to 1. At time T5,
when the I2.3 contact closes, R transitions from 0 to 1, and ET, Q, and
output Q2.6 are reset to 0.

Page 3-36
TONR, PT, and RT Timer Coil Instructions

As shown in the accompanying graphic, a LAD program can also use a

TONR timer

coil instruction to perform the same function as a TONR timer box

instruction. Like the box instruction, a TONR timer coil has an
associated data block that stores the PT and ET values.

The accompanying graphic also shows a PT timer coil instruction, also

called a preset timer coil instruction, and an RT timer coil instruction,
also called a reset timer coil instruction.

These instructions can be used with timer box instructions or other

timer coil instructions and can be placed in a mid- line or end position
in a network.

When the PT timer coil instruction receives power flow, it loads a

preset time to the specified timer. When the RT timer coil instruction
receives power flow, it resets the specified timer.

Page 3-37
IEC Counters

For LAD programs, S7-1200 PLCs support the IEC counter instructions shown in
the

accompanying graphic.

CU, CD, and CTUD counter instructions use software counters with a
maximum counting rate that is limited by the execution rate of the
organization block (OB) they are placed in. S7-1200 PLCs also provide
high-speed counters for counting events that occur faster than can
be handled by IEC counters.

Each IEC counter instruction uses a data block (DB) to maintain counter
data. The number of counter instructions that you can use in a user
program is limited only by the amount of memory in the CPU.

The amount of memory required for an instruction depends on the

data type selected to store count values; therefore, it makes sense to
choose the data type that matches the application requirements. The
accompanying graphic also shows the data types available for IEC
counters in S7-1200 PLCs.

Page 3-38
CTU Counter Instruction

A CTU counter, also called a count up counter, is an instruction that

counts up with

each 0 to 1 transition of the count up parameter (CU). When the count

value parameter (CV) reaches the preset value (PV), the output
parameter
(Q) transitions from 0 to 1. CV continues to increment with each 0 to 1
transition of CU until the high limit of the data type selected is reached.
When the reset parameter (R) transitions from 0 to 1, CV and Q are
reset to 0.

The accompanying graphic shows a CTU counter in a network and an

associated counting diagram. In this example, PV is equal to 3. Each
closure of the I1.1 contact causes a 0 to 1 transition of CU, which
increments CV. At time T3, when CV equals PV, Q and output Q2.1
transition from 0 to 1. The count continues at time T4 when CV
increments to 4. Because the data type selected for the counter in
this example is unsigned integer (units), it could count up to 65,535.
At time T5, when the I2.1 contact close, R transitions from 0 to 1, and
CV, Q, and output Q2.1 are reset to 0.

Page 3-39
CTD Counter Instruction

A CTD counter, also called a countdown counter, is an instruction that

counts down with each 0 to 1 transition of the countdown parameter
(CD). When the LOAD parameter transitions from 0 to 1, the count
value parameter (CV) is set equal to the present value (PV), and the
output parameter (Q) is reset to 0. Each 0 to 1 transition of CD
decrements CV by 1. When CV reaches 0, Q is set to
1. CV continues to decrement by 1 with each 0 to 1 transition
of CD until the low limit of the data type is reached.

The accompanying graphic shows a CTD counter in a network and an

associated counting diagram. In this example, PV is equal to 3. At time
T1, the I2.2 contact closes causing a 0 to 1 transition of LOAD, which
sets CV to 3 and resets Q and output Q2.2 to 0. Prior to time T2, the
I2.2 contact opens, and LOAD is reset to 0. Thereafter, each closure of
the I1.2 contact causes a 0 to 1 transition of CD, which decrements CV.
At time T4, when CV equals 0, Q and output Q2.2 transition from 0 to
1. Because the data type selected for the counter in this example is
unsigned integer (Uints), it stops counting down at 0. At time T6, when
the I2.2 contact closes, LOAD transitions from 0 to 1, CV is set equal to
3, and Q and output Q2.2 are reset to 0.

Page 3-40
CTUD Counter Instruction

A CTUD counter, also called a count up and down counter, is an

instruction that counts up with each 0 to 1 transition of the count up
parameter (CU) and counts down with each 0 to 1 transition of the
count down parameter (CD). If CU and CD both transition from 0 to 1
at the same time, the count does not change.

The current value of the count is available at the count value

parameter (CV). The maximum and minimum values of CV and the
present value parameter (PV) are determined by the data type selected
for the counter.

A 0 to 1 transition of the LOAD parameter sets CV equal to PV. A 0 to 1

transition of the reset parameter (R) resets CV to 0. QU is equal to 1 if
CV is greater than or equal to PV. QD is equal to 1 if CV is less than or
equal to 0.

Page 3-41
CTUD Counter Instruction Example

The accompanying graphic shows a CTUD counter in a network. For this

example, PV is equal to 3. The counting diagram shown in the
accompanying graphic is for the following sequence of events.

• At the start of the sequence, CV is 0, so QD and output Q3.3 are 1,

and QU and output Q2.3 are 0.
• At time T1, the I1.3 contact closes, CU transitions from 0 to 1, and
CV is incremented to 1. Because CV is greater than 0, QD and
output Q3.3 are reset to 0.
• Prior to time T2, the I1.3 contact opens. At time T2, the I1.3
contact closes, CU transitions from 0 to 1, and CV increments to 2.
• Prior to time T3, the I1.3 contact opens. At time T3, the I1.3 contact
closes, CU transitions from 0 to 1, and CV increments to 3. Because
CV is equal to PV, QU and output Q2.3 are set to 1.
• Prior to time T4, the I1.3 contact opens. At time T4, contact I1.3
closes, CU transitions from 0 to 1, and CV increments to 4.
• At time T5, the I2.3 contact closes, CD transitions from 0 to 1, and
CV decrements to 3.
• Prior to time T6, the I2.3 contact opens. At time T6, contact I2.3
closes, CD transitions from 0 to 1, and CV decrements to 2. Because
CV is now less than PV, QU and output Q2.3 are reset to 0.
• At time T7, the I4.3 contact closes, LOAD is set to 1, CV is set equal
to PV, and QU and output Q2.3 are set to 1.

Page 3-42
Simulators

Engineered to provide a real-world experience, Siemens simulators are

fully functional, ready-to-use systems available in a variety of
configurations.

System-level design makes the simulators an invaluable tool for

program testing and debugging, reinforcing learning, shop floor
troubleshooting, and more. With portable construction and hard-shell
cases, they can be easily transported. Custom-built systems are also
available.

Page 3-43
Additional LAD Instructions

The instructions shown in the previous lessons are only a few of the
many types of instructions that can be included in a Siemens PLC LAD
program. A LAD program can include a variety of basic and extended
instructions.

The basic instructions are grouped in the following categories: bit logic
operations, timer operations, counter operations, comparator
operations, math functions, move operations, conversion operations,
program control operations, word logic operations, and shift and rotate
operations.

The extended instructions are grouped in the following categories: date

and time-of-day, distributed I/O, interrupts, diagnostics, pulse, recipe
and data logging, data block control, and addressing.

In combination, these instructions provide SIMATIC S7 PLCs with the

full range of LAD programming capabilities to meet a broad range of
applications.

Page 4-44
Additional S7-1200 PLC Programming Languages

In addition to the LAD programming language, S7-1200 PLCs support

the following IEC 61131 programming languages.

• Function block diagram (FBD) is a graphical programming language

similar to LAD. However, rather than using contact logic, FBD uses
Boolean logic instructions with similar functionality to the logic
gates of a digital logic circuit.

• Structured control language (SCL), referred to in the IEC 61131

specification as structured text, is a high-level, PASCAL-based
programming language. SCL is generally considered the best PLC
programming language to use for complex algorithms and
processing of complex data structures.

Because the choice of a programming language is done by program

block, the most appropriate language can be chosen for each block
based on the tasks performed by that block.

Page 4-45
 Integrated Technology

S7-1200 PLCs have built-in technology such as high-speed inputs,

high-speed outputs, and PID control that reduces the need for
specialty modules, reducing space and cost.

High-speed inputs
Up to six high-speed counters can be used. Three inputs at 100 kHz and
three inputs at 30 kHz are seamlessly integrated for counting and
measuring functionality.

High-speed outputs
Two high-speed pulse train outputs at 100 kHz are integrated for
controlling the speed and position of a stepper motor or a servo
drive. They can alternatively be used as pulse width-modulated
outputs for controlling the speed of a motor, positioning a valve, or
controlling
a heating element.

PID control
PID control loops with auto-tune allow for simple closed- loop process
control applications.

Page 4-46
Integrated Web Server

The web server for the S7-1200 provides web Page access to data
about your CPU and process data. You can access S7-1200 web Page s
from a PC or a mobile device. The web server displays the Page s in a
format and size compatible with the device you use to access the Page
s.

Examples of standard S7-1200 web Page information include:

• Start Page with general information about the CPU

• Identification Page with detailed CPU information
• Diagnostic buffer Page with diagnostic information
• Module information Page with information about
communication and signal modules
• Communication Page with network and other
communication information
• Variable status Page with CPU variables and related
information

The S7-1200 also supports user-defined web Page s for access to CPU
data.

Page 4-47
Chapter 4 – Additional Information

SIMATIC Controllers

Because every machine or plant has individual requirements for

system performance and application complexity, Siemens offers a full
range of PLCs to provide you with the perfect control solution for
each application.

This course has focused on S7-1200 basic controllers designed for small
to medium applications. Additional Siemens PLCs include S7-1500
advanced controllers for medium and complex applications, S7-1500
software controllers for PC-based applications, and ET 200SP
distributed controllers for decentralized applications.

All basic, advanced, and distributed controllers are also available as

failsafe versions for implementation of failsafe applications.

Page 4-48
S7-1500 Advanced Controller

The S7-1500 Advanced Controller sets the standard for system

performance and usability. The seamless integration of the S7-1500
controller into the TIA Portal offers advantages such as shared data
management, a uniform operating concept, and centralized services.
This simplifies the use of universal functions.

S7-1500 PLCs are quick and easy to install and set up. For you, this
means a shorter time-to-market and a higher rate of return on your
investment.

There are various S7-1500 CPU versions available in several

performance categories. The portfolio includes standard CPUs and
standard CPUs with the option of integrating C/C++ code. Compact
CPUs have integrated digital and analog I/O channels and allow
counter inputs and pulse inputs to be directly recorded on the CPU.
Failsafe CPUs can concurrently run standard and safety programs.
Technology CPUs incorporated motion control functions for
demanding solutions.

Page 4-49
S7-1500 Software Controller

S7-1500 software controller for PC-based automation with SIMATIC

Industrial PCs is operated independently of Windows, thus offering a
high level of system availability. This is advantageous for fast controller
ramp-up and makes it possible to update or reboot while the control
system is running.

S7-1500 software controller features both know-how and access

protection as well as important automation functions for motion
control and interfaces to PROFIBUS and PROFINET. Use TIA Portal for
efficient engineering.

S7-1500 software controller ODK supports the development of

Windows and real-time library functions and enables the integration of
Code C++ higher-level language programs.

Page 4-50
ET 200SP Distributed Controller

ET 200SP distributed controllers feature the same functionalities as

CPU 1511 and CPU 1513 for S7-1500 controllers. This includes
integrated trace functions, integrated system diagnostics, integrated
security, integrated web server, and symbolic programming.

ET 200SP standard and failsafe CPUs come with 3 integrated Ethernet

ports, 2 Ethernet connection ports can be flexibly selected by means of
bus adapters as a cost saving feature.

ET 200SP CPUs can also be configured as interface modules with the

PROFINET iDevice functionality. An iDevice is a local IO controller that
also functions as an IO device for a central IO controller. The central IO
controller has direct access to the IO image in the local controller, so
communication is simple and fast, and no complex programming or
additional communication hardware are required.

ET 200SP CPUs support the PROFIenergy profile for improved energy

efficiency, PROFINET isochronous real- time (IRT) communication for
motion control, and DP master communication with PROFIBUS DP
devices.

Page 4-51
S7-300 and S7-400 Controllers

S7-300 PLCs have a space-saving modular design and are suited to a

wide range of automation tasks. SIMATIC
S7-300 CPUs are available in Standard, Compact (C), Failsafe (F), and
Technology (T) versions.

S7-400 PLCs have high processing speeds and are especially suitable for
data-intensive tasks such as coordinating overall plants and controlling
lower-level systems. S7-400 CPUs are available in Standard, Failsafe (F),
and High-availability (H) versions.

S7-300 and S7-400 PLCs are configured and programmed using STEP
7 Professional (TIA Portal) or a version of STEP 7 Professional that is
not in TIA Portal.

Page 4-52
ET 200 Distributed I/O Systems

ET 200 distributed I/O systems offer standard and failsafe solutions for
use in a control cabinet or without a cabinet directly on the machine.

The ET 200 modular design includes digital and analog I/O, intelligent
modules with CPU functionality, safety technology, motor starters,
frequency converters, and technology modules.

TIA Portal makes the integration of safety technology easier and more
efficient.

ET 200 distributed I/O systems can be integrated into your existing

automation system via PROFIBUS DP or PROFINET.

Systems designed for use in a control cabinet include:

ET 200SP, ET 200MP, ET 200S, ET 200M, and ET 200iSP.

Systems designed for use directly on a machine without a control

cabinet include: ET 200AL, ET 200pro,
ET 200eco PN, and ET 200eco.

Page 4-53
SIMATIC HMI Panels

SIMATIC HMI Panels are available for virtually any application and can
be intuitively configured in TIA Portal using SIMATIC WinCC software.
This results in increased engineering efficiency, especially when
additional Siemens automation products are used. The interaction with
STEP 7 does away with multiple entries and ensures maximum data
consistency.

Panel models have Integrated functionality across all display sizes.

Because the software is scalable, you can start with a small solution
and expand it at any time.
Innovative graphical user interfaces open up new possibilities for
intuitive operation and monitoring.

SIMATIC HMI includes the following panel types.

• SIMATIC HMI Comfort Panels: Designed for applications requiring

the highest performance and functionality.
• SIMATIC HMI Basic Panels: Cost-efficient, high resolution
visualization solutions.
• SIMATIC HMI Mobile Panels: Maximum mobility and flexibility.
• SIMATIC HMI Key Panels: Flexible expandability by keys or even
safety functions.

Page 4-15