Step7

Programmable logic controllers

Part 1 - Introduction
PLC basic course
Fest AG

October 2004
 Introduction Hardware Software

Table of contents

Introduction
Hardware
Design
Manufacturer
Function
Software
Mode of operation
Variables
Program structures

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General description
„ Features:
Data capture
„ Collection of analogue values (flow rate, temperatures,
„ positions as well as e.g. speeds of drives, frequency
„ converters)
„ Collection of digital signals (e.g. pressure switch or
„ feedback signals from drives)

Control
„ frequency converters / positioning drives / rolls etc.

Visualization
„ OPs (e.g. OP170 with Pro-Tool)
„ PCs (e.g. standard PC with WinCC, LabView, Intouch)

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General description

„ PLC tasks:

ƒ Measuring
ƒ Controlling
ƒ Feedback controlling

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General description
Definition PLC: Small computers with automation functions in
industrial environments

Formerly: relais controls, pneumatic and hydraulic

valves / controllers
¾hardwired programmed or wired programmed!
Fixed programming given by wiring, or free
programming by changeable connexions.

Today: Highly specialized computers with controlling and

feedback controlling
¾Stored-program! Free programming by
RAM memory, reprogrammable by EPROM
Memory or replacement programmable by
PROM- and ROM- memory.

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HPC PLC
Hardwired programmed vs. Programmable logic controller

S1 S4 K1 K1 S1 S4 S2 S3

S2
Automation unit

S3

K1 H1 H1

Function change by:

Rewiring Reprogramming
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 Introduction Hardware Software

Table of contents

Introduction
Hardware
Design
Function
Software
Mode of operation
Variables
Program structures

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 Introduction Hardware Software

Basic design of PLC

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Why different types of PLCs?

„ - processor speed
„ - addressability
„ - memory

„ - plant size

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Design
Power supply

CPU modules

Input modules

Output modules

Communication modules

Function modules

Operating units

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Power supply

-provides internal supply voltage for the individual

components
-designed for power supply of controllers, and not for
signal and actuating elements
- Permanent surveillance of voltage with regard to
overvoltage or undervoltage
- additional converters for power rating units if
necessary
- Battery for memory buffering

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CPU modules

• processor

• memory

• EPROM with program (optional)

• programming interface (optional)

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Input modules

• digital inputs

• analogue inputs

• special inputs for:

temperature sensor
resistance measurement
etc.

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output modules

• digital outputs

• analogue outputs

• relais outputs

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Communication modules

• field busses (ASI, profibus ...)

• Industrial Ethernet, TCP/IP

• programming interfaces

• serial interfaces (RS422, RS485 ...)

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Function modules

• positioning units

• control units

• counter units

• timepiece units

• image evaluation module

• etc.

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Operating units

• Operator Panels

• Touch Screens

• Text Displays

• Keyboards

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Structure automation system

PC PC
Station 1 Station 2

comm. bus system

(e.g. Ethernet)

SPC SPC

COM
COM

CPU
CPU

COM

I/O
I/O
I/O

I/O
I/O
I/O

I/O
I/O

I/O

field bus

COM
COM

COM
CPU

CPU
I/O

I/O
I/O

I/O

I/O
I/O

I/O
input and output
decentral periphery

sensors bus system (e.g. ASI)

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Basic design of PLC

Data flow

Data input Data processing Data output

Signal Adaption Processing Amplification Output

input

Power supply

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Design of PLC
Programmable controller

Signal
generator Inputs Central unit Outputs Positioner

Program memory

Control unit

Timing
Flag
elements

Process Counter
image

Accu Address and

Data bus

Central power supply

Power supply for Power supply for
signal generator actuating elements,
signal lamps

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 Introduction Hardware Software

Table of contents

Introduction
Hardware
Design
Manufacturer
Function
Software
Mode of operation
Variables
Program structures

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PLC program flow

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Cycle time PLC

serial processing of instructions

Time need for processing the program: cycle time
depends on program length and microprocessor pulse frequency of PLC
used
also depends on program structure and efficiency of program
Performance characteristic of PLC, indicate in milliseconds per 1 K
(1024 binary instructions).
Example: PLC with a cycle time of 20 msec /1 K instructions, program 5
kbyte, PII is updated during a time slice of about 100 ms.
Processor does not work with the real inputs and outputs, but only with
copies of signal conditions (updated at the beginning / end of a cycle)

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Process image of inputs and outputs

Inputs

0 1 PII 1

Read inputs
Times
Counters
Flags

Process
program Alarm
program
e.g.
time,
process
alarm

Write outputs
Processor Program memory
0 1 PIO 1

Outputs

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Information processing terms

Value (condition) “0“ or “1“

1 BIT

7 6 5 4 3 2 1 0
1 BYTE = 8 Bits

15 8 7 0
1 word = 16 Bits = 2 Bytes

Byte Byte

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Bit-, Byte, word address

7 6 5 4 3 2 1 0

BIT ADRESS .0 ... .7

E1.7 E1.6 E1.5 E1.4 E1.3 E1.2 E1.1 E1.0

7 6 5 4 3 2 1 0

BYTE ADRESS E1.0 ... E1.7

WORD ADRESS EW0 EW2

EB0 EB1 EB2 EB3

EW1

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Number formats

binary
decimal
hexadecimal

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Decimal numbers

base = 10
figures: 0 . . . 9

e.g.: 234510
= 2 • 10 3 + 3 • 10 2 + 4 • 10 + 5
= 2 • 1000 + 3 • 100 + 4 • 10 + 5
= 2000 + 300 + 40 + 5

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Binary numbers
base = 2
figures: 0 . . 1

e.g.: 1001012
=1•25+0•24+0•23+1•22+0•2+1
= 1 • 32 + 0 • 16 + 0 • 8 + 1 • 4 + 0 • 2 + 1
= 32 + 4 + 1
= 3710

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Hexadecimal numbers
base = 16
figures: 0 . . . 9 A B C D E F
A=10, B=11, C=12, D=13, E=14, F=15

e.g.: FEDC16
= 15 • 16 3 + 14 • 16 2 + 13 • 16 + 12
= 15 • 4096 + 14 • 256 + 13 • 16 + 12
= 61440 + 3584 + 208 + 12
= 6524410

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Control instruction

Control instruction
(smallest unit in the user program)

U E 1.0

Operation part Operand part

(What has to be (What can it be done with?)
done?)
U E 1.0

Operand Parameter
characteristic

E 1.0

Byte adress Bit adress

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Variable declaration
A 7.3 address of variable

single-bit value
I Input B Byte (8 Bit)-value
O Output W Word (16 Bit)-value
F Flag D Double word (32 Bit)-value
DM Data module

Bit: E40.5 - A40.2 - M40.1 - DB1.DBX40.7

Byte: EB24 - AB24 - MB24 - DB1.DBB24
Word: EW8 - AW8 - MW8 - DB1.DBW8
Real: ED12 - AD12 - MD12 - DB1.DBD12

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Programming languages
IEC 1131 basically states 5 programming languages,
which can be divided into 2 groups:

1.Text-based 2.Graphical
Instruction Set (IS) Contact Plan (COP)

Structured Text (ST) Function Block Language (FBL)

Sequential Function Chart (SFC)

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Contact Plan (COP)

-functions represented by circuit symbols

(normally open contacts, normally closed contacts)
- packatised to networks similar to a circuit diagram
- basically restricted to binary signals

- Source: Relais wiring

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Contact Plan (COP)

Flow sheet Contact plan

S1 = E1.0 E1.0 E1.1 A2.0

S2 = E1.1

H1 = A2.0

- Representation of input variables as switch contacts

- coil turns on as result of a combination

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Instruction Set (IS)

„ universally applicable machine language

„ comparable with assembler
„ most common
„ little options for a structured programming

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Instruction Set (IS)

Flow sheet Instruction set

S1 = E1.0 U E 1 0
U E 1 1
= A 2 0
S2 = E1.1

H1 = A2.0

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Example for IS
One instruction is composed as follows:

jump label: Operator Operand (*comment*)

L E 0.1 (*Load input 0.1 into Accu *)

O E 0.2 (*Accu = Accu or input 0.2 *)
O A 1.1 (*Accu=Accu or output 1.1 *)
U E 0.3 (*Accu=Accu and input 0.3 *)
U E 0.4 (*Accu=Accu and input 0.4 *)
= A 1.1 (*output 1.1=Accu *)

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Structured Text (ST)

- C-like, high level language, uses abstract commands unlike machine-
oriented IS
Advantages:
very compact wording
Clear set-up, because of instruction blocks
Extensive and complex tasks practicable
Disadvantages:
Transformation into machine-code cannot be influenced directly, as it is generated
by compiler
loss in efficiency by higher level of abstraction (as a rule ST-Code is more slowly
than IS-Code)

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Examples for ST
Example 1:
Q1.1:=(I0.1 OR I0.2 OR Q1.1) AND I0.3 AND I0.4;

Example 2:
IF (I0.1 OR I0.2 OR Q1.1) THEN
IF (I0.3 AND I0.4) THEN
Q1.1:=1;
ELSE
Q1.0:=0;
END_IF;
END_IF;

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Sequence Control (SC)

„ Industrial automation tasks can easily be divided into

single steps.
„ SC offers tools for structuring, in order to organise the
PLC program in steps.
„ Transition from one step to one or more (parallel)
following steps is done by a transition condition.
„ The actions effected during the single steps as well as
the transitions are performed in one of the above -
mentioned languages.

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Example for SC
I0.1 Step 0
S0
R Q1.1
I0.2 I0.3 I0.4
T0
I0.3 Step 1
S1
S Q1.1
I0.4
T1

S0

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Function Plan (FUP/FBS)

„ instead of relais diagram symbols of digital circuits are

used

„ well structured and clear programming is possible

„ Operations in whole numbers / with floating point are

graphically and clearly possible

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Function Plan (FUP)

Flow sheet Function plan

S1 = E1.0 E1.0 &

A2.0
E1.1

S2 = E1.1

H1 = A2.0

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Basic program structure

1. program (PROG,OB): main program, allocation of periphery

and global variables,...

2. Function Block (FB): Block with input, output and static

variables (with memory)

3. Function (FUN, FC): subprogram with input and output

variables (without memory)

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Linear and structured program processing

Linear programming Structured programming

OB1 OB1 FB FB FC

FB FB FB

FB FC FC

Level 0 Level 0 Level 1 Level 2 Level 3

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Call of program module

Calling program module

(OB, FB, FC)

Program Program
processing processing

Operation that calls a

different program module

End of program module

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