Jürgen Kaftan PLC Basic Course with SIMATIC S7 Jürgen Kaftan PLC Basic Course with SIMATIC S7

Structure and Function of Programmable Logic Controllers, Programming with the SIMATIC S7 First
Edition Jürgen Kaftan 1967-1971 Apprenticeship as an electrician 1971-1973 Skilled tradesman in the
trade of electrician 1973-1975 Training as a state-certified electrical engineer 1975-1977 Employed as a
technician 1977-1978 School for master craftsmen, graduated as master electrician 1979-1992
Nuremberg vocational training centre for hearing and speech impaired persons, Master Trainer 1985-
1992 Course Leader for PLCs in vocational training (BFH) for hearing and speech impaired persons 1985-
1992 Course Leader for PLCs at the Chamber of Crafts 1992-1995 IKH Elektrogerätebau – System
Training Courses (Managing Director) Since 1995 Manager of IHK Systemschulungen for Hardware and
Software (Chamber of Industry and Commerce hardware and software system training courses) in
Weißenburg and Roth (Central Franconia) Jürgen Kaftan is the author of the following reference books
published by Vogel: PLC Basic Course 1 PLC Basic Course 2 PLC Basic Course with SIMATIC S7 The book
includes a Siemens AG demonstration CD-ROM »STEP 7 Professional, Edition 2004 SR4, Trial License«
including: STEP 7 V5.3 SP3, S7-GRAPH V5.3 SP2, S7-SCL V5.3 SP1, S7- PLCSIM V5.3 SP1 and can be used
for test purposes for 14 days. The software only runs under Windows 2000 Professional SP4 and above
or Windows XP Professional SP1 and above. For further information on the Internet, visit
www.siemens.de/sce/promotoren. Further information: www.vogel-buchverlag.de ISBN 978-3-8343-
3201-1 First Edition 2011 All rights reserved including translation. No part of this work may be
reproduced, processed using any type of electronic system, duplicated or transmitted in any way or in
any form (printing, photocopying, microfilm or using any other process) without the express written
consent of the publisher. The exceptions stated expressly in Para. 53, 54 of the German Copyright Act
are not affected. Printed in Germany Copyright 1998 by Vogel Industrie Medien GmbH & Co. KG,
Würzburg Book jacket illustration: Michael M. Kappenstein, Frankfurt 5 Foreword Programmable logic
controllers, known for short as PLCs, are an integral part of automation at the lower, middle and upper
performance levels. Due to the ever increasing size and complexity of the hardware and software
required in automation projects, the industry has had to develop faster, more capable and effective
automation systems and to simplify handling for users. All the exercises in this book have been
developed and tested using Siemens' SIMATIC S7-300 PLC. The command set of this controller ranges
from binary processing to 32-bit floating point arithmetic. The controller is programmed under the
Windows XP operating system and it is assumed that users have an appropriate basic knowledge. All the
procedures for programming the SIMATIC S7-300 are demonstrated exactly and are easy to understand
for users. The topic builds up from "easy to hard" and is ideally suited for use in vocational and technical
training colleges, etc. as well as for use on a teach-yourself basis. I would like to thank the Wükro-
Lehrsysteme company in Würzburg as well as everybody who has helped in the completion of this book.
I am always grateful to receive feedback from readers and users. Weißenburg/Heuberg (Central
Franconia) Jürgen Kaftan 6 7 Contents
Foreword....................................................................................................... 5 1
Introduction.................................................................................... 13 1.1 Number
system ............................................................................... 13 1.2.2
Byte................................................................................................. 14 1.2.3
Word............................................................................................... 14 1.2 Terms from computer
science .......................................................... 14 1.2.1
Bit ................................................................................................... 14 1.2.4 Bit
address....................................................................................... 15 1.2.5 Byte
address.................................................................................... 15 1.2.6 Word
address .................................................................................. 15 2 Arrangement of a
PLC..................................................................... 17 2.1 Structure of a
PLC........................................................................... 18 2.2 Structure of an automation
unit ...................................................... 18 2.3 Hardware
requirements................................................................... 18 2.3.1 Hardware
structure ......................................................................... 20 2.4 Software
requirements..................................................................... 20 2.4.1 STEP 7 programming
language ....................................................... 20 2.4.2
Objects............................................................................................ 20 2.4.3
Projects ........................................................................................... 21 2.4.4 Configuring an S7-
300.................................................................... 22 2.4.5
Parameterization ............................................................................. 22 3 Way of Functioning of a
PLC .......................................................... 23 3.1 Modules of the
PLC ........................................................................ 23 3.1.1 Power supply
unit ........................................................................... 23 3.1.2 Program
memory ............................................................................ 24 3.1.3 Central processing unit
(CPU)......................................................... 25 3.1.4 Bus
system....................................................................................... 27 3.1.5 Input and output
modules............................................................... 27 4 Program Processing and
Programming ............................................ 29 4.1 Linear program
processing .............................................................. 29 4.2 Structured
programming ................................................................. 30 4.3 Control
instruction.......................................................................... 31 4.3.1 Operation
part ................................................................................ 32 8 4.3.2 Examples for digital
operations....................................................... 32 4.3.3 Examples of binary
operations........................................................ 32 4.3.4 Examples of organizational
operations............................................ 33 4.3.5 Operand
part .................................................................................. 33 4.4
Addressing ...................................................................................... 34 4.4.1 Symbolic
Addressing ....................................................................... 34 4.4.2 Absolute
addressing ........................................................................ 34 4.4.3 Immediate
addressing...................................................................... 34 4.4.3.1 Direct
addressing............................................................................. 34 4.4.3.2 Memory-indirect
addressing............................................................ 35 4.5 Program
representation................................................................... 35 4.5.1 Ladder diagram
(LAD).................................................................... 36 4.5.2 Function block diagram FBD (STEP 7 V3.x and
above) .................. 36 4.5.3 Statement list STL ........................................................................... 36 4.6
Flags................................................................................................ 37 4.6.1 Retentive
flags................................................................................. 37 4.6.2 Non-retentive
flags.......................................................................... 38 5 Logic
operations.............................................................................. 39 5.1 Basic logic
operations...................................................................... 39 5.1.1 Clearing the
CPU ............................................................................ 40 5.1.2 Creating
projects............................................................................. 42 5.1.3 Inserting the SIMATIC 300
station.................................................. 43 5.1.4 Configuring and
parameterizing...................................................... 43 5.1.5 Arrangement of the power
supply ................................................... 45 5.1.6 Arrangement of the CPU
314.......................................................... 46 5.1.7 Arrangement of the input
module ................................................... 46 5.1.8 Arrangement of the output
module ................................................. 47 5.1.9 Parameterizing the CPU
314 ........................................................... 47 5.1.10 Saving the global
configuration....................................................... 49 5.1.11 Transferring the configuration to the
CPU ...................................... 49 5.2 Logical AND operation user program ............................................. 50
5.2.1 Entering FCs (FC 1) ........................................................................ 50 5.2.2 S7 block
function ............................................................................ 52 5.2.3 Entering OB
1 ................................................................................. 55 5.2.4
Downloading .................................................................................. 58 5.2.5
Testing............................................................................................. 59 5.2.6 Specifying trigger
conditions ........................................................... 60 5.2.7 Deactivating the FBD program
status.............................................. 63 5.2.8 Testing with
STL ............................................................................. 63 5.2.9 Testing with
LAD............................................................................ 65 5.2.10 Extending from two to three inputs (3rd.
input I0.2)....................... 67 5.2.10.1 Extending with STL ........................................................................ 67
9 5.2.10.2 Extending with LAD ....................................................................... 69 5.2.10.3 Extending with
FBD........................................................................ 71 5.2.11 Reducing from 3 inputs to 2 (delete
I0.2)........................................ 73 5.2.11.1 Reducing with
STL.......................................................................... 73 5.2.11.2 Reducing with
LAD ........................................................................ 74 5.2.11.3 Reducing with
FBD......................................................................... 74 5.3 Logical OR operation user
program................................................ 75 5.3.1 Entering the program using the PC
(FBD) ....................................... 75 5.3.2 Create the
project............................................................................ 76 5.3.3 Copy SIMATIC station 1 into another
project................................. 77 5.3.4 Change OB 1................................................................................... 80
5.3.5 Downloading .................................................................................. 82 5.3.6
Testing............................................................................................. 82 6 Program
Input................................................................................. 85 6.1 AND before
OR.............................................................................. 85 6.2 OR before
AND.............................................................................. 88 6.3 Poll for signal state
0....................................................................... 91 6.4 Exclusive OR
operation .................................................................. 94 6.5 Polling
outputs................................................................................ 96 6.6 Inserting
networks........................................................................... 98 6.7 Latch circuit with the
PC................................................................. 101 6.8 Practical examples of control with the
PC....................................... 105 6.8.1 Temperature difference....................................................................
105 6.8.2 Drinks machine ............................................................................... 106 6.8.3
Intercom.......................................................................................... 108 6.8.4
Generator........................................................................................ 110 6.8.5 Boiler
control .................................................................................. 112 6.8.6 Smelting
furnaces............................................................................ 113 6.9 Flip-
flop .......................................................................................... 116 6.9.1 R-S flip-
flop..................................................................................... 116 6.9.2 Entering the
program ...................................................................... 118 6.9.3 Pump
controller .............................................................................. 122 7 Creating Momentary Impulses (Edge
Instructions).......................... 127 7.1 Momentary impulse with a rising edge (FP) ....................................
127 7.2 Momentary impulse with a falling edge (FN) .................................. 128 7.3 Program
input................................................................................. 128 7.4 Acknowledgement
circuit................................................................ 132 8 Timing
Functions............................................................................ 135 8.1 Timing value
specification............................................................... 135 8.2 Release a time
(FR) ......................................................................... 136 8.3 Current
value .................................................................................. 136 10 8.4 Reset
time ....................................................................................... 137 8.5 Selection of times (five different
ones) ............................................. 137 8.5.1 Pulse timer
(SP) ............................................................................... 137 8.5.2 Extended pulse timer
(SE) ............................................................... 139 8.5.3 Switch-on delay timer
(SD).............................................................. 140 8.5.4 Retentive switch-on delay timer
(SS) ............................................... 142 8.5.5 Switch-off delay timer
(SF).............................................................. 143 8.6 PC program input of timing
functions............................................. 144 8.6.1 Garage
lighting................................................................................ 147 8.6.2 Filling
system .................................................................................. 149 8.6.3 Compressor
system ......................................................................... 150 9 Clock
Generators ............................................................................ 153 9.1 PC program input with clock
generator .......................................... 154 9.1.1 Channel
switch................................................................................ 156 9.1.2 Paging
system.................................................................................. 157 9.1.3 Air
supply ....................................................................................... 159 10
Counters ......................................................................................... 163 10.1 Load and transfer
functions ............................................................ 163 10.2 Counter
functions ........................................................................... 164 10.2.1 Release a counter
(FR) .................................................................... 164 10.2.2 Counting
forwards.......................................................................... 164 10.2.3 Counting
backwards....................................................................... 164 10.2.4 Set
counter...................................................................................... 165 10.2.5 Count value
definition..................................................................... 165 10.2.6 Reset counter
(R) ............................................................................ 165 10.2.7 Poll count value
(L/LC) ................................................................... 165 10.2.8 Poll signal state of counter
(binary)................................................. 166 10.3 PC program input cleaning
bath...................................................... 167 11
Comparators................................................................................... 169 11.1 Comparison
functions..................................................................... 169 11.1.1 Equal to =
= .................................................................................... 169 11.1.2 Not equal
<>................................................................................... 170 11.1.3 Greater than equal to
>= ................................................................. 170 11.1.4 Greater than
>................................................................................. 170 11.1.5 Less than equal to
<= ...................................................................... 170 11.1.6 Less than STOP, ˆ can be reset by the user
program with menu: PLC > Diagnostic/Setting > Clear/Reset. I I I I Q Q A A 38 By using retentive bit
memories, you can save the last plant or machine status before leaving the operating status. In the case
of a restart, the plant or machine can continue working at the point at which it came to a standstill. You
specify the retentive areas by parameterizing in the S7 Configuration tool. 4.6.2 Non-retentive bit
memories ˆ Are reset when changing from operating mode RUN>STOP and in the case of POWER ON. 39
5.1 Basic logic operations Entering the logical AND operation program using the PC according to FBD
(see Figure 5.1). Figure 5.1 Entering the logical AND operation: a) Connection to the PLC, b) Schematic
diagram, c) LAD, d) FBD + Power supply - 24 V DC Table 5.1 Assignment list Symbol Operand Comment
S1 I0.0 «NO contact» switch S2 I0.1 «NO contact» switch P1 Q4.0 Indicator light INP UTS O U TPUTS 5
Logic operations I0.0 Q4.0 I0.1 P L C I0.0 I0.1 Q4.0 I0.0 I0.1 Q4.0 40 Before you enter the logical AND
operation program in the SIMATIC S7, you must create a project. Only then can you configure and
parameterize the CPU. To be on the safe side, you should first clear the CPU to ensure that there are no
"old" blocks in it. You program the S7-300, according to the following procedure: 5.1.1 Clearing the CPU
Proceed as follows: Ö Click on the SIMATIC Manager Ö In the SIMATIC Manager click on menu item: PLC
> Display Accessible Nodes Clear the CPU Create the project Configure and parameterize the CPU Save
the configuration table Load the configuration into the CPU Ö The following window is displayed: Click
Double click on the MPI address 41 The CPU is now reset, i.e. the entire user program is deleted, the
system parameters and module parameters are reset to the default settings. With this, the CPU severs
all the existing connections. Ö Close the window and return to SIMATIC Manager. Ö The following
window is displayed: Click on the target system using menu item: PLC > Diagnostic/Setting > Operating
Mode... ... display the current operating status of the CPU. You switch the CPU to the STOP status and
confirm by clicking on OK and then leave the dialog box by clicking on Close. The CPU enters the STOP
status. You can only carry out a memory reset of the PLC in the STOP status. You can now clear the CPU.
Click on menu: PLC > Diagnostic/Setting > Clear/Reset... Confirm the action. Important: A key-operated
switch is attached to the CPU. This switch must be in the RUN-P or STOP position. 42 5.1.2 Creating
projects Now, you create the logical AND operation project for the user program. Ö In the SIMATIC
Manager click on menu item: File > New... Ö The following window is displayed: Here, you must enter
the logical AND operation project. Ö The project has now been created. Ö The following window is
displayed: Click on OK to confirm entry of the logical AND operation. 43 5.1.3 Inserting the SIMATIC 300
station Go to menu item: Insert > Station > SIMATIC 300 Station A hardware station has now been
inserted in the logical AND operation project. 5.1.4 Configuring and parameterizing To be able to enter
the logical AND operation user program, you must first configure and parameterize the SIMATIC station.
The system inserts a SIMATIC 300 station in the current project (logical AND operation). The station and
its name are displayed in the project window. Select the SIMATIC station in the project. Ö Call the
configuration table using menu item: Edit > Open Object Click here > then insert: Hardware components
44 The system displays the hardware catalog that contains all the hardware components. Select the
SIMATIC 300 station. Click on the «+» sign on the lefthand side of the SIMATIC 300 station. The «+» sign
turns into a «-» sign (subdirectory). This subdirectory contains all the hardware components of the S7-
300 station. Choose the Rail in Rack 300. The DIN rail is the subrack that all the hardware components
are plugged into. Drag the DIN rail to the workspace and drop it there. (Click on the DIN rail, hold down
the mouse button and drag it to the desired location). The system displays a table containing the DIN rail
and the slots. 45 Ö The detail view of the configuration table is shown in the window. The order
numbers and addresses of the modules are displayed in the detail view of the configuration table You
now put the power supply onto the DIN rail. For all subsequent examples, we will be using the 2 A PS
307 power supply. 5.1.5 Arrangement of the power supply Click on the «+» sign in the hardware list next
to the power supply PS 300. The system opens the subdirectory containing the different power supplies.
Drag the power supply PS307 2A into the configuration table and drop it onto slot 1. The power supply is
now installed. 46 5.1.6 Arrangement of the CPU 314 Click on the CPU 300 in the hardware list and use
the «+» sign to open the subdirectory containing the different CPU types. Choose the CPU314 with order
number 314-1AE01-0AB0. We will be using this CPU to test all the exercises. Order number Drag the CPU
into the configuration table and drop it onto slot 2. The CPU 314 is now installed. 5.1.7 Arrangement of
the input module Click on the hardware list next to the SM modules DI300, then click on the «+» sign.
The system opens the subdirectory containing the different DI (digital input modules). Choose module
16 DI with order number 321-1BH00-0AA0. This module has 16 digital inputs. Drag the input module
into the configuration table and drop it onto slot 4. Important: Slot 3 must be empty. It is reserved for
the IM module. The digital input module (DI) with 16 inputs is now installed. 47 5.1.8 Arrangement of
the output module Click on the hardware list next to the SM modules DO300, then click on the «+» sign.
The system opens the subdirectory containing the different DO (digital output modules). Choose module
16 DO with order number 322-1BH00-0AA0. It has 16 digital outputs. Drag the output module into the
configuration table and drop it onto slot 5. The digital output module is now installed. You have now
completed the configuration table. 5.1.9 Parameterizing the CPU 314 To be able to use the CPU 314 for
exercises, you must parameterize it appropriately. In the configuration table, double click on slot 2
(CPU314). 48 Ö The following window is displayed: Click on Cycle/Clock Memory In this dialog box, you
store the information on the CPU and its settable parameters. For other exercises, we will be using a
clock memory (built-in clock generator). To be able to use the clock generator, you must parameterize
the CPU. Bit memory 100 (MB 100) is used. The individual bits of MB 100 can then be called using
different frequencies. Change the Scan Cycle Monitoring Time to 100 ms. Click on OK to leave the dialog
box. The CPU is now parameterized for exercises. 49 5.1.10 Saving the global configuration To retain the
global configuration, you must save it in the logical AND operation project. Choose menu item: Station >
Save The entire configuration is saved in the logical AND operation project on the PC's hard drive. The
global configuration is now saved in the logical AND operation project. 5.1.11 Transferring the
configuration to the CPU For the configuration to take effect, you must load it in the S7-300. Go to menu
item: PLC > Download... Select the modules using menu item: Select All Confirm with OK. Ö The
following window is displayed: 50 Confirm with OK. The system downloads the generated global
configuration into the CPU with node address 2. The changed parameters such as the clock memory and
scan cycle monitoring time do not become effective until you carry out a restart. 5.2 Logical AND
operation user program You can create a user program in STL (Statement List), LAD (Ladder Diagram) or
FBD (Function Block Diagram). First of all, you program the user program in the FBD type of
representation. For the logical AND operation example we have chosen, you need two blocks, namely an
organization block and a function block. Organization block (OB 1) Organization block OB 1 is the
interface between the operating system of the CPU and the user program. In this block, you specify the
sequence of processing. A Function (FC) A function is a code block without a memory. It can, however,
transfer parameters, which makes it particularly good for recurring functions. The displayed modules
will be stopped for loading of the system data. Confirm with OK. The download will be finished. Restart
your system. 51 5.2.1 Entering FCs (FC 1) In the SIMATIC Manager, open the logical AND operation
project using menu item: File > Open... Ö The following window is displayed: Select the logical AND
operation project and click on OK to confirm. Ö The following window is displayed: Open the logical AND
operation project by double clicking on the project. Keep clicking on the «+» signs to get to the bottom
level of the subdirectory where the blocks container is installed. Select the Blocks container 52 5.2.2 S7
block function Choose menu item: Insert > S7 block>Function In this dialog box, you choose the type of
representation (STL, FBD or LAD): in this case, FBD. The system displays FC1 and OB 1 offline in the
project window, i.e. there is no connection to the CPU yet. Click on OK to confirm. Ö The following
window is displayed: Double click 53 Ö The following window is displayed: The window is divided into
two parts and contains: ●Avariable declaration table in the top part ●Astatement section in the bottom
part The variable declaration table is not needed, since the user program FC 1 does not contain any local
variables (use the mouse to push the variable declaration table upwards out of the way). In the
statement section, you enter the program with FBD elements, for example. It is, however, also possible
to enter the program in STL or in LAD. An incremental STL/ LAD/ FBD Editor is integrated in the
statement section that carries out a syntax check each time you enter a statement. Possible input errors
are indicated in red. You must always correct errors of this type, otherwise there would be no function.
The following texts must be entered in the statement section: The block title The block comment The
network comment 54 You add the FBD element logical AND operation by clicking on the AND symbol:
You must now parameterize the AND symbol by clicking on the respective inputs. Enter I0.0 and I0.1.
The output of the AND operation must be assigned separately. 55 Click When you click on the output
symbol, an output is assigned. Enter Q4.0. You save the program using menu item: File > Save. 5.2.3
Entering OB 1 In the SIMATIC Manager, open the logical AND operation project using menu item: File >
Open... Ö The following window is displayed: Select the logical AND operation project and click on OK to
confirm. 56 Ö The following window is displayed: Open the logical AND operation project by double
clicking on the project. Keep clicking on the «+» signs to get to the bottom level of the subdirectory
where the Blocks container is installed. Select menu item S7 block and use menu item Insert > S7
block>Organization Block to insert an OB 1. The system displays OB 1 offline in the project window, i.e.
there is no connection to the CPU yet. Click on OK to confirm. In this dialog box, you choose the type of
representation (STL, FBD or LAD): in this case, STL. Jump instructions can only be programmed in STL. 57
Ö The following window is displayed: Double click Ö The following window is displayed: Statement
section Now, you write the following absolute jump instruction in network 1: CALL FC 1 Network
comment You save OB 1 using menu item: File > Save. 58 5.2.4 Downloading To test the logical AND
operation program, it must first be downloaded into the CPU of the S7-300 programmable controller. It
is possible to download individual blocks as well as complete user programs into the S7-300. To be able
to download the user program into the S7-300 programmable controller, the following requirements
must be fulfilled: There must be an online connection between the PC and the programmable controller.
The program that you want to load must be error-free. The CPU S7-300 must be in the STOP status. In
the SIMATIC Manager (offline view), you now call the blocks subdirectory. With the Shift key pressed
down, click on FC1 and OB1. Both blocks are highlighted. Then choose menu item: PLC > Download...
Both blocks FC 1 and OB 1 are downloaded into the programmable controller. This means that the
logical AND operation project is loaded in the programmable controller. 59 5.2.5 Testing To check the
functionality of a user program, you must test it. To do this, you must go through the following
sequence: Open the block online Specify the settings for the test display Specify the trigger conditions
Choose the test environment Start or stop the test In the SIMATIC Manager, choose menu item: View >
Online Important: This is conditional upon the CPU is switched to the RUN position (online connection).
Ö The following window is displayed: Double click on FC1 60 Ö The following window is displayed: The
system now represents the logical AND operation online, i.e. there is now a connection from the PC to
the programmable controller. 5.2.6 Specifying trigger conditions It is of no consequence whether you
carry out testing in STL, LAD or FBD; when doing this, you can always specify the trigger conditions, the
test environment or the setting of the test display. You call the trigger condition using menu item: Debug
> Call Environment... 61 Using the trigger condition, you set the call environment of the block to be
tested. The block can only be tested if the trigger condition is fulfilled. You can choose from tree
settings. For our logical AND operation example, we do not need a condition. Here, the call environment
is of no consequence. Ö The following window is displayed: You can choose from two test situations: 1.
Process Here, the system only determines on the first pass the status of statements looping through. 2.
Laboratory Here, the system determines on every pass the status of statements looping through. In the
present logical AND operation example, we chose the process test situation. From the menu item,
choose: Options > Customize... 62 Ö The following window is displayed: In this dialog box, you must
choose different settings like, the color and the line width or the font, for example by clicking on them.
Choose using menu item: Debug > Monitor Ö The following window is displayed: Here the color for
program status blue is chosen. Now, you connect at inputs I0.0 and I0.1 alternating 1 or0signals and
observe the changing program status. In the following screenshot, all the inputs I0.0 and I0.1 are
carrying a1signal. This means that output 4.0 is carrying a1signal. The AND condition is fulfilled. Confirm
the setting by clicking on OK. 63 The system only displays the program status for the area that is visible
in the editor. Table 5.2 Function table I0.0 I0.1 Q4.0 0 0 0 0 1 0 1 0 0 1 1 1 5.2.7 Deactivating the FBD
program status From the menu item, choose: Debug > Monitor and click on Monitor. You deselect the
program status by clicking on Monitor or pressing Ctrl + F7. 5.2.8 Testing with STL You can also use the
STL type of representation to test the logical AND operation program that you entered in FBD. From the
menu item, choose: View > STL the Statement List type of representation The requirements for
displaying the STL in status operation are the same as for FBD: ● the block must be error-free, ● the CPU
must be in RUN mode, ● the block must be opened in online mode. 64 Ö The following window is
displayed: The logical AND operation program is displayed in STL. Choose menu item: Debug > Monitor
Ö The following window is displayed: The system displays the STL status in table form. This table shows
the status bit, the RLO and the default status. Now, you connect at inputs I0.0 and I0.1 alternating 1
or0signals and observe the changing program status. In the following screenshot, all the inputs I0.0 and
I0.1 are carrying a1signal. This means that output Q4.0 carries a1signal. The AND condition is fulfilled. 65
The system only displays the program status for the area that is visible in the editor. Table 5.3 Function
table I0.0 I0.1 Q4.0 0 0 0 0 1 0 1 0 0 1 1 1 You quit the program status using menu item: Debug >
Monitor and click on Monitor. 5.2.9 Testing with LAD You can also use the LAD type of representation to
test the logical AND operation program that you entered in FBD. From the menu item, choose: View >
LAD the Ladder Diagram type of representation The requirements for displaying the ladder diagram in
status operation are the same as for FBD ● the block must be error-free, ● the CPU must be in RUN
mode, ● the block must be opened in online mode. 66 Ö The following window is displayed: The logical
AND operation program is displayed in LAD. From the menu item, choose: Debug > Monitor Ö The
following window is displayed: The system displays the program status as LAD for the area that is visible
in the editor. Now, you connect at inputs I0.0 and I0.1 alternating 1 or0signals and observe the changing
program status. In the following screenshot, all the inputs I0.0 and I0.1 are carrying a1signal. This means
that output 4.0 is carrying a1signal. The AND condition is fulfilled. 67 The system only displays the
program status for the area that is visible in the editor. Table 5.4 Function table E0.0 E0.1 A4.0 0 0 0 0 1
0 1 0 0 1 1 1 You quit the program status using menu item: Debug > Monitor and click on Monitor.
5.2.10 Extending from two to three inputs (3rd. input I0.2) 5.2.10.1 Extending with STL Choose the
following window: With the cursor in the following position, press the Return key. 68 Ö The following
window is displayed: In the space you make by pressing the Return key, insert statement: A I 0.2. The
window after inserting statement «I0.2»: The AND operation has now been extended from 2 inputs to 3.
Switch the CPU to the STOP status. Choose menu item: PLC > Download... Download AND operation with
3 inputs into the CPU. Switch the CPU to the RUN status and test the program. Window in test mode
(STL): Table 5.5 Function table I0.0 I0.1 I0.2 Q4.0 0 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 0 0 0 1 0 1 0 1 1 0 0 1 1 1
1 69 You quit the program status using menu item: Debug > Monitor and click on Monitor. 5.2.10.2
Extending with LAD Choose the Ladder Diagram type of representation Menu item: View > LAD Ö The
following window is displayed: Click on the following grid: Here, you click on the NO contact symbol. 70
The system inserts a NO contact into the AND operation. The added NO contact is parameterized with
I0.2. You then switch the CPU to the STOP status and load and test (RUN status) the program. Ö Window
in test mode (LAD): Table 5.6 Function table I0.0 I0.1 I0.2 Q4.0 0 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 0 0 0 1 0 1
0 1 1 0 0 1 1 1 1 71 You quit the program status using menu item: Debug > Monitor and click on Monitor.
5.2.10.3 Extending with FBD Ö Choose the following window: Select input I0.1 with the mouse. Click on
it with the mouse 72 Ö The following window is displayed: The added input I0.2 is parameterized. The
AND operation has now been extended from 2 inputs to 3. Switch the CPU to the STOP status. Choose
menu item: PLC > Download... Download the program into the CPU, test the program. Window in test
mode (FBD): Table 5.7 Function table I0.0 I0.1 I0.2 Q4.0 0 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 0 0 0 1 0 1 0 1 1 0
0 1 1 1 1 73 You quit the program status using menu item Debug > Monitor and click on Monitor. 5.2.11
Reducing from 3 inputs to 2 (delete I0.2) 5.2.11.1 Reducing with STL This restores the initial status. Ö
The initial status is the following window: Use the mouse to highlight the row to be deleted, press the
«Del» key, the row is removed. The AND operation with 2 inputs is restored. Switch the CPU to the STOP
status and choose menu item: PLC > Download... After this, download the AND operation with 2 inputs
into the CPU and switch the CPU to the RUN status. Then test the program. 74 5.2.11.2 Reducing with
LAD This restores the initial status. Ö The initial status is the following window: Use the mouse to
highlight the AND symbol to be deleted, press the «Del» key, the NO contact is removed. The AND
operation with 2 inputs is restored. Switch the CPU to the STOP status and choose menu item: PLC >
Download... After this, download the AND operation with 2 inputs into the CPU and switch the CPU to
the RUN status. Then test the program. 5.2.11.3 Reducing with FBD Ö The initial status is the following
window: Use the mouse to highlight input I0.2, press the «Del» key, input I0.2 is removed. 75 The AND
operation with 2 inputs is restored. Switch the CPU to the STOP status and choose menu item: PLC >
Download... Then, download the AND operation with 2 inputs into the CPU and switch the CPU to the
RUN status. Finally, test the program. 5.3 Logical OR operation user program 5.3.1 Entering the program
using the PC (FBD) Table 5.8 Assignment list Symbol Operand Comment S3 I0.2 «NO contact» switch S4
I0.3 «NO contact» switch P2 Q4.1 Indicator light Figure 5.2 Entering the logical OR operation: a)
Connection to the PLC, b) Schematic diagram, c) FBD, d) LAD + Power supply - 24 V DC EINGÄNGE A U
SGÄNGE INP UTS O U I0.2 TPUTS Q4.1 I0.3 P L C I0.3 I0.2 Q4.1 I0.2 I0.3 Q4.1 76 Before you enter the «OR
operation» program into the SIMATIC S7-300, you must create a project (see also Figure 5.2). You do this
in the same way as with the AND operation. Do not carry out a memory reset on the CPU; otherwise, the
logical «AND operation» program will be lost. For all the following exercises, we will be using the
SIMATIC S7-300 station, just like in the first exercise (logical AND operation program). In the case of a
memory reset, our station 1 would also be lost. The following steps explain programming of the logical
«OR operation» program. 5.3.2 Create a project In the SIMATIC Manager click on menu item: File >
New... Here, you enter the logical OR operation project. Ö The following window is displayed: Click on
OK to confirm. The logical OR operation project has now been created. 77 Ö The following window is
displayed. You must now insert the SIMATIC station into this window. Since we are working with the
same SIMATIC station as in the previous project, you do not need to create a new station. You copy the
SIMATIC station from the logical AND operation project to the logical OR operation project. 5.3.3 Copy
SIMATIC station 1 into another project Use menu item: File > Open... to open the «logical AND
operation» project Ö The following window is displayed: Doubleclick on the AND operation Ö The
following window is displayed: Use the mouse to select the SIMATIC station (1), click on menu item: Edit
> Copy, the station (1) is copied to the clipboard. 78 After this, click on menu items: File > Close Ö The
following window is displayed: Ö The following window is displayed: You are now back in the logical OR
operation project Click on MPI(1) interface to select it and click on menu item: Edit > Paste Ö The
following window is displayed: The system pasted SIMATIC station (1) from the clipboard with all the set
and configured parameters. Now click on the «+» signs down to the lowest level of the directory. At the
lowest level, the Blocks container is installed. 79 Select the Block container and use menu item: Insert >
S7 block>Function to insert a Function FC 2. Click on OK to confirm. FBD setting Ö The following window
is displayed: Function FC2 was inserted. Double click on FC2. Ö The following window is displayed: Insert
comments 80 Clicking on the OR box inserts the OR symbol. Ö The following window is displayed:
Parameterize the inputs of the OR operation with I0.2, I0.3 and Q4.1. You save the program using menu
item: File > Save 5.3.4 Change OB 1 Use the SIMATIC Manager to open the following window:
Doubleclick on the OB1 symbol 81 Ö The following window is displayed: Change the texts for the OR
operation appropriately. Change the command line: CALL FC 1 to CALL FC 2 and change the command
texts to an appropriate one and confirm by pressing Return. Ö The following window is displayed: Now
save the changed OB 1 under menu item: File > Save OB 1 is now available for the logical OR operation
project. 82 5.3.5 Downloading To test the logical OR operation program, it must first be downloaded
into the CPU of the S7-300 programmable controller. It is possible to download individual blocks as well
as complete user programs into the S7-300. To be able to download the user program into the S7-300
programmable controller, the following requirements must be fulfilled: ˆ There must be an online
connection between the PC and the programmable controller. ˆ The CPU S7-300 must be in the STOP
status. In the SIMATIC Manager (offline view), you then call the Blocks subdirectory. With the Ctrl key
pressed down, click on FC2 and OB1. Both blocks are highlighted. Choose menu item: PLC > Download...
The logical OR operation project is now present in the programmable controller. 5.3.6 Testing To check
the functionality of a user program, you must test it. You must keep to the following sequence: ˆ Open
the block online ˆ Specify the settings for the test display ˆ Specify the trigger conditions ˆ Choose the
test environment ˆ Start or stop the test In the SIMATIC Manager, choose menu item: View > Online 83
Ö The following window is displayed: Double click on FC2 Ö The following window is displayed: The
system now represents the logical OR operation online, i.e. there is now a connection from the PC to the
programmable controller (CPU). Now, use menu item: Debug > Call Environment... to call the trigger
condition, and choose: No condition and the desired settings from menu item: Options > Customize...
then from menu item: Debug > Monitor or function keys Ctrl + F7 84 Ö The following window is
displayed: Now, you connect at inputs I0.2 and I0.3 alternating 1 or0signals and observe the changing
program status. Window: FBD type of representation Now you can test the program in LAD and STL Ö
Window: LAD Ö Window: STL You must check the results of logic operations in accordance with the
function table. Table 5.9 Function table I0.2 I0.3 Q4.1 0 0 0 0 1 1 1 0 1 1 1 1 85 6.1 AND before OR The
logical AND before OR operation corresponds to parallel switching of several series-switched contacts in
the wiring diagram.With these subbranches that are composed of series and parallel connections,
output Q4.2 carries a signal state of 1 if in at least one subbranch all the series-connected contacts are
closed (have a signal state of 1). AND before OR operations are programmed in the STL method of
representation without brackets; however, the parallel-switched subbranches must be separated from
one another by entering an O (OR function). In this connection, the AND functions are processed first
and the system forms from these results the result of the OR function. The first AND function (I0.0, I0.1)
is separated from the second AND function (I0.2, I0.3) by the individual O (OR function). AND operations
have priority and are therefore always processed before OR operations. 6 Program Input 86 Before you
enter the AND before OR program into the SIMATIC S7-300, you must create a project (see Figure 6.1);
in this case project AND before OR. In this connection, you must not carry out a memory reset of the
CPU, otherwise all the programs would be lost. For all the following exercises, we will be using the
SIMATIC S7-300 station, just like in the first exercise (logical AND operation program). In the case of a
memory reset, our station 1 would also be lost. Figure 6.1 Entering the logical AND operation: a)
Connection to the PLC, b) Schematic diagram, c) LAD, d) FBD Table 6.1 Assignment list Symbol Operand
Comment S1 I0.0 «NO contact» switch S2 I0.1 «NO contact» switch S3 I0.2 «NO contact» switch S4 I0.3
«NO contact» switch P1 Q4.2 Indicator light + Power supply - 24 V DC EINGÄNGE A U SGÄNGE INP UTS O
U I0.0 TPUTS Q4.2 I0.1 P L C I0.1 I0.2 Q4.2 I0.2 I0.3 I0.0 I0.3 I0.0 I0.1 I0.2 I0.3 Q4.2 87 You must keep to
the following steps when programming the AND before OR program: ˆ Create project AND before OR ˆ
Create block FC 3 ˆ Program AND before OR in FBD ˆ Change OB 1 ˆ Download FC 3 and OB 1 into the
CPU ˆ Test the program The following window shows the AND before OR operation in FBD: Method of
representation: LAD 88 Method of representation: STL Test the program. 6.2 OR before AND The logical
OR before AND operation corresponds to series switching of several parallel-switched contacts in the
wiring diagram. In the case of this connection composed of series and parallel connections, output Q4.3
only has a signal state of 1 if in both parallel subbranches at least one of the contacts has a signal state
of 1. For OR operations to have priority over AND operations, they must be joined by brackets. Before
we enter the OR before AND program into the SIMATIC S7-300, we must create a project (see Figure
6.2). 89 You create the OR before AND project. In this connection, you must not carry out a memory
reset of the CPU, otherwise all the programs would be lost. For all the following exercises, we will be
using the SIMATIC S7-300 station, just like in the first exercise (logical AND operation program). In the
case of a memory reset, our station 1 would be lost. Table 6.2 Assignment list Symbol Operand
Comment S1 I1.0 «NO contact» switch S2 I1.1 «NO contact» switch S3 I1.2 «NO contact» switch S4 I1.3
«NO contact» switch P3 Q4.3 Indicator light Figure 6.2 Creating the logical AND operation: a) Connection
to the PLC, b) Schematic diagram, c) LAD, d) FBD + Power supply - 24 V DC INP UTS O U I1.0 TPUTS Q4.3
I1.1 P L C I1.2 I1.1 Q4.3 I1.2 I1.3 I1.0 I1.3 I1.0 I1.1 I1.2 I1.3 Q4.3 90 You must keep to the following steps
when programming the OR before AND program: ˆ Create project OR before AND ˆ Create block FC 4 ˆ
Program AND before OR in FBD ˆ Change OB 1 ˆ Download FC 4 and OB 1 into the CPU ˆ Test the
program In the following window, the OR before AND logic operation is represented in FBD. Method of
representation: FBD Method of representation: LAD 91 Test the program. 6.3 Poll for signal state 0 In a
circuit with contacts, polling for signal state 0 corresponds to an NC contact. Before you enter the Poll
for signal state 0 program into the SIMATIC S7-300, you must create a Poll for signal state 0 project (see
Figure 6.3). Again, for all the following exercises we will be using the SIMATIC S7-300 station, just like in
the first exercise (logical AND operation program). Here too, you must observe the following: In the case
of a memory reset, our station 1 would be lost. Proceed as follows: ˆ Create Poll for signal state 0 project
ˆ Create block FC 5 ˆ Program poll for 0 in FBD ˆ Change OB 1 ˆ Download FC 5 and OB 1 into the CPU ˆ
Test the program Method of representation: STL 92 The following window shows the Poll for 0 program
in FBD. Method of representation: FBD Table 6.3 Assignment list Symbol Operand Comment S2 I0.2
Switch «NO contact» S3 I0.3 Switch «NC contact» P1 Q4.1 Indicator light + Power supply - 24 V DC Figure
6.3 Creating the project: a) Connection to the PLC, b) Schematic diagram, c) LAD, d) FBD INP UTS O U I0.2
TPUTS Q4.1 I0.3 P L C I0.3 I0.2 Q4.1 I0.2 I0.3 Q4.1 93 Method of representation: LAD Test the program.
Method of representation: LAD 94 6.4 Exclusive OR operation The circuit shows an Exclusive OR
operation (X) in which output Q4.0 is only activated (signal state 1) if one single input has a signal state
of 1. In a circuit with contacts, this can only be implemented using NC and NO contacts. Before you can
enter the Exclusive OR operation program into the SIMATIC S7- 300, you must create the Exclusive OR
project (see Figure 6.4). For all the following exercises we will be using the SIMATIC S7-300 station, just
like in the first exercise (logical AND operation program). Table 6.4 Assignment list Symbol Operand
Comment S0 I1.0 Switch «NO contact» S1 I1.1 Switch «NO contact» P1 Q4.0 Indicator light Figure 6.4
Creating the project: a) Connection to the PLC, b) Schematic diagram, c) LAD, d) FBD INP UTS O U I1.0
TPUTS Q4.0 I1.1 P L C I1.0 I1.0 I1.1 Q4.0 I1.1 I1.0 I1.0 I1.1 I1.1 Q4.0 + Power supply - 24 V DC 95 Proceed
as follows: ˆ Create the Exclusive OR project ˆ Create block FC 6 ˆ Program Exclusive OR in FBD ˆ Change
OB 1 ˆ Download FC 6 and OB 1 into the CPU ˆ Test the program The following windows show the
Exclusive OR program. Method of representation: FBD Method of representation: LAD 96 Test the
program. 6.5 Polling outputs There are different conditions for activating outputs Q4.0 and Q4.1. In
these cases, you must provide each output with its own current path or a separate logic symbol. Since
the programmable controller can poll the signal state of inputs as well as of outputs, bit memories, etc.,
the system polls in the AND operation for output Q4.0 and output Q4.1. Before you can enter the Polling
outputs program into the SIMATIC S7-300, you must create the Polling outputs project. Method of
representation: STL 97 For all the following exercises we will be using the SIMATIC S7-300 station, just
like in the first exercise (logical AND operation program). Proceed as follows when programming the
Polling outputs program: ˆ Create the Polling outputs project ˆ Create block FC 7 ˆ Program Polling
outputs in FBD ˆ Change OB 1 ˆ Download FC 7 and OB 1 into the CPU ˆ Test the program The first two
procedures will not be described here (see the AND operation procedure). In this example, you must,
however, insert a second network. Table 6.5 Assignment list Symbol Operand Comment S1 I1.0 Switch
«NO contact» S2 I1.1 Switch «NO contact» S3 I1.2 Switch «NO contact» P1 Q4.0 Indicator light P2 Q4.1
Indicator light Figure 6.5 Creating the project: a) Connection to the PLC, b) Schematic diagram, c) LAD, d)
FBD + Power supply - 24 V DC INP UTS O U I1.0 TPUTS Q4.0 I1.1 P L C Q4.0 I1.0 I1.1 Q4.0 I1.2 Q4.1 I1.2
Q4.1 I1.0 I1.1 I1.2 Q4.0 Q4.0 Q4.1 98 6.6 Inserting networks Ö The following window is open: Click here
or choose menu item: Insert > Network Ö The following window is displayed: Here, you can insert the
second network. The Polling outputs example needs a second network. Click on the project Click on 99 Ö
The following window is displayed: The inputs are parameterized according to the assignment list. The
program is further executed after the learned steps. You delete networks in the following order: ˆ Click
on network 2 (heading), ˆ Choose menu item: Edit > Delete or press the DEL key, ˆ The network is
deleted. You undo the command using menu item: Edit > Undo or by pressing Ctrl + Z. 100 The following
windows show the Polling outputs program. Method of representation: LAD Method of representation:
STL Test the program. 101 6.7 Latch circuit with the PC The circuit that is commonly used in protective
controls for an L/U function is a latch circuit. To deactivate the contactor, two variants are possible
depending on whether activation or deactivation has priority. When programming, you must note that
even when using a PLC the pushbutton that activates towards OFF should have NC contacts for safety
reasons and must be polled for a1signal. Switched-on dominant Table 6.6 Assignment list Symbol
Operand Comment S1 I1.0 Button «NO contact» S2 I1.1 Button «NC contact» K1 Q4.0 Auxiliary contact +
Power suply - 24 V DC Figure 6.6 Creating the Switched-on dominant project: a) Connection to the PLC,
b) Schematic diagram, c) LAD, d) FBD a) b) c) d) INP UTS O U TPUTS I1.0 Q4.0 I1.1 P L C Q4.0 I1.0 Q4.0
I1.1 Q4.0 I1.1 I1.0 Q4.0 102 Proceed as follows: ˆ Create the Latch circuit project ˆ Create block FC 8 ˆ
Program Latch circuit project in FBD ˆ Change OB 1 ˆ Download FC 8 and OB 1 into the CPU The
subsequent windows show the program in the STL, LAD and FBD methods of representation as a
solution. Switched-off dominant Table 6.7 Assignment list Symbol Operand Comment S3 I0.0 Button
«NO contact» S4 I0.1 Button «NC contact» K2 Q4.1 Auxiliary contact + Power supply - 24 V DC Figure 6.7
Creating the Switched-off dominant project: a) Connection to the PLC, b) Schematic diagram, c) LAD, d)
FBD a) b) c) d) INP UTS O U TPUTS I0.0 Q4.1 I0.1 P L C Q4.1 I0.0 I0.1 Q4.1 Q4.1 I0.0 I0.1 Q4.1 103 Method
of representation: STL Method of representation: LAD 104 Test the program. Method of representation:
FBD 105 6.8 Practical examples of control with the PC 6.8.1 Temperature difference + Power supply - 24
V DC Figure 6.8 Example of control – Temperature difference circuit: a) Schematic diagram b)
Connection to a PLC Description of function (Figure 6.8) If power controller S1 is activated, the system is
ready for operation. Thermostat F1 switches at 25 °C, and thermostat F2 at 20 °C. If the temperature
drops below 20 °C, then the contact elements of both thermostats are closed and contactor K1 picks up.
If the temperature rises above 20 °C, thermostat F2 opens; however, contactor K1 stays picked-up via
the NO contact of K1 that is parallel-switched to F2 until the temperature rises above 25 °C and
thermostat F1 opens. Indicator light P1 lights up with the contactor energized. The system can be
deactivated again via power controller S1. Table 6.8 Assignment list Symbol Operand Comment S1 I0.0
Plant temperature difference «ON» NO contact F1 I0.1 Thermostat 25 °C «NC contact» F2 I0.2
Thermostat 20 °C «NC contact» K1 Q4.0 Auxiliary contact for switching duty P1 Q4.1 Indicator light INP
UTS O U I0.0 TPUTS Q4.0 I0.1 P L C I0.2 Q4.1 106 Proceed as follows: ˆ Create a Temperature difference
project in FBD ˆ Choose a function (we suggest FC 9) ˆ Organize OB 1 ˆ Download the program into the
CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change
programs in online mode without needing to put the switch into the STOP position). ˆ Change the
methods of representation: > FBD > LAD > STL End of the exercise. 6.8.2 Drinks machine Coin insertion
Valve Tea powder Valve Water Valve Coffee powder Case Coffee powder Water Tea powder Tea Coffee
Input Output Figure 6.9 Example of control Drinks machine: Technology scheme Description of Function
After inserting an appropriate coin in the slot, users can choose the desired drink by pressing the Tea or
Coffee button. For methodical reasons, the problem is simplified to three input variables. The beverage
should always be dispensed if users press the tea or coffee button after inserting a coin. The following
operation is carried out: The solenoid valve ZW releases the hot water. Hot water is added to the tea or
coffee powder. (To make things simpler, no milk or sugar is added). 107 ZK = Coffee powder runs out ZT
= Tea powder runs out ZW = Hot water runs out If none of the pushbuttons are pressed, all the input
signals are «0». Task: A drinks machine is to be programmed in accordance with the specified Function
Block Diagram (Figure 6.10). Table 6.9 Function table A (Tea) B (Coffee) C (Coin) ZT (Tea powder) ZK
(Coffee powder) ZW (Water) 000000 001000 011011 010000 101101 100000 111000 110000 Figure 6.10
Specifications of the drinks machine task: a) FBD, b) Connection to the PLC a) b) + Power supply - 24 V
DC INP UTS O U TPUTS I0.0 Q4.0 I0.1 P L I0.2 C Q4.1 Q4.2 108 Proceed as follows: ˆ Program the drinks
machine in FBD ˆ Choose a function (we suggest FC 10) ˆ Organize OB 1 ˆ Download into the CPU ˆ Test
the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change programs in
online mode without needing to put the switch into the STOP position). ˆ Change the methods of
representation: > FBD > LAD > STL 6.8.3 Intercom Description of Function In a company, three senior
staff members are intended to be able to speak to the secretary (see Figure 6.11). These people are the
Managing Director A, the Works Manager B and the Factory Supervisor C. In accordance with the
positions of these people in the company, their conversations are given different priorities, i.e. the
Managing Director has the highest priority, the Factory Supervisor is only put through if neither of the
other users is speaking (see Figure 6.12). Table 6.10 Assignment list Symbol Operand Comment A I0.0
Input "Tea preselection" B I0.1 Input "Coffee preselection" C I0.2 Coin insertion ZW Q4.0 Solenoid valve
«Water» ZT Q4.1 Solenoid valve «Tea» ZK Q4.2 Solenoid valve «Coffee» Managing Director Works
Manager Factory Supervisor Secretary Linkage system Figure 6.11 Intercom: Technology scheme 109
Table 6.11 Function table Input variable A B C 0 0 0 0 0 1 0 1 0 0 1 1 1 0 0 1 0 1 1 1 0 1 1 1 X=1,Ais
speaking Y = 1, B is speaking, i.e., A = 0 Z=1,Cis speaking, i.e., A = 0, B=0 You should also ensure that
when somebody wants to speak, the higher priority is prioritized (see Figure 6.13) and a call with a lower
priority is interrupted. Figure 6.12 Definition of the switching variables Table 6.12 Function table Output
variable X Y Z 0 0 0 0 0 1 0 1 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 Figure 6.13 Create project: a) FBD, b)
Connection to the PLC a) b) + Power supply - 24 V DC INP UTS O U TPUTS I0.0 Q4.0 I0.1 P L I0.2 C Q4.1
Q4.2 110 Proceed as follows: ˆ Program the Intercom in FBD ˆ Choose a function (we suggest FC 11) ˆ
Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In
this switch position, it is possible to change programs in online mode without needing to put the switch
into the STOP position). ˆ Change the methods of representation: > FDB > LAD > STL 6.8.4 Generator
Description of Function A generator (see Figure 6.14) supplies a maximum of 7 kW. It is possible to
connect four motors to the generator in series. These motors consume the following: PA =5kW PB =1kW
PC =3kW PD =2kW Table 6.13 Assignment list Symbol Operand Comment A I0.0 Managing Director B I0.1
Works Manager C I0.2 Factory Supervisor X Q4.0 Relay – Managing Director is speaking Y Q4.1 Relay –
Works Manager is speaking Z Q4.2 Relay – Factory Supervisor is speaking Figure 6.14 Generator:
Technology scheme Generator Motor 1 Motor 2 Motor 3 Motor 4 111 Proceed as follows: ˆ Program the
generator in FBD ˆ Choose a function (we suggest FC 12) ˆ Organize OB 1 ˆ Download the program into
the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change
programs in online mode without needing to put the switch into the STOP position). ˆ Change the
method of representation: > FDB > LAD > STL End of the exercise. At output A there should be a1signal if
more than 7 kW is switched-on (see Figure 6.15). The signal renders the last starting command
ineffective. Figure 6.15 Create project: a) FBD, b) Connection to the PLC a) b) + Power supply - 24 V DC
Table 6.14 Assignment list Symbol Operand Comment PA I0.0 Motor 5 kW PB I0.1 Motor 1 kW PC I0.2
Motor 3 kW PD I0.3 Motor 2 kW A Q4.0 Indicator light INP UTS O U TPUTS I0.0 Q4.0 I0.1 P L C I0.2 I0.3
PA PB PC PD PA PB PC PD 112 6.8.5 Boiler control Description of Function It is intended to fill a boiler
(Figure 6.16) with water. If the boiler is empty (the min. probe is not activated), water inflow valve M1
activates and the container fills up automatically. On reaching the max. probe, the water valve is closed
again; when reaching the bottom water level, the process starts from the beginning again. The plant is
switched-on with switch S0. The water inflow valve is displayed by indicator light P0 (see Figure 6.17).
Figure 6.16 Boiler control: Technology scheme Water inflow Float Water Water outflow balance weight
Water level max. Water level min. + Power supply - 24 V DC Figure 6.17 Boiler control: a) Schematic
diagram, b) Connection to the PLCINP UTS O U I0.0 TPUTS Q4.0 I0.1 P L C I0.2 Q4.1 Q4.2 113 Proceed as
follows: ˆ Program the boiler control in FBD ˆ Choose a function (we suggest FC 13) ˆ Organize OB 1 ˆ
Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the method of representation: > FDB > LAD > STL 6.8.6 Smelting furnaces
Figure 6.18 Smelting furnaces: Technology scheme Table 6.15 Assignment list Symbol Operand
Comment S0 I0.0 Plant boiler control «On» – NO contact S1 I0.1 Min. water probe – NC contact S2 I0.2
Max. water probe – NC contact K1 Q4.0 Auxiliary contact M1 Q4.1 Water inflow valve P0 Q4.2 Indicator
light for water inflow Description of Function A company operates four smelting furnaces (A, B, C and D).
To supply the electrical energy that they need, daily peak times have been agreed. If this maximum
value is exceeded, the company must pay a high price. Furnace A Furnace B Furnace C Furnace D 114
The four smelting furnaces have the following individual connection values (i.e. relative to the maximum
value on a percentage basis): A=65 % B=45 % C=25 % D=25 % An interlocking circuit is intended to make
it impossible to switch in a furnace if this leads to the permissible maximum current consumption being
exceeded. If due to a fault, more furnaces are switched-in, it is intended for an alarm signal to be issued.
It is assumed that two furnaces are never switched-on at the same time (see Figure 6.19). Figure 6.19
Connection to the PLC Table 6.16 Assignment list Symbol Operand Comment A I0.0 Furnace 1 B I0.1
Furnace 2 C I0.2 Furnace 3 D I0.3 Furnace 4 Va Q4.0 Indicator light P1 Vb Q4.1 Indicator light P2 Vc Q4.2
Indicator light P3 Vd Q4.3 Indicator light P4 Vp Q4.4 Indicator light P5 + Power supply - 24 V DC INP UTS
O U I0.0 TPUTS Q4.0 I0.1 P L C I0.2 Q4.1 Q4.2 I0.3 Q4.3 Q4.4 115 Furnace «A» is operating Furnace «B» is
operating Furnace «C» is operating Furnace «D» is operating Va > switchgear equipment for furnace «A»
locked. Vb > switchgear equipment for furnace «B» locked. Vc > switchgear equipment for furnace «C»
locked. Vd > switchgear equipment for furnace «D» locked. Vp > alarm has triggered. The circuit in FBD
is shown in Figure 6.20. Table 6.17 Function table ABCDVa Vb Vc Vd Vp 000000000 000100000
001000000 001110000 010010000 010110000 011010000 011110000 100001000 100101100
101001010 101100001 110000001 110100001 111000001 111100001 116 Proceed as follows: ˆ
Program the smelting furnaces in FBD ˆ Choose a function (we suggest FC 14) ˆ Organize OB 1 ˆ
Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the methods of representation: > FDB > LAD > STL ˆ Compare the results with
the function table End of the exercise. 6.9 Flip-flop 6.9.1 R-S flip-flop Every circuit that has two stable
status conditions and that can be switched from one status to another by means of corresponding input
signals is considered to be a signal latch (latch circuit with a control relay). In digital technology, they are
also referred to as flip-flops. Figure 6.20 FBD 117 According to DIN 40 900, an R-S function is
represented as a rectangle with a set input S and a reset input R. A brief signal state of 1 at set input S
sets up the set/reset function. A brief signal state of 1 at reset input R leads to the set/ reset function
being reset (switched off). A signal state of 0 at inputs R and S does not change the previously set status.
If there is a1signal at both inputs at the same time, set or reset dominant is carried out. You must take
into account this Set or Reset dominant at programming. Set = switch on or reset = switch off: with
a1signal only; no effect with a 0 signal (signal state is retained). Reset dominant Figure 6.21 The
controller processes the statements that you programmed last with priority. In Figure 6.21, the set
operation is executed first and then the reset operation, i.e. if both inputs (S and R) have 1 signals in this
case, the system resets dominant the flip-flop (memory). Output Q4.0 carries a0signal. In practice, this is
the memory that is used most. Set dominant Figure 6.22 The controller handles the statements that you
programmed last with priority. In Figure 6.22, the system sets the memory if both inputs are carrying 1
signals. I1.1 I1.0 Q4.0 I0.1 I0.0 Q4.1 118 6.9.2 Entering the program Task (Figure 6.23): ˆ Program R-S
flip-flop in FBD ˆ Choose function FC 10 ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the
program ˆ Change the methods of representation: > FDB > LAD > STL Fenster im Testmodus (FUP) +
Power supply - 24 V DC Figure 6.23 R-S function for the task: a) Connection to the PLC, b) Reset
dominant (FBD), c) Set dominant (FBD) Table 6.18 Assignment list Symbol Operand Comment S1 I1.1
Button «NO contact» S2 I1.0 Button «NO contact» S3 I0.1 Button «NO contact» S4 I0.0 Button «NO
contact» P1 Q4.0 Indicator light P2 Q4.1 Indicator light INP UTS O U I1.1 TPUTS Q4.0 I1.0 P L C I0.1 Q4.1
I0.0 I1.1 I1.0 Q4.0 I0.1 I0.0 Q4.1 119 The previous steps for creating a project will no longer be explained
in detail here. Ö The following window is displayed: Insert network comments Call FC 10 Ö The following
window is displayed: Click on Program elements: Overview on/off Ö The following window is displayed:
All the program elements are stored in the hardware catalogue and you can drag and drop them into
the respective window. Here, click on the «+» character in the bit combination container. 120 For our R-
S function (Reset dominant), we need the following function (SR): Drag and drop to the workspace. Ö
The following window is displayed: Here, you can drag and drop the corresponding bit combination to
the workspace. Set or reset flip-flop Ö The following window is displayed: 121 Ö After completing the
program, the following window is displayed: FBD method of representation with two networks: 1st
network: Reset dominant 2nd network: Set dominant The subsequent windows show the program in the
LAD and STL methods of representation as a solution. Method of representation: LAD 122 Method of
representation: STL Test the program. 6.9.3 Pump controller Figure 6.24 Pump controller: Technology
scheme Pump Water B5 "max" B4 "min" Q11 123 Description of Function Filling of a water container
(Pump On) is carried out automatically after switching on the plant if the bottom level has been reached.
On reaching the top fill level, the pump switches off. To prevent switching off due to water "sloshing",
the Fill level max. condition must be present for at least 1 second. The liquid-level switches are emulated
by sensors. Automatic-manual switching is carried out using button S1. Indicator light P1 shows manual
operation. In manual mode, it is only possible to switch on the pump using button S2 Manual On. Switch
off is carried out using button S3 Manual Off, or when the maximum fill level "B5 max." is reached. After
switch on, the plant is in automatic mode. The two fill level sensors, "B4 min." and "B5 max.", can now
switch the pump motor on and off respectively via contactor Q11. The "min." level condition only needs
to be pending briefly; the "max." level condition must be present for at least 1 second. S2 and S3 have
no effect in automatic mode. Using button S1, manual -automatic switching is carried out via a T flip-flop
(pulse circuit – binary scaler). In manual mode, "S4 min." has no effect and the pump can only be
switched on by activating S2 Manual On. After this, it is possible to switch off using S3 Manual Off or by
activating S5 "max." The associated logic diagram is shown in Figure 6.25, with Figure 6.26 showing the
connection to the PLC. 124 Manual - automatic switch over Manual On Manual Q4.1 Auto Q4.1 Time
stage Pump Manual - automatic T-Flip-Flop Figure 6.25 Logic diagram Manual Off 125 Proceed as
follows: ˆ Program Pump controller in FBD, LAD and STL ˆ Choose a function (we suggest FC 29) ˆ
Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In
this switch position, it is possible to change programs in online mode without needing to put the switch
into the STOP position). ˆ Change the methods of representation: > FBD > LAD > STL Table 6.19
Assignment list Symbol Operand Comment S1 I0.1 Button «NO contact» – Manual/automatic switchover
S2 I0.2 Button «NO contact» – Pump Manual On S3 I0.3 Button «NC contact» – Pump Manual Off B4 I0.4
Liquid-level switch «NC contact» min. level B5 I0.5 Liquid-level switch «NC contact» max. level Q11 Q4.0
Power contactor «Pump motor» P1 Q4.1 Indicator light «Manual/automatic» Figure 6.26 Connection to
the PLC + Power supply - 24 V DC INP UTS O U I0.1 TPUTS Q4.0 I0.2 P L C I0.3 Q4.1 I0.4 I0.5 126 127 7
Creating Momentary Impulses (Edge Instructions) Rather than acquiring a static signal state 0 and 1,
edge instructions acquire a signal change, e.g. of an input. The program of an edge instruction
corresponds to an edge-detecting contact in a relay circuit. 7.1 Momentary impulse with a rising edge
(FP) Figure 7.1 Programmed momentary impulse with a rising edge: a) in FBD, b) in STL, c) signal time
diagram a) b) c) If the system detects a rising (positive) edge (change from 0 to 1) at I0.0 (see Figure 7.1),
it sets output Q4.0 to 1 for one OB 1 cycle. A rising edge is detected by the automation system saving
the RLO (that supplied operation "A") in edge trigger memory M2.0 and comparing it with the RLO of the
previous cycle. Rising edge Momentary impulse Cycle time 1-Signal 0-Signal 0-Signal 0-Signal 1-Signal 1-
Signal Q4.0 Q4.0 Q4.0 Q4.0 I0.0 M2.0 I0.0 A I0.0 FP M2.0 = Q4.0 128 If the system detects a falling edge
(see Figure 7.2) at I0.1 (change from 1 to 0), it sets output Q4.1 to 1 for one OB 1 cycle. A falling edge is
detected by the automation system saving the RLO (that supplied operation "A") in edge trigger memory
M2.1 and comparing it with the RLO of the previous cycle. 7.3 Program input Task: ˆ Program the
momentary impulses in FBD ˆ Use function FC 11 ˆ Organize OB 1 ˆ Download the program into the CPU
ˆ Test the program ˆ Change the methods of representation: > FBD > LAD > STL 7.2 Momentary impulse
with a falling edge (FN) Figure 7.2 Programmed momentary impulse with a falling edge: a) in FBD, b) in
STL, c) signal time diagram a) b) c) 1-Signal 0-Signal 0-Signal 0-Signal 1-Signal 1-Signal Falling edge
Momentary impulse Cycle time Q4.1 Q4.1 Q4.1 I0.1 M2.1 A I0.1 FN M2.1 = Q4.1 M2.1 I0.1 129 The
preceding steps for configuration will no longer be explained in detail here. Table 7.1 Assignment list
Symbol Operand Comment S1 I0.0 Button «NO contact» S2 I0.1 Button «NO contact» P1 Q4.0 Indicator
light P2 Q4.1 Indicator light Figure 7.3 Momentary impulse program input: Connection to the PLC +
Power supply - 24 V DC INP UTS O U TPUTS Call FC11 Ö The following window is displayed: Insert
network comments Click on Program elements: Overview on/off I0.0 I0.1 Q4.0 Q4.1 P L C 130 Drag the
momentary impulse for the falling edge (NEG) into the second network of the workspace too. Ö The
following window is displayed: Click on the «+»-sign of bit combination Ö The following window is
displayed: Click on POS and drag and drop Momentary Impulse into the workspace The window shows
the FBD with two networks: 1st network: momentary impulse with a rising edge 2nd network:
momentary impulse with a falling edge In the following windows, the program is shown with LAD and
STL as a solution. 131 Method of representation LAD: Method of representation STL: Test the program.
132 7.4 Acknowledgement circuit Description of Function In the case of a digital circuit, it is intended for
a warning lamp to flash at a frequency of 2 Hz ifafalse signal (disturbance) occurs. After activating an
acknowledgement key S2, it is intended for the warning lamp to change from flashing to steady light
that goes out when the false signal disappears (see Figure 7.4). + Power supply - 24 V DC INP UTS O U
TPUTS Figure 7.4 a) Logic diagram of acknowledgement circuit, b) Connection to the PLC Table 7.2
Assignment list Symbol Operand Comment B1 I0.0 Disturbance «NO contact» S2 I0.1 Acknowledge
disturbance «NO contact» P1 Q4.0 Indicator light P L C I0.0 Q4.0 I0.1 133 Proceed as follows: ˆ Program
the acknowledgement circuit in STL, LAD and FBD ˆ Choose a function (we suggest FC 28) ˆ Organize OB
1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the methods of representation: STL > FBD > LAD 134 135 8 Timing Functions
The S7-300 programmable controller with the CPU 314 has 128 timers (0...127) that you can use for
different functions. The program specifies the runtime and it can be between 0.01 seconds and 9990
seconds or 2 hours, 46 minutes and 30 seconds. To implement control jobs, it is very often necessary to
use different timing functions. The timing functions are integrated into the central processing unit of the
programmable controller (PLC). Setting of the desired time and starting of the timing function must be
carried out via the user program. A 16-bit word is assigned to each of the different timing functions. 8.1
Timing value specification You can specify the time duration TV (runtime) as a predefined constant, as an
input word IW, as an output word QW, asadata word DBW/DIW or as a memory word MW (see Figure
8.1). Figure 8.1 FBD for TV Starting from the left, a timer word has two status bits that the processor
needs for processing the timing functions. They are irrelevant for specifying the time duration, i.e., they
are of no significance for the time sequence. After these, there are two bits for the time base and four
bits each for the BCD-coded current value. Figure 8.2 presents the current value of 137 with the time
base 1 s. Constant Data word Input word Output word Memory word TV 136 8.2 Release a time (FR) A
positive edge change from 0 to1in the RLO of the release operation (FR) releases a time. The release
operation (FR) is only present in STL type of representation. The release (FR) is not needed for starting
up or for the normal function of a time. This function is only used to post-trigger a running time or to
start it up again. Restarting the timer only leads to a function if the system continues to process the start
operation with a1signal. 8.3 Current value Bits 12 and 13 of the timer word contain the time base in
binary-coded form. This defines the interval in which the timer word is reduced by 1 unit. The smallest
time base is 10 ms, and the largest is 10 s. Values whose resolutions are too big for the desired range are
rounded-down (FBD see Figure 8.3). Figure 8.2 Current value Irrelevant: these bits are ignored, if the
time is started. Time base 1 Second Current value BCD-coded (0-999) 1 3 7 Table 8.1 Time base Time
base Time range 0.01 s 00 10 ms-9sand 990 ms (9.990 sec.) 0.1 s 01 100 ms -1mand 39 s and 900 ms
(1:39.900 min.) 1 s 10 1s-16mand 39 s (16:39 min.) 10 s 11 10s-2hand 46 m und 30 s (2:46:30 hours)
Figure 8.3 FBD for FR Current value 2 s I0.0 I0.1 Q4.0 MW1 MW3 TV 137 8.4 Reset time A signal at the
reset input (R) of the timer resets the timer; the time sequence is ended. The output (Q) of the timer is
reset. Poll current value A current value is stored in binary-coded form in a timer word. This value can be
loaded as a dual number (BI) or as a BCD number (BCD) into the accumulator and transferred from there
to other operand areas. With STL programming, you use L T1 for dual polling or LC T1 for BCD polling.
Polling the signal state of the timer (binary) Q You can poll a time for its signal state 0 or 1. You can poll
using A T1, AN T1, ON T1 etc. and use the result for further logic operations. 8.5 Selection of times (five
different ones) 8.5.1 Pulse timer (SP) Figure 8.4 FBD for SP Output Q (see Figure 8.4) carries a1signal
after starting of timer pulse (SP). The output is reset when the specified time has expired, if the start
signal is reset to 0 or if a1signal is pending at the reset input (see Figure 8.5). I0.0 I0.1 Q4.0 MW1 MW3
TV 138 Explanation of the signal status diagram for pulse timer (SP) 1 Output Q4.0 carries a1signal after
start-up. 2 Output Q4.0 is reset when the time has expired. 3 Output Q4.0 is reset if the start signal goes
to 0. 4 Output A4.0 is reset if the reset input has a1signal. 5 A positive edge change from 0 to1of the
release operation (FR) restarts the time completely. Restarting is only possible if the start operation
continues to carry a1signal. Statement list for Figure 8.4 A I0.2 FR T1 release of timer T1 (only possible in
STL) A I0.0 L S5T#2S load start time 2sin accumulator 1 SP T1 start time T1 as pulse A I0.1 R T1 reset T1 A
T1 = Q4.0 binary polling of time T1 L T1 load time T1 in binary-coded form T MW1 transfer the value into
memory word MW1 LC T1 load time T1 BCD-coded T MW3 transfer the value into memory word MW3
Figure 8.5 Signal status diagram SP with FR 1 signal 0 signal 0 signal 0 signal 1 signal 1 signal Signal status
diagram for a pulse timer (SP) with release (FR) I0.2 I0.0 I0.1 Q4.0 139 8.5.2 Extended pulse timer (SE)
Output Q (Figure 8.6) carries a1signal after starting of the extended pulse timer (SE) (Figure 8.7). Output
Q is reset if the specified time duration expires or the reset input has a1signal. During the time
sequence, switching on the start input does not reset output Q (latch circuit). If another signal change
occurs at the signal input while the time is running, the time is restarted (retriggered). Explanation of the
signal status diagram for an extended pulse timer SE 1 Output Q4.0 carries a1signal after start-up. 2
Output Q4.0 is reset when the time has expired. 3 Output Q4.0 is reset if the start signal goes to 0. 4
Timer is restarted (retriggered). 5 Output Q4.0 is reset if the reset input has a1signal. Figure 8.6 FBD for
SE Figure 8.7 Signal status diagram SE 1 signal 0 signal 0 signal 0 signal 1 signal 1 signal Signal status
diagram for an extended pulse timer (SE) I0.0 I0.1 Q4.0 MW1 MW3 I0.0 I0.1 Q4.0 TV 140 Statement list
for Figure 8.6 A I0.0 L S5T#2S load start time 2sin accumulator 1 SE T1 start time T1 as extended pulse A
I0.1 R T1 reset T1 A T1 = Q4.0 binary polling of time T1 L T1 load time T1 in binary-coded form T MW1
transfer the value into memory word MW1 LC T1 load time T1 BCD-coded T MW3 transfer the value into
memory word MW2 8.5.3 Switch-on delay timer (SD) After starting the switch-on delay timer (SD),
output Q (Figure 8.8) does not carry a1signal until the programmed time has expired and RLO =1is still
pending at the start input. Output Q is reset if the start input is switched-off or a1signal is pending at the
reset input of the timer. Figure 8.8 FBD for SD I0.0 I0.1 Q4.0 MW1 MW3 TV 141 Explanation of signal
status diagram for timer SD 1 Output Q4.0 carries a1signal when the time has expired. 2 Output Q4.0 is
reset if the start input is switched-off. 3 Output Q4.0 is reset if the reset input has a1signal. Statement
list for Figure 8.8 A I0.0 L S5T#2S load start time 2sin accumulator 1 SD T1 start time T1 as a switch-on
delay A I0.1 R T1 reset timer T1 A T1 = Q4.0 binary polling of time T1 L T1 load time T1 in binary-coded
form T MW1 transfer the value into memory word MW1 LC T1 load time T1 BCD-coded T MW3 transfer
the value into memory word MW3 Figure 8.9 Signal status diagram SD 1 signal 0 signal 0 signal 0 signal 1
signal 1 signal Explanation of the signal status diagram for a switch-on delay timer SD 1 2 3 -T- -TI0.0 I0.1
Q4.0 142 8.5.4 Retentive switch-on delay timer (SS) After starting the retentive switch-on delay timer
(SS), output Q (Figure 8.10) does not carry a1signal until the programmed time has expired (Figure 8.11).
The function no longer needs a1signal after starting at the start input, which means that this input can
be switched-off (latch circuit). Output Q is reset if a1signal is pending at the timer's reset input.
Switching the start input off and back on again has the effect of restarting (retriggering) the timing
function while the time is running. Figure 8.10 FBD for SS Figure 8.11 Signal status diagram SS 1 signal 0
signal 0 signal 0 signal 1 signal 1 signal Explanation of signal status diagram for timer SS 1 Output Q4.0
carries a1signal when the time has expired. 2 Output Q4.0 is reset if the reset input has a1signal. 3 The
function no longer needs a1signal after starting at the start input. 4 Switching the start input off and
back on again has the effect of restarting (retriggering) the timing function while the time is running.
Signal status diagram for a retentive switch-on delay timer (SS) I0.0 I0.1 Q4.0 MW1 MW3 I0.0 I0.1 Q4.0
TV 143 Statement list for Figure 8.10 A I0.0 L S5T#2S load start time 2sin accumulator 1 SS T1 start time
T1 as a latching switch-on delay A I0.1 R T1 reset timer T1 A T1 = Q4.0 binary polling of time T1 L T1 load
time T1 in binary-coded form T MW1 transfer the value into memory word MW1 LC T1 load time T1
BCD-coded T MW3 transfer the value into memory word MW3 8.5.5 Switch-off delay timer (SF) Figure
8.12 FBD for SF If there is a signal change from 0 to1at the input, output Q (Figure 8.12) switches on
directly. If there is a signal change from 1 to0at the input, output Q continues to supply a signal state of
1 until the programmed time has expired. This means that switching off the start input has the effect of
delaying switch off of the output by the specified time duration. Output Q is also switched-off if the
reset input is carrying a1signal. Switching on the timer again while the time is running has the effect of
pausing the expiring time and not restarting it again until the next switchoff of the start input. If the start
and reset inputs of the timing function are carrying a1signal, the output of the timer is not set until the
dominant reset is switchedoff (Figure 8.13). I0.0 I0.1 Q4.0 MW1 MW3 TV 144 Figure 8.13 Signal status
diagram SF 1 signal 0 signal 0 signal 0 signal 1 signal 1 signal Explanation of signal status diagram for
timer SF 1 Output Q4.0 carries a1signal if the start input is carrying a1signal. 2 Output Q4.0 keeps
carrying a1signal until the time has expired. 3 Switching on again has the effect of pausing the expiring
time. 4 The output of the timer is switched-off at resetting. 5 If the start and reset inputs are carrying
a1signal, the output of the timer is not set until the dominant reset is switched-off. Statement list for
Figure 8.12 A I0.0 L S5T#2S load start time 2sin accumulator 1 SF T1 start time T1 as a switch-off delay A
I0.1 R T1 reset timer T1 A T1 = Q4.0 binary polling of time T1 L T1 load time T1 in binary-coded form T
MW1 transfer the value into memory word MW1 LC T1 load time T1 BCD-coded T MW3 transfer the
value into memory word MW3 8.6 PC program input of timing functions You must test all five timing
functions SP, SE, SD, SS and SF with the following specified current values: Signal status diagram for a
switch-off delay timer (SF) I0.0 I0.1 Q4.0 145 Table 8.2 Assignment list Symbol Operand Comment S1 I0.0
Timer «SP»(T1) Switch ON S2 I0.1 Timer «SP» (T1) Button reset P1 Q4.1 Timer «SP»(T1) Indicator light S3
I0.2 Timer «SE» (T2) Button ON S4 I0.3 Timer «SE» (T2) Button reset P2 Q4.2 Timer «SE» (T2) Indicator
light S5 I0.4 Timer «SD» (T3) Switch ON S6 I0.5 Timer «SD» (T3) Button reset P3 Q4.3 Timer «SD» (T3)
Indicator light S7 I0.6 Timer «SS» (T4) Button ON S8 I0.7 Timer «SS» (T4) Button reset P4 Q4.4 Timer
«SS» (T4) Indicator light S9 I1.0 Timer «SF» (T5) Button ON S10 I1.1 Timer «SF» (T5) Button reset P5 Q4.5
Timer «SF» (T5) Indicator light SP T1 specified time = 1.5 s SE T2 specified time = 1.75 s SD T3 specified
time =2s SS T4 specified time = 2.3 s SF T5 specified time =3s ˆ Program the timing functions in FBD ˆ
Choose the function ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the program ˆ Change
the methods of representation: > FBD > LAD > STL Figure 8.14 Connection to the PLC + Power supply - 24
V DC INP UTS O U TPUTS I0.0 I0.1 Q4.1 Q4.2 P L C I0.2 I0.3 I0.4 Q4.5 Q4.4 Q4.3 I0.5 I0.6 I0.7 I1.0 I1.1 146
The preceding steps for configuration will no longer be explained in detail here. e.g. call FC 12 Insert
network comments Ö The following window is displayed: Click on the Program element: Overview
on/off Click on the «+»-sign of bit combination Timers. Click on S_PULSE and drag and drop timer to the
network 1 workspace. 147 Parameterize timer SP Enter the 1.5 s current value using the following
characters: S5T#1.5s The important thing to remember when doing this is that you must enter a period
after the number 1 and not a comma. Drag and drop timers SE (S_PEXT), SD (S_ODT), SF (S_OFFDT) and
SS (S_ODTS) to the workspace (insert one network for each timer). Test the timing functions in online
mode. 8.6.1 Garage lighting Figure 8.15 Garage lighting: Technology scheme Parameterize the timer as
specified 148 Time delay SF Figure 8.16 Garage lighting: block diagram Description of Function It is
intended that the garage lighting (Figure 8.15) should not go out as soon as you press the switch; rather,
it should go out a short while later so that users are not left stumbling in the dark. In this example, we
choose a time of 1 minute (see Figure 8.16). Table 8.3 Assignment list Symbol Operand Comment S1 I0.0
System «On» – NO contact P1 Q4.0 Indicator light Figure 8.17 Connection to the PLC Proceed as follows:
ˆ Program the garage lighting in FBD, LAD and STL ˆ Choose a function (we suggest FC 19) ˆ Organize OB
1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the methods of representation: > FBD > LAD > STL + Power supply - 24 V DC INP
UTS O U TPUTS I0.0 P Q4.0 L C 149 8.6.2 Filling system Figure 8.18 Filling system: Technology scheme
Magazine Description of Function When you press the Start pushbutton, the conveyor belt transports
crates that have been released from a store to below a silo. If sensor B2 is contacted, the conveyor belt
stops and the crate is filled with liquid on a time-dependent basis. If time-restricted supply of liquid is
completed, i.e. the crate is full, it is transported on. While the Start pushbutton is pressed, the process
keeps repeating until the silo is empty. When the silo is empty, a warning light lights up until the silo is
filled up again. Table 8.4 Assignment list Symbol Operand Comment S1 I0.0 Switch «Start» - NO contact
B2 I0,1 Sensor «Crate under silo» B3 I0.2 Message «Silo empty» M1 Q4.0 Valve on silo M2 Q4.1 Release
for crates Q11 Q4.2 Conveyor belt motor (power contactor) P1 Q4.7 Warning light «Silo empty» 150 +
Power supply - 24 V DC Figure 8.19 Connection to the PLC Proceed as follows: ˆ Program the filling
system in FBD ˆ Choose a function (we suggest FC 20) ˆ Organize OB 1 ˆ Download the program into the
CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change
programs in online mode without needing to put the switch into the STOP position). ˆ Change the
methods of representation: > FBD > LAD > STL 8.6.3 Compressor system Figure 8.20 Compressor system:
Technology scheme Operating console Description of Function The compressor system (see Figure 8.20)
is supplied with 400 V AC. An automatic star-delta connection ensures that the motor M11 starts up
evenly. The compressor system is monitored by a temperature probe R10 and a pressure monitor for
Compressor Pressure line INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2 Q4.1 Q4.2 Q4.7 151 water (S3) and
a pressure monitor for air (S4). The monitoring circuit R10, S3 and S4 forms a safety chain. If one of the
sensors takes on another switch position, motor M1 switches off, and indicator light P2 lights up (see
Figure 8.21 and Figure 8.22). Figure 8.21 Main electric circuit Figure 8.22 Control circuit Air pressure
monitor Water pressure monitor Temperature monitoring NTC simulation 152 Table 8.5 Assignment list
Symbol Operand Comment S1 I0.0 Pushbutton NC contact - Plant «Off» S2 I0.1 NO contact - Plant «On»
B3 I0.2 NC contact (water pressure monitor) B4 I0.3 NC contact (air pressure monitor) B5 I0.4 NC contact
(temperature monitoring - NTC) F1 I0.5 Overcurrent release for motor Q11 Q4.0 Star contactor Q12
Q4.1 Mains contactor Q13 Q4.2 Delta contactor P1 Q5.0 Indicator light for operation P2 Q5.1 Indicator
light for fault K1 T1 Timer for switch-on delay of 2.5 seconds K2 Bit memory Auxiliary contact Figure 8.23
Connection to the PLC + Power supply - 24 V DC Proceed as follows: ˆ Program the compressor system in
FBD ˆ Choose a function (we suggest FC 21) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test
the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change programs in
online mode without needing to put the switch into the STOP position). ˆ Change the methods of
representation: > FBD > LAD > STL INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2 Q4.1 Q4.2 I0.3 Q5.0 Q5.1
I0.5 I0.4 153 9 Clock Generators Clock generators are used for a range of different inspection,
monitoring and control jobs. In digital technology, they are referred to as astable flip-flops. In practical
applications, you often need a flashing frequency for disturbance and operational messages. In the CPU
S7-300, a parameterizable clock memory is already present that you can set at CPU configuration (see
Section 5.1.9). Clock memories are bit memories within a clock memory byte. If we consider memory
byte MB100, for example, bit memories M100.0, M100.1, M100.2, M100.3...M100.7 are present in it.
This means that the memory byte has 8 bits. Each of the individual bits in the memory byte can be
polled and further-processed. Here, this memory byte is given the name clock memory byte MB100,
since memory byte MB100 was stated at CPU configuration. A clock memory changes its value
periodically as shown in the following table. Figure 9.1 Duty cycle 1:1 Interpulse Pulse period Interpulse
Pulse period Interpulse period 1 signal 0 signal Table 9.1 Bit .7 .6 .5 .4 .3 .2 .1 .0 Period (S) 2 1.6 1 0.8 0.5
0.4 0.2 0.1 Frequency (Hz) 0.5 0.625 1 1.25 2 2.5 5 10 A frequency of 1 Hz, for example, would mean that
when using memory byte MB100 the system would have to poll bit memory M100.5. The clock memory
clocks at a ratio of 1:1 (see Figure 9.1), i.e. the interpulse period is the same as the pulse length. 154
Table 9.2 Assignment list Symbol Operand Comment S1 I0.0 Release 0.5 Hz S2 I0.1 Release 0.625 Hz S3
I0.2 Release 1 Hz S4 I0.3 Release 1.25 Hz S5 I0.4 Release 2 Hz S6 I0.5 Release 2.5 Hz S7 I0.6 Release 5 Hz
S8 I0.7 Release 10 Hz P1 Q4.0 Indicator light for clock frequency 0.5 Hz P2 Q4.1 Indicator light for clock
frequency 0.625 Hz P3 Q4.2 Indicator light for clock frequency 1 Hz P4 Q4.3 Indicator light for clock
frequency 1.25 Hz P5 Q4.4 Indicator light for clock frequency 2 Hz P6 Q4.5 Indicator light for clock
frequency 2.5 Hz P7 Q4.6 Indicator light for clock frequency 5 Hz P8 Q4.7 Indicator light for clock
frequency 10 Hz 9.1 PC program input with clock generator We want to test all 8 clock frequencies of
memory byte MB100, which was configured as a clock memory byte in the CPU configuration (see
chapter 5.1.9). Each pulse frequency is to be released with a switch and displayed on the module output
byte QB4 (8 clock generators with a start-stop device and different frequencies). Proceed as follows: ˆ
Program the clock generator in FBD ˆ Choose a function (we suggest FC 13) ˆ Organize OB 1 ˆ Download
the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is
possible to change programs in online mode without needing to put the switch into the STOP position). ˆ
Change the methods of representation: > FBD > LAD > STL 155 Figure 9.2 Connection to the PLC All clock
frequencies are tested in online mode. + Power supply - 24 V DC The preceding steps for creating a
project will no longer be explained in detail here. Ö The following window is displayed: Insert network
comments and the corresponding networks. M100.7 = 0.5 Hz M100.6 = 0.625 Hz M100.5 =1Hz M100.4 =
1.25 Hz M100.3 =2Hz M100.2 = 2.5 Hz M100.1 =5Hz M100.0 = 10 Hz Call FC 13 INP UTS O U TPUTS I0.0 P
Q4.0 L C I0.1 I0.2 Q4.1 Q4.2 I0.3 Q4.3 Q4.4 I0.5 I0.4 I0.7 I0.6 Q4.7 Q4.6 Q4.5 156 Description of Function
Transmitting information on a digital basis is very secure and economic. Serial data transfer yields
particularly favourable plant and operating costs. Figure 9.3 shows several pieces of information that
come from different sources and are transmitted in chronological order via a transmission channel Üg to
the receiver. Figures 9.4 a) and 9.4 b) show the FBD and the connection to the PLC. Figure 9.3 Channel
switch: Technology scheme Transmitter 1 Figure 9.4 a) FBD b) Connection to the PLC 9.1.1 Channel
switch Transmitter 2 To receiver channel Üg (Üg = Transmission channel) + Power supply - 24 V DC
Channel Üg Channel 2 Channel 1 INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 157 Proceed as follows: ˆ
Program the channel switch in FBD ˆ Choose a function (we suggest FC 22) ˆ Organize OB 1 ˆ Download
the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is
possible to change programs in online mode without needing to put the switch into the STOP position). ˆ
Change the methods of representation: > FBD > LAD > STL 9.1.2 Paging system Description of Function
By means of a paging system with only one lamp, it is possible to page three different people. Using
switch S1, you switch the lamp on; person 1 is paged. Using switch S2 and switch S3, you switch the
lamp on intermittent. A clock generator determines the light on and light off periods. Figures 9.5 a) and
9.5 b) show the associated FBD and the PLC connection. Figure 9.5 a) FBD, b) Connection to the PLC
Table 9.3 Assignment list Symbol Operand Comment S1 I0.0 Channel 1 S2 I0.1 Channel 2 T M100.0 Pulse
frequency P1 Q4.0 Indicator light + Power supply - 24 V DC INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2
Q4.0 158 Proceed as follows: ˆ Program the paging system in FBD ˆ Choose a function (we suggest FC 23)
ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P:
In this switch position, it is possible to change programs in online mode without needing to put the
switch into the STOP position). ˆ Change the methods of representation: > FBD > LAD > STL Table 9.4
Assignment list Symbol Operand Comment S1 I0.0 «NO contact» switch S2 I0.1 «NO contact» switch S3
I0.2 «NO contact» switch P1 Q4.0 Indicator light 159 Figure 9.6 Air supply: Technology scheme, b) Main
electric circuit Valve Air exit to the stations Pressure switch Air pressure tank Valve Compressor
Operating console a) b) 9.1.3 Air supply 160 Description of Function The system is for supplying air to an
assembly line. The plant is switched-on with switch S1. The compressor pumps air into the container.
The pressure in this container is monitored by pressure switch S2. At the maximum pressure, S2 opens;
at the minimum pressure, S2 closes; when air is removed, the pressure drops in the air container. If the
pressure switch falls below S2 min. (S2 closed), an air request is received. The compressor starts up and
switches off again on reaching the maximum pressure (S2 open). If the compressor is switched-on, this is
shown by indicator light P0. Using pushbutton S3, you carry out the lamp test. If there is a compressor
fault, the steady light changes to a flashing light with a frequency of 1 Hz (interpulse period 1:1). Figure
9.6 Air supply: c) Circuit diagram Takt Table 9.5 Assignment list Symbol Operand Comment S1 I0.0 Air
supply system «On» – NO contact B1 I0.1 Pressure switch P – NC contact S3 I0.2 Lamp test – NO contact
Q1 I0.3 Motor relay switch auxiliary contactor – NO contact Q1 I0.4 Motor relay switch auxiliary
contactor – NC contact Pulse frequency M100.0 Clock memory P0 Q4.1 Indicator light for fault – steady
light/flashing light Q11 Q4.0 Power contactor for compressor 161 Figure 9.6 Air supply: d) Connection to
the PLC Proceed as follows: ˆ Program the air supply in FBD ˆ Choose a function (we suggest FC 24) ˆ
Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In
this switch position, it is possible to change programs in online mode without needing to put the switch
into the STOP position). ˆ Change the methods of representation: > FBD > LAD > STL + Power supply - 24
V DC INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2 Q4.1 I0.3 I0.4 162 163 10 Counters If you want to
exchange information in the STEP 7 programming language between the process input image (PII) and
the process output image (PIQ) as well as to further-process the timer and counter values, the
comparison and calculation operations, you must work with the load command (L) and the transfer
command (T). Exchanging information does not function directly; rather, it always flows via the
accumulator. The accumulator is a special register in the processor and functions as a buffer. The load
and transfer functions (see Figure 10.1) are always executed independent of the result of logic operation
(RLO). 10.1 Load and transfer functions Figure 10.1 Principle: directional flow of information Sorce
memory Load (L) from the source memory into the accumulator At loading, the system copies the
contents of the addressed source memory and writes it to the accumulator. When doing this, the
contents of the accumulator up to now are overwritten. At transfer, the system copies the contents of
the accumulator and writes them to the addressed target memory (see Figure 10.2). Since the
accumulator is only copied, it is available for further transfer operations. Target memory Transfer (T)
from the accumulator to the target memory Accu 1 164 Loading and transferring are unconditional
operations that are executed in every cycle regardless of the RLO. 10.2 Counter functions In control
engineering, counter functions are needed to acquire piece counts or pulses and to evaluate times and
distances. With the SIMATIC S7, counters are integrated in the CPU. The counting range of the counter is
between 0 and 999. In the S7-CPU 314 used here, 64 counters are integrated to which the functions
listed below (see Figures 10.3a and 10.3b) can be assigned. 10.2.1 Release a counter (FR) A positive edge
change from 0 to1in the RLO of the release operation (FR) releases one counter. No release is requested
for setting a counter or for normal counter operations. However, if you want to set a counter before the
corresponding count operation (CU, CD or S) or count forwards or backwards, you can do this with a
release. This is only possible, however, if the RLO bit has a signal state of 1 before the corresponding
operation (CU, CD or S). The release operation (FR) is only present in the STL type of representation.
10.2.2 Counting forwards The value of the addressed counter is incremented by 1. The function only
becomes effective with a positive edge change of the logic operation programmed before CU. If the
count value reaches the top limit of 999, it is no longer incremented. A carry is not formed. 10.2.3
Counting backwards The value of the addressed counter is decremented by 1. The function only
becomes effective with a positive edge change of the logic operation programmed before CD. If the
count value reaches the bottom limit of 0, it is no longer decremented. Example STL: L IW0 T QW4 L +5 T
QW6 BE Figure 10.2 Flow of information: Schematic representation Constant Accumulator Accumulator
IW0 QW4 QW6 165 10.2.4 Set counter You can set the counter to a specific value. From this value
onwards, it is possible to count forwards or backwards. If, for example, you want to set the counter to
the value 8: STL A I0.0 Polling the signal state L +5 Loading the count value S C1 Setting the counter with
the loaded count value (with a positive edge change) 10.2.5 Count value definition If a counter is set, the
system uses the contents of accumulator 1 as the count value. It is possible to load the count value
either in binary-coded form or BCD-coded. The following operations are possible: ˆ Input word IW.. ˆ
Output word QW.. ˆ Memory word MW.. ˆ Data word DBW/DIW.. ˆ Local data word LW.. ˆ Constants
DW#16#, +8, B#16#, 2#...etc. 10.2.6 Reset counter (R) In the case of a result of logic operation RLO 1, the
counter is set to 0 (reset). An RLO 0 does not affect the counter. Resetting of a counter has a static
effect. If a reset condition is fulfilled, it is not possible to carry out setting or counting. 10.2.7 Poll count
value (L/LC) A count value is stored in binary-coded form in a counter word. The value in the counter can
be loaded as a dual number (BI) or as a BCD number (BCD) into the accumulator and transferred from
there to other operand areas. With STL programming, it is possible to choose between L Z1 (load
counter 1) for polling as a dual number and LC C1 (load counter 1 in coded form) for polling the BCD
number. 166 10.2.8 Poll signal state of counter (binary) It is possible to poll the counter for its signal
state: ˆ Signal state 0: Counter is at a value of 0 ˆ Signal state 1: Counter is ready to count You can poll
the signal status conditions with A C1, AN C1, ON C1 etc. and use them for further logic operations.
Release FR (only in STL) A I0.7 FR C1 Counting forewards A I0.0 CU C1 Set A I0.2 L8 S 1 Reset A I0.3 R C1
Requests (digital) L C1 (dual coded) T MW2 L C C1 T QW4 Request (binary) A C1 = Q4.0 Figure 10.3b
Function chart Figure 10.3a Programming the counter Counting backwards A I0.1 CD C1 I0.0 MW2 I0.3
I0.2 I0.1 Q4.0 QW2 C1 CU CD PV CV CV_BCD CU FR CD S R Q4.0 167 Description of Function A cleaning
bath (see Figure 10.4) is intended to remove the flux from soldered PCBs. A basket is hooked in and
unhooked manually. If you activate pushbutton S1, the basket automatically enters the cleaning bath
five times and stays there for 15 s in each case to clean the boards. After the cleaning process, the
basket can be removed or be filled up and lowered again. The signal lamp shows automatic mode. Table
10.1 Assignment list Symbol Operand Comment S1 I0.0 «Start» pushbutton B2 I0.1 Limit switch at top –
NC contact B3 I0.2 Limit switch at bottom – NC contact Q11 Q4.0 Motor downwards Q12 Q4.1 Motor
upwards P1 Q4.2 Indicator light for automatic mode 10.3 PC program input cleaning bath Figure 10.4
Cleaning bath: Technology scheme Basket at top Basket at bottom Cleaning bath Operating console 168
Proceed as follows: ˆ Program the cleaning bath in FBD ˆ Choose a function (we suggest FC 25) ˆ
Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In
this switch position, it is possible to change programs in online mode without needing to put the switch
into the STOP position). ˆ Change the methods of representation: > FBD > LAD > STL Figure 10.5
Connection to the PLC + Power supply - 24 V DC INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2 Q4.1 Q4.2
169 11 Comparators Using the comparison functions, the system directly compares two digital values
with one another that are located in accumulators 1 and 2. However, the values to be compared must
first be saved to the accumulator using load instructions. The length of the operands (byte, word) is
stated in conjunction with the operands, e.g. IB, IW, QB, MB, MW, etc. The result of the comparison is
binary. A comparison is conditional upon both numbers having the same format. The following pairs of
numeric values can be compared: ˆ 2 integers (16-bit, symbol: I) ˆ 2 integers (32-bit, symbol: D) ˆ 2 real
numbers (floating point numbers 32-bit, symbol: R) 11.1 Comparison functions In the STEP 7
programming language, you can choose six different comparisons: 11.1.1 Equal to = = FBD LAD STL IW0
IW2 IW0 IW2 Q4.7 L IW0 L IW2 ==l = Q4.7 Q4.0 Q4.7 170 11.1.2 Not equal <> Arithmetic block Akku 1
Accu 1 Akku 2 Accu 2 11.1.3 Greater than equal to >= 11.1.4 Greater than > 11.1.5 Less than equal to <=
FUP AWL AWL FBD LAD STL IW0 IW2 IW0 IW2 Q4.7 L IW0 L IW2 <>l = Q4.7 Q4.7 L IW0 = Q4.0 STL IW 0
IW 2 Accu 1 Accu 2 IW 0 VKE L IW2 FBD LAD STL IW0 IW2 IW0 IW2 Q4.7 L IW0 L IW2 >=l = Q4.7 Q4.7 FBD
LAD STL IW0 IW2 IW0 IW2 Q4.7 L IW0 L IW2 >l = Q4.7 Q4.7 FBD LAD STL IW0 IW2 IW0 IW2 Q4.7 L IW0 L
IW2 <=l = Q4.7 Q4.7 171 Description of Function At an airstrip, it is intended to place nine lamps (runway
lights) on the left and on the right next to the runway. These runway lights are intended to allow pilots
to land safely after dark. The runway lights are switched-on from the control tower using switch S1.
11.1.6 Less than < FUP KOP AWL 11.2 PC program input runway light Figure 11.1 Runway light:
Technology scheme FBD LAD STL IW0 IW2 IW0 IW2 Q4.7 L IW0 L IW2 FBD > LAD > STL 11.3 Program
input sequence function Description of Function Using switch S1, you activate the clock memory of the
CPU 1 Hz (Start-Stop facility). The cycle is counted in a counter C1. On reaching three clock pulses, it is
intended that output Q4.0 carries a1signal. On reaching five clock pulses, it is intended that output Q4.1
carries a1signal and on reaching seven clock pulses, it is intended that output Q4.2 carries a1signal. On
switching off switch S1, it is intended that all the outputs be set to 0. The process can start again from
the beginning. Figure 11.4 Connection to the PLC + Power supply - 24 V DC Table 11.2 Assignment list
Symbol Operand Comment S1 I0.0 «Start» switch P1 Q4.0 Indicator light P1 P2 Q4.1 Indicator light P2 P3
Q4.2 Indicator light P3 INP UTS O U TPUTS I0.0 P Q4.0 L C Q4.1 Q4.2 175 Proceed as follows: ˆ Program
the sequence function in FBD ˆ Choose a function (we suggest FC 27) ˆ Organize OB 1 ˆ Download the
program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is
possible to change programs in online mode without needing to put the switch into the STOP position). ˆ
Change the methods of representation: > FBD > LAD > STL Figure 11.5 FBD I0.0 Q4.0 Q4.1 Q4.2 I0.0
M100.5 Q4.2 MW4 MW4 MW4 MW4 C1 CU CD PV CV CV_BCD >=I >=I >=I 176 177 12 Practical Examples
with Simulators Description of Function The control procedures for converting the numbers 0...9 to BCD
code (8-4-2-1 code) for representation using a seven-segment display are intended to be implemented
using a programmable logic controller. The signals of numbers 0...9 are entered in the PLC using
switches S1...S4 in the BCD code. It is intended to display 12.1 Seven-segment display Figure 12.1 Seven-
segment display: Technology scheme 178 on the seven-segment display the corresponding digits 0...9.
To do this, the system must trigger the appropriate segments for each digit. Table 12.1 Assignment list
Symbol Operand Comment S1 I0.0 Binary position 1-value 1 S2 I0.1 Binary position 2-value 2 S3 I0.2
Binary position 4-value 4 S4 I0.3 Binary position 8-value 8 a Q4.0 Seven-segment display - Segment a b
Q4.1 Seven-segment display - Segment b c Q4.2 Seven-segment display - Segment c d Q4.3 Seven-
segment display - Segment d e Q4.4 Seven-segment display - Segment e f Q4.5 Seven-segment display -
Segment f g Q4.6 Seven-segment display - Segment g M0.0 M0.0 Evaluation of number 0 M0.1 M0.1
Evaluation of number 1 M0.2 M0.2 Evaluation of number 2 M0.3 M0.3 Evaluation of number 3 M0.4
M0.4 Evaluation of number 4 M0.5 M0.5 Evaluation of number 5 M0.6 M0.6 Evaluation of number 6
M0.7 M0.7 Evaluation of number 7 M1.0 M1.0 Evaluation of number 8 M1.1 M1.1 Evaluation of number
9 Figure 12.2 Assignment of segments to the decimal digits Figure 12.3 Connection to the PLC + Power
supply - 24 V DC INP UTS O U TPUTS I0.0 P Q4.0 L C Q4.1 Q4.2 Q4.3 Q4.4 Q4.6 Q4.5 I0.3 I0.2 I0.1 179
Proceed as follows: ˆ Program the seven-segment display in FBD, LAD and STL ˆ Choose a function (we
suggest FC 0) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on the
CPU to RUN-P: In this switch position, it is possible to change programs in online mode without needing
to put the switch into the STOP position). ˆ Change the methods of representation: > FBD > LAD > STL
12.2 Star-delta starting The control procedures for automatic star-delta starting of a three-phase
asynchronous motor are intended to be implemented using a programmable logic controller. Figure 12.4
Star-delta starting: Technology scheme 180 Table 12.2 Assignment list Symbol Operand Comment S0
I0.0 OFF button (NC contact) S1 I0.1 ON button (NO contact) F2 I0.2 Overcurrent relay (NC contact) Q11
Q4.0 Mains contactor Q12 Q4.1 Star contactor Q13 Q4.2 Delta contactor T1 T1 Wait time M1 M0.0 Bit
memory for start of T1 Figure 12.5 Connection to the PLC + Power supply - 24 V DC Function or problem
description A three-phase asynchronous motor is intended to be started up via a star-delta connection.
On activating pushbutton S1 (NO contact), the motor is intended to start up in a star connection
(contactor Q11 and star contactor Q12 ON), and then switch to a delta connection (star contactor Q12
OFF and delta contactor Q13 ON). On activating pushbutton S0 (NC contact), the controller is
immediately switched to the idle state. When the overcurrent relay F2 (NC contact) operates, the
controller is also deactivated via the PLC (see Figure 12.4). Proceed as follows: ˆ Program the star-delta
connection in FBD, LAD and STL ˆ Choose a function (we suggest FC 1) ˆ Organize OB 1 ˆ Download the
program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is
possible to change programs in online mode without needing to put the switch into the STOP position). ˆ
Change the methods of representation: > FBD > LAD > STL INP UTS O U TPUTS I0.0 P Q4.0 L C I0.1 I0.2
Q4.1 Q4.2 181 Figure 12.6 Traffic light controller: Technology scheme 12.3 Traffic light controller The
control procedures for the traffic lights at a pedestrian crossing are intended to be implemented using a
programmable logic controller for daytime and nighttime operation. Description of Function The traffic
lights for a pedestrian crossing are controlled in two operating modes: ˆ Daytime operation, ˆ Nighttime
operation. Daytime operation The traffic lights switch automatically. In this connection, a set switching
cycle repeats continuously. The switchboards of the traffic lights within a switching cycle are shown in
the following pulse time diagram (see Figure 12.7). The assumed clock frequency is 0.5 Hz. 182
Nighttime operation You set nighttime operation using switch S0. When you do this, the switching cycle
of daytime operation is interrupted immediately and the yellow signal lamp of the driver's traffic light
operates at a flashing rate of 0.5 Hz. Figure 12.8 Connection to the PLC + Power supply - 24 V DC Table
12.3 Assignment list Symbol Operand Comment S0 I0.0 Day-Night switch P1 Q4.0 Car – Red P2 Q4.1 Car–
Yellow P3 Q4.2 Car– Green P4 Q4.3 Pedestrian – Red P5 Q4.4 Pedestrian – Green Q5.0 Q5.0 Counter
value 1 Q5.1 Q5.1 Counter value 2 Q5.2 Q5.2 Counter value 3 Q5.3 Q5.3 Counter value 4 C1 C1 Cycle
counter MB1 MB1 Cycle memory M2 M2.0 Bit memory for reset counter M3 M100.7 Clock memory 0.5
Hz Cycle Car-Red Car-Yellow Car-Green Pedestrian-Red Pedestrian-Green Figure 12.7 Pulse time
diagramINP UTS O U TPUTS I0.0 P Q4.0 L C Q4.1 Q4.2 Q4.4 Q4.3 183 Proceed as follows: ˆ Program the
traffic light controller in FBD, LAD and STL ˆ Choose a function (we suggest FC 2) ˆ Organize OB 1 ˆ
Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the methods of representation: > FBD > LAD > STL 12.4 Conveyor belt
controller The control procedures for a conveyor belt system (see Figure 12.9) are intended to be
implemented using a programmable logic controller. Figure 12.9 Conveyor belt controller: Technology
scheme 184 Description of Function Using pushbuttons S1...S4, it is intended to switch on and off
conveyor belts 1 and 2. One ON and OFF lamp each will show the operating status. Belts 1 and 2 may
not carry out conveying at the same time. Belt 3 is intended to automatically start up whenever belt 1
or2is carrying out conveying. Belt monitors signal the movement of the conveyor belts at a pulse
frequency of 10 Hz. This frequency is specified by a clock memory in the CPU and transferred to the
simulator. If the belt monitor pulses fail (standstill or conveyor break), the encoders supply the signal
state 0. During the three-second long start-up stage, the belt monitor pulses should not be evaluated.
After activating the OFF buttons, you should run empty belts 1 and 2 for another 2sand belt 3 for
another 6sbefore switching off. If the monitor signals of belt 1 or2fail during operation, you should
immediately switch off the respective drive while belt 3 keeps running empty for another 6 s before
being switched off. The OFF lamp of belt 1 or2should indicate the disturbance by flashing in a 2-Hz-cycle
(clock memory in the CPU!) If the belt monitor pulses of belt 3 fail, all the drives must switch off
immediately. Figure 12.10 Connection to the PLC + Power supply - 24 V DC Pulse frequency INP UTS O U
TPUTS I0.0 P Q5.0 L C Q5.1 Q5.2 Q5.4 Q5.3 Q5.7 Q5.6 Q5.5 I0.6 I0.5 I0.4 I0.3 I0.2 I0.1 185 Table 12.4
Assignment list Symbol Operand Comment S1 I0.0 ON button belt 1 S2 I0.1 ON button belt 2 S3 I0.2 OFF
button belt 1 S4 I0.3 OFF button belt 2 B5 I0.4 Monitor belt 1 B6 I0.5 Monitor belt 2 B7 I0.6 Monitor belt
3 P1 Q5.0 ON lamp belt 1 P2 Q5.1 ON lamp belt 2 P3 Q5.2 OFF lamp belt 1 P4 Q5.3 OFF lamp belt 2 Q11
Q5.4 Drive M1 belt 1 Q12 Q5.5 Drive M1 belt 2 Q13 Q5.6 Drive M1 belt 3 P5 (Pulse frequency) Q5.7 10-
Hz clock-pulse rate T0 T0 Time for starting time: 3 seconds T1 T1 Time for belt monitoring belt 1/2: 0.12
seconds T2 T2 Time for belt monitoring belt 3: 0.12 seconds T5 T5 Time for switch-off delay belt 1: 2
seconds T6 T6 Time for switch-off delay belt 2: 2 seconds T7 T7 Time for switch-off delay belt 3: 6
seconds Memory 1 M100.3 Memory for 2-Hz clock generator Memory 2 M100.0 Memory for 10-Hz clock
generator Proceed as follows: ˆ Program the conveyor belt controller in FBD, LAD and STL ˆ Choose a
function (we suggest FC 4) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the program
(Switch on the CPU to RUN-P: In this switch position, it is possible to change programs in online mode
without needing to put the switch into the STOP position). ˆ Change the methods of representation: >
FBD > LAD > STL 186 12.5 Reaction vessel The control procedures for a chemical process in a reaction
vessel (see Figure 12.11) are intended to be implemented using a programmable logic controller. Figure
12.11 Reaction vessel: Technology scheme Description of Function In a reaction vessel, it is intended
that a chemical process run at a specific temperature and at a specific pressure. The reaction vessel has
a temperature probe and a pressure gauge for measuring the temperature and pressure. The
temperature and pressure are controlled by a heater H, a cooling water intake K and a safety valve S.
The actuators of the reaction vessel should allow the following switch-on conditions: 187 Safety valve S:
pressure P too high Cooling water intake K: temperature too high Heater H: temperature too low or P
too low and temperature normal If actuators cooling water intake K or heater H are switched-on, the
circulator must be activated. The sequence of the reaction is divided into three operating status
conditions: 1. Start-up: P too low 2. Normal: P normal 3. Alarm: P too high The technology scheme
shows the arrangement of the encoders and actuators. Figure 12.12 Connection to the PLC + Power
supply - 24 V DC Circulator Safety valve Cooling water intake Heater Start-up Normal mode Alarm
Tabelle 12.5 Assignment list Symbol Operand Comment PG I0.0 Pressure too high PK I0.1 Pressure too
low TG I0.2 Temperature too high TK I0.3 Temperature too low U Q4.0 Circulator S Q4.1 Safety valve K
Q4.2 Cooling water intake H Q4.3 Heater AN Q4.4 Start-up NB Q4.5 Normal mode AL Q4.6 Alarm INP
UTS O U TPUTS I0.0 P Q4.0 L C Q4.1 Q4.2 Q4.4 Q4.3 Q4.6 Q4.5 I0.3 I0.2 I0.1 188 Proceed as follows: ˆ
Program the reaction vessel in FBD, LAD and STL ˆ Choose a function (we suggest FC 0) ˆ Organize OB 1 ˆ
Download the program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch
position, it is possible to change programs in online mode without needing to put the switch into the
STOP position). ˆ Change the methods of representation: > FBD > LAD > STL 12.6 Container filling system
The control procedures for a container filling system (see Figure 12.13) are intended to be implemented
using a programmable logic controller. Figure 12.13 Container filling system: Technology scheme 189
Description of Function Three supply containers with signal transmitters B1, B3, B5 for the full signal (NO
contact) and B2, B4, B6 for the empty signal (NC contact) can be emptied manually in any order you like.
Using the controller, it is intended that only one container with an empty signal will ever keep being
filled until the full signal is triggered. The containers are to be filled in the order in which they were
emptied. If, for example, the containers were emptied in the order 2-1-3, they must be filled in this
order too. For filling, the PLC controls valves M1, M2 and M3. Using switches S10, S11 and S12 (on the
PLC), the containers are emptied via valves M4, M5 and M6. Figure 12.14 Connection to the PLC + Power
supply - 24 V DC Table 12.6 Assignment list Symbol Operand Comment B1 I1.0 Container 1 full B2 I1.1
Container 1 empty B3 I1.2 Container 2 full B4 I1.3 Container 2 empty B5 I1.4 Container 3 full B6 I1.5
Container 3 empty S10 I0.0 Empty container 1 S11 I0.1 Empty container 2 S12 I0.2 Empty container 3 M1
Q4.0 Solenoid valve 1 M2 Q4.1 Solenoid valve 2 M3 Q4.2 Solenoid valve 3 M4 Q4.3 Solenoid valve 4 M5
Q4.4 Solenoid valve 5 M6 Q4.5 Solenoid valve 6 M0.0 M0.0 Container 1 empty M0.1 M0.1 Container 2
empty M0.2 M0.2 Container 3 empty INP UTS O U TPUTS I1.0 P Q4.0 L C Q4.1 Q4.2 Q4.4 Q4.3 Q4.5 I1.3
I1.2 I1.1 I0.2 I0.1 I0.0 I1.5 I1.4 190 Proceed as follows: ˆ Program the container filling system in FBD, LAD
and STL ˆ Choose a function (we suggest FC 0) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ
Test the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change programs
in online mode without needing to put the switch into the STOP position). ˆ Change the methods of
representation: > FBD > LAD > STL 12.7 Automatic tablet filler The control procedures for an automatic
tablet filler (see Figure 12.15) are intended to be implemented using a programmable logic controller.
Figure 12.15 Automatic tablet filler: Technology scheme P1 P2 P3 191 Description of Function An
automatic tablet filler is intended to continuously fill tubes with a selectable number of tablets. After
switching on the system using the ON switch, you must choose the desired number of tablets. A belt
drive motor M drives the conveyor belt until a tablet tube arrives at the filling location, which encoder
GA on the PLC must confirm. Valve M1 then opens the supply hopper and light barrier B1 counts the
tablets. Once the set number of tablets has been reached, the valve closes again and the belt drive
motor is set in motion. This process is repeated continuously. If you want to set a different number of
tablets by pressing the corresponding pushbutton, an ongoing filling process must still be completed
with the old number. When switching off the system, a filling process that has been started is
completely finished before all the actuators are deactivated. Control requires signal processing: ˆ The
memory states TSP3, TSP5, TSP7 must result from the briefly pending input signals S1, S2, S3 of the
desired number of tablets. ˆ Intermediate memories TA3, TA5, TA7 are intended to prevent unclear
number selections (pressing S1, S2, S3 several times). ˆ It should always be possible to switch directly
from one number of tablets to another at any time. ˆ If the system is switched-off, storing of the number
of tablets must be cleared. Figure 12.16 Connection to the PLC + Power supply - 24 V DC INP UTS O U
TPUTS I0.1 P Q4.1 L C Q4.2 Q4.3 Q4.5 I0.4 Q4.4 I0.3 I0.2 I0.6 I0.5 On 192 Table 12.7 Assignment list
Symbol Operand Comment On I0.1 Switch system On – On = 1 on GA I0.2 Encoder of filling location – GA
= 1 reached S1 I0.3 Pushbutton number 3–S1=1pushed S2 I0.4 Pushbutton number 5–S2=1pushed S3
I0.5 Pushbutton number 7–S3=1pushed B1 I0.6 Light barrier – B1=0free Q11 Q4.1 Belt drive motor –M=1
running M1 Q4.2 Valve Y = 1 open P1 Q4.3 Lamp number of tablets 3–P1=1lit-up P2 Q4.4 Lamp number
of tablets 5–P2=1lit-up P3 Q4.5 Lamp number of tablets 7–P3=1lit-up Memory 0 M40.0 Status bit
memory Memory 1 M40.1 Status bit memory Memory 2 M40.2 Status bit memory Memory 3 M40.3
Status bit memory Memory 4 M40.4 Status bit memory Memory 5 M40.5 Status bit memory Memory 6
M40.6 Status bit memory TA3 M50.0 Intermediate memory 3 TSP3 M50.1 Tablet memorizing counter 3
TA5 M50.2 Intermediate memory 5 TSP5 M50.3 Tablet memorizing counter 5 TA7 M50.4 Intermediate
memory 7 TSP7 M50.5 Tablet memorizing counter 7 MY M60.6 Switch-on memory MX M60.7 Initializing
pulse memory (pulse 1=cycle time) N3 C1 Decrementer for 3 tablets N5 C2 Decrementer for 5 tablets N7
C3 Decrementer for 7 tablets Proceed as follows: ˆ Program the automatic tablet filler in FBD, LAD and
STL ˆ Choose a function (we suggest FC 1) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test
the program (Switch on the CPU to RUN-P: In this switch position, it is possible to change programs in
online mode without needing to put the switch into the STOP position). ˆ Change the methods of
representation: > FBD > LAD > STL 193 12.8 Door access control system The control procedures for an
access control system (see Figure 12.17) are intended to be implemented using a programmable logic
controller. Figure 12.17 Door access control system: Technology scheme Description of Function It is
only possible to enter or leave a clean room through an air-lock with two automatically closing doors, A
and B. The first door is opened using an external door opener, whereas the second door opens
automatically but only after the first door has closed. Both doors close automatically after three seconds
have expired. If during closing of a door, the associated light barrier is interrupted or the associated
external or internal door opener is activated, the door opens again immediately. The internal door
openers are mounted as a safety measure in case somebody enters the air-lock without first having
activated one of the external door openers after they found the door open when somebody else had
just left the airlock. Two limit switches are provided for each door that signal whether the doors are
open or closed. Next to the external door openers, indicator lights are mounted that show whether the
controller has detected the pushbutton being pressed. 194 Figure 12.18 Connection to the PLC + Power
supply - 24 V DC Open Open Closed Closed Display 1 Display 2 Table 12.8 Assignment list Symbol
Operand Comment S1 I0.1 Door opener door 1 outside NO contact S2 I0.2 Door opener door 2 outside
NO contact S3 I0.3 Door opener door 1 inside NO contact S4 I0.4 Door opener door 2 inside NO contact
S5 I0.5 Limit switch door 1 closed NO contact S6 I0.6 Limit switch door 1 open NO contact S7 I0.7 Limit
switch door 2 closed NO contact S8 I1,0 Limit switch door 2 open NO contact B1 I1.1 Light barrier door 1
NC contact B2 I1.2 Light barrier door 2 NC contact M1A Q4.1 Motor door 1 open M1Z Q4.2 Motor door 1
closed M2A Q4.3 Motor door 2 open M2Z Q4.4 Motor door 2 closed Display 1 Q4.5 Display pushbutton
S1 Display 2 Q4.6 Display pushbutton S2 Control requires signal processing: ˆ Since the controller cannot
necessarily respond immediately toabutton being pressed by opening an air-lock door, display memory
states DISPL.1 or DISPL.2 must result from the briefly pending input signals S1 or S2 of the external door
openers. The display memories are reset in each case when the corresponding air-lock door opens. ˆ For
the controller to remember that it has to open the other door in each case despite the display memory
being cleared, two key memories TSP1 or TSP2 are INP UTS O U TPUTS I0.1 P Q4.1 L C Q4.2 Q4.3 Q4.5
I0.4 Q4.4 I0.3 I0.2 I0.6 I0.5 Q4.6 I0.7 I1.0 I1.1 I1.2 195 needed in addition. The key memories are reset
when the second door in each case is opened. Proceed as follows: ˆ Program the door access control
system in FBD, LAD and STL ˆ Choose a function (we suggest F 5) ˆ Organize OB 1 ˆ Download the
program into the CPU ˆ Test the program (Switch on the CPU to RUN-P: In this switch position, it is
possible to change programs in online mode without needing to put the switch into the STOP position). ˆ
Change the methods of representation: > FBD > LAD > STL 12.9 Pump controller The control procedures
for a pump controller (see Figure 12.19) are intended to be implemented using a programmable logic
controller. Description of Function Four pumps pump liquid from a suction container into a network. By
switching the pumps in or off on a step-by-step basis, it is intended to maintain the pressure in the
network at a constant level within a specific range (see Figure 12.20). 196 Figure 12.19 Pump controller:
Technology scheme 197 Figure 12.20 + Power supply - 24 V DC Switching-off Switching-in Pressure too
high Pressure too low Normal pressure Pressure ˆ At switching-in as well as at switching-off, it is
intended that the system waits for a specific response time to ensure that no switching pulses are
triggered in the case of brief changes in pressure. ˆ Whenever the pressure is below the normal value for
more than 5 s, it is intended that a switch-in pulse is triggered. ˆ Whenever the pressure is above the
normal value for more than 5 s, it is intended that a switch-off pulse is triggered. ˆ In this connection, it
is intended to guarantee that all four pumps have as similar a runtime and switching rate as possible. ˆ
At switch-off, the pump with the longest runtime must always be deactivated; at switching-in, the pump
with the longest idle time must be switched-on. Pump 4 Pump 1 Pump 2 Pump 3 Figure 12.21
Connection to the PLC INP UTS O U TPUTS I0.0 P Q4.0 L C Q4.1 Q4.2 Q4.3 I0.1 198 Table 12.9 Assignment
list Symbol Operand Comment S1.1 I0.0 Pressure too low S1.2 I0.1 Pressure too high P1 Q4.0 Pump 1 P2
Q4.1 Pump 2 P3 Q4.2 Pump 3 P4 Q4.3 Pump 4 T1 T1 Switch-on delay SD T2 T2 Switch-off delay SF M1
M0.1 Pulse flag for pump On M2 M1.1 Pulse flag for pump Off M3 M0.0 Flag for Start T1 M4 M1.0 Flag
for Start T2 M5 M2.0 Register pumps On M6 M2.1 Register pumps On M7 M2.2 Register pumps On
M33.0 M33.0 Register pumps On M33.1 M33.1 Register pumps On M33.2 M33.2 Register pumps On M8
M2.3 Register pumps Off M9 M2.4 Register pumps Off M10 M3.3 Register pumps Off M11 M3.4 Register
pumps Off Proceed as follows: ˆ Program the pump controller in FBD, LAD and STL ˆ Choose a function
(we suggest FC 3) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the program (Switch on
the CPU to RUN-P: In this switch position, it is possible to change programs in online mode without
needing to put the switch into the STOP position). ˆ Change the methods of representation: > FBD > LAD
> STL 199 13 Sequence Control Systems 13.1 Introduction Processing or process sequences that comply
with a specific sequence (see Figure 13.1) are controlled by sequence control systems. Sequence control
systems have the following advantages: ˆ Quick and easy configuration and programming, ˆ Clear
program structure, ˆ Easy changing of control procedures, ˆ Easy troubleshooting in the case of
disturbances, ˆ Different operating modes. Figure 13.1 Complete control programmed with a sequence
control system Interlock Step enabling condition Basic position Release of the sequence cascade Setup
operation Single step operation Automatic Start OFF operation Quit Disturbance and operational
messages Sequence cascade Command output (Individual controls) Orders to the final controlling
devices Operating modes 200 13.2 Components of a sequence control system The functions of a
sequence control system are divided into four parts (see Figure 13.2). Figure 13.2 Sequence control
system and its components Operating modes Sequence cascade Command output Disturbance and
operational messages Components of a sequence control system Operating modes In the mode section,
you edit the different conditions for the operating modes. You set the operating mode, e.g. manual or
automatic mode using selector switches or a corresponding pushbutton on an operator panel. The result
is displayed and signalled to the sequence cascade and the command output in the form of release
signals. The following operating modes are customary: AUTOMATIC In this operating mode, the system
processes the sequence cascade of the control procedures without the operating staff intervening.
SINGLE STEP In this operating mode, the sequence cascade is processed manually step by step, e.g. it is
possible to advance at commissioning. SET UP In this operating mode, it is possible to activate manually
the individual actuators independently of the controller's program. Sequence cascade In the sequence
cascade, the program for the step by step function cycle of the controller is processed. The steps of the
sequence are run through one after another with only one step ever being set. 201 Command output
Here, the commands that are activated by the individual steps of the sequence are combined with the
release signals of the mode section and the interlock signals from the process. Apart from this, the
system takes into account the commands for controlling the individual actuators manually. This
command output function corresponds to an individual controller. Disturbance and operational
messages Here, the disturbance and operational messages are generated and the current sequence step
is displayed. 13.3 Type of representation Figure 13.3 Sequence cascade Transition (Short
interconnection) Initial step Logical AND operation is represented by a multiplication sign (l) Step "Start"
Action Action, set latching Closed sequence cascade "On" Time delay Contactor Q1: = 1 Contactor Q1: =
0 "Off" Action, reset latching Latency time 7s/X10 "Latency time" Logical OR operation is represented by
an addition sign (+) Negation is represented by an apostrophe (S3) 202 13.4 Linear sequence cascade
With the linear sequence cascade, the steps are run through one after another with only one step ever
being set. A step is set if the one before it is switched-on and the step enabling condition for the step is
fulfilled. Step enabling conditions include, for example, limit switches, timers, sensors, operating modes,
etc. The step enabling condition can be process- or time-dependent. The individual steps can output
commands to the actuators. 13.5 Sheet metal bending device The control procedures for a sheet metal
bending device are intended to be implemented using a programmable logic controller (see Figure 13.4).
Figure 13.4 Sheet metal bending device: Technology scheme Cylinder 3 Sheet metal strap Cylinder 2
Cylinder 1 203 Description of Function Metal sheet is bent on a sheet metal bending device. Once the
metal sheet has been inserted manually (F5 key) and the start key has been pressed, cylinder 1 extends
and secures the metal sheets. Cylinder 2 first bends the metal sheet by 90° before cylinder 3 gives it its
final shape. The technology scheme shows which solenoid must be controlled in each case. Mode
section The mode section makes it possible to operate the sheet metal bending device in automatic
single-step mode or, alternatively, in manually controlled single-step mode. Figure 13.5 Connection to
the PLC + Power supply - 24 V DC Table 13.1 Assignment list Symbol Operand Comment S0 I0.0
Start/single step B1 I0.1 Back limit position cylinder 1 B2 I0.2 Front limit position cylinder 1 B3 I0.3 Back
limit position cylinder 2 B4 I0.4 Front limit position cylinder 2 B5 I0.5 Back limit position cylinder 3 B6
I0.6 Front limit position cylinder 3 M1 Q4.1 Solenoid valve cylinder 1 forwards M2 Q4.2 Solenoid valve
cylinder 1 backwards M3 Q4.3 Solenoid valve cylinder 2 forwards M4 Q4.4 Solenoid valve cylinder 2
backwards M5 Q4.5 Solenoid valve cylinder 3 forwards M6 Q4.6 Solenoid valve cylinder 3 backwards INP
UTS O U TPUTS I0.0 Q4.6 P L C I0.1 I0.2 Q4.1 Q4.2 Q4.3 I0.3 Q4.4 I0.5 I0.4 I0.6 Q4.5 204 Automatic mode
You preselect automatic mode using switch S10 (S10 = 0). In this operating mode, it is possible to trigger
the automatic sequence of the bending process using the start key S0 if the plant and the sequence
cascade are in the basic position. Pushbutton S12 is used to end automatic mode in step "0". Single-step
mode with step enabling conditions You set single-step mode using switch S10 (S10 = 1). In this
operating mode, activating pushbutton S0 switches on the sequence step that follows next in each case,
assuming that the step enabling conditions are fulfilled. The output commands assigned to the sequence
step are only executed while pushbutton S9 is switched. If you switch to single step during automatic
mode, the controller comes to a halt at the current sequence step. Step enabling is then carried out
using pushbutton S0. Proceed as follows: ˆ Program the sheet metal bending device in FBD, LAD and STL
ˆ Choose a function (we suggest FC 1) ˆ Organize OB 1 ˆ Download the program into the CPU ˆ Test the
program (Switch on the CPU to RUN-P: In this switch position, it is possible to change programs in online
mode without needing to put the switch into the STOP position). ˆ Change the methods of
representation: > FBD > LAD > STL 205 Figure 13.6 Sequence cascade Initial step Solenoid valve cylinder
1 forwards Solenoid valve cylinder 2 forwards Solenoid valve cylinder 2 backwards Solenoid valve
cylinder 3 forwards Solenoid valve cylinder 3 backwards Set step bit memory Solenoid valve cylinder 2
backwards (Start) (Front limit position cylinder 1) (Front limit position cylinder 2) (1 second) (Back limit
position cylinder 2) (Front limit position cylinder 3) Time stage T1 206 207 14 Safety Regulations When
programming programmable logic controllers, you must comply with the (DIN VDE 0113) rules in
common use in contactor controls. 14.1 Rules You must prevent status conditions that could endanger
people or damage machines. After restoring the mains voltage that has failed, machines must not be
able to start up automatically. If there are disturbances in the PLC, the commands from the emergency
STOP switch and from the safety limit switches must always be effective. This means that the protective
devices must be effective directly on the actuators in the power circuit (manual level). Deactivation must
not be blocked due to faults in the encoder circuits (e.g. wire breaks or earth faults). Switching on is
carried out with the working current (NO contact); switching off is carried out with the standby current
(NC contact). These rules apply by analogy to sequence control systems too. 208 14.2 Emergency STOP
control release Figure 14.1 shows the principle of the entire power supply of a controller. SIMATIC S7
Figure 14.1 Power supply of a controller The entire plant is activated using main switch Q1. Facilities
must not be switched off by the emergency STOP switch which may endanger people due to these
facilities having been switched off (e.g. presses, clamping devices, auxiliary supplies, etc.). The
emergency STOP switch Q2 must only switch off drives and actuators that can cause a dangerous
situation for people and facilities (VDE 0113). If the emergency STOP switch is activated, this is
communicated to the PLC (I1.2) via the auxiliary contactor. When programming, you should note that
the input is programmed accordingly as an emergency STOP switch. The emergency STOP switch can
also be arranged in the supply line instead of the main switch. However, this is only allowed if after an
emergency STOP command some of the actuators do not still have to be supplied with energy. The
emergency STOP status cannot be saved either. After switching on the power supply and restoring the
voltage after a power failure, no commands must be output to the actuators via the outputs of the
programmable controller if this leads to people or machinery being endangered. Final controlling
Auxiliary circuit Geberspannung devices Power supply 230/380 V Harmless electric circuits lamps etc.
Harmfull electric circuits Emergency STOP Final controlling devices Drives Emergency STOP switch Main
switch P1 209 14.3 Example of a control release Figure 14.2 Control release in FBD Output Q4.0 is
switched on in a latching manner using pushbutton S1 via input I1.0. Output Q4.0 is switched off: ˆ
Manually using pushbutton S0 at input I1.1, ˆ Via input I1.2 in the case of an emergency STOP, ˆ In the
case of a disturbance of the encoder voltages, ˆ In the case of a power failure due to the process image
being deleted. Output Q4.0 can be used in a controller program for switch on or switch off conditions.
Using contactor K1 allows you to specify that specific actuators and electric circuits can only be switched
on in the case of a control release. I1.1 I1.2 I1.0 Q4.0 210 211 Appendix Solutions according to the
examples 212 Example of a solution according to chapter 6.8.1 213 214 Example of a solution according
to chapter 6.8.2 215 216 Example of a solution according to chapter 6.8.3 217 218 Example of a solution
according to chapter 6.8.4 219 220 Example of a solution according to chapter 6.8.5 221 222 Example of
a solution according to chapter 6.8.6 223 224 225 226 Example of a solution according to chapter 6.9.3
227 228 229 230 Example of a solution according to chapter 7.4 231 232 233 Example of a solution
according to chapter 8.6.1 234 Example of a solution according to chapter 8.6.2 235 236 237 238 239
240 Example of a solution according to chapter 8.6.3 241 242 243 244 245 246 Example of a solution
according to chapter 9.1.1 247 Example of a solution according to chapter 9.1.2 248 249 250 Example of
a solution according to chapter 9.1.3 251 252 Example of a solution according to chapter 10.3 253 254
255 256 257 258 Example of a solution according to chapter 11.2 259 260 261 262 263 264 265 Example
of a solution according to chapter 11.3 266 267 268 Example of a solution according to chapter 12.1 269
270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 Example of a solution according to
chapter 12.2 285 286 287 288 289 290 Example of a solution according to chapter 12.3 291 292 293 294
295 296 297 298 Example of a solution according to chapter 12.4 299 300 301 302 303 304 305 306 307
Example of a solution according to chapter 12.5 308 309 310 311 312 Example of a solution according to
chapter 12.6 313 314 315 316 317 318 319 Example of a solution according to chapter 12.7 320 321 322
323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 Example of a solution according to
chapter 12.8 338 339 340 341 342 343 344 345 346 347 348 349 350 351 Example of a solution
according to chapter 12.9 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 Example
of a solution according to chapter 13.5 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382
383 Applicable practical know-how Comprehensive teaching support for educational institutions
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