Computer Based Automation Systems

Programmable Logic Controller Laboratory

Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 1 of 17

Computer Based Automation Systems

Programmable Logic
Controller (PLC) Laboratory





Task 1: Programming
Task 2: Programming with Blocks
Task 3: Control of a beverage vending machine


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 2 of 17

Optional memory card Power supply
Status indicators
Input voltage
select switch
Signal modules CPU






Optional battery
On/off switch
Power supply
connector
MPI and Profibus connectors
Mode select switch



Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 3 of 17

Task 1: Programming


1. Introduction

In the laboratory we work with the PLC SIMATIC S7-300 from the Siemens AG.
A common PC is used as the programming unit executing the development system
SIMATIC Manager STEP 7 with the included editors.

The PC is connected to the PLC by a special V24/TTY-connection. The PLC consists of a
central processing unit and five input and output modules. The inputs and outputs of the
PLC can be accessed via a connection-panel located directly under the PLC central rack.
Figure 1.1 shows the structure of the training system. It consist in the upper part from left
to right of a central unit (PLC) S7-315-2 DP, a module with 16 binary inputs (SM321), a
module with 16 binary outputs (SM322), two modules with two analog inputs each
(SM331) and a module with two analog outputs (SM332). The inputs and outputs are
extended to the connection-panel in the lower level of the training system.

On the left side of the connection panel are the power switch and the power supply
connector of the whole system as well as DC voltage outputs.

Right of those are the connectors for 16 binary inputs (red female connector), which have
the addresses:
Left: I0.0 ... I0.7, Right: I1.0 ... I1.7.

Next to the right are the connectors of 16 binary outputs (blue connectors) with the
addresses:
Left: Q4.0 ... Q4.7, Right: Q5.0 ... Q5.7.

Next are 4 analog inputs labeled E.1 to E.3. The input voltages can be provided by
potentiometer (internal) or via the red connectors (external) depending on the associated
switches underneath. The PLC addresses of the analog inputs are
E.0: PIW288, E.1: PIW290, E.2: PIW304, E.3: PIW306

On the control panel to the right are 2 analog outputs labeled A.0 and A.1. The output
voltage can be accessed via the blue connectors. The voltage value is additionally shown
by the related analog scale. The PLC addresses of the analog outputs are:
A.0: PQW320, A.1: PQW322.



Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 4 of 17


Figure 1.1: Laboratory PLC Training System


The program development and user interface software for the automation system is
STEP 7 running on the PC. It is started by clicking on the desktop icon SIMATIC
Manager.

2. Introduction to SIMATIC Manager

The SIMATIC Manager is the main tool of the Programming Software STEP 7.
Programming begins with opening or creating a project and with configuring the
hardware of the station thereafter. With the hardware configuration the program gets the
necessary information about the PLC system structure. Figure 2.1 shows an already
created project with the project name SPS_S7_Ver22". The project consists of several
nested container. The containers contain data and programs. The container with the
project name contains all other containers starting with the container SIMATIC 300 which
is the station name.

Figure 2.2 shows the structure of a project.


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 5 of 17


Figure 2.1: Project window in the SIMATIC manager


2.1 Creating a new project

1. Creating a new project: Start the SIMATIC Manager by double clicking on its
desktop icon and create a new project with the pull down menu File new.
Choose a name for the project.

2. Insert a station: Select the project and insert a station with Insert Station
SIMATIC 300 Station.

3. Configuring a station: Select the container SIMATIC 300(1) in the left part of the
window and the SIMATIC Manager displays the Hardware container in the right half
of the window. Double-clicking on the Hardware container starts the Hardware
Configuration tools, with which you edit the configuration tables. Choose the Rail
(Folder Rack-300), the power supply (Folder PS-300), the CPU (the PLC central
processing unit; Folder CPU-300) and the required signal modules (Folder SM-300)
one after each other from the hardware catalog (Fig. 2.3) and place them on the
open table in the appropriate slots by drag and drop. Make sure that the order
number of each module you pick given in the hardware catalog corresponds exactly
to the order number of the hardware module printed on the front side of the module!
Also be sure, that the slot number in the table of the hardware configuration
corresponds to the number of the hardware slot labeled on the front side of the
module (down left). Slot 3 is reserved for an optional interface module to a further
rack. Figure 2.4 shows a special configuration (which is not the configuration of the
laboratory system!). The CPU is plugged in slot 2. Store and compile the result of
the hardware configuration by selecting Station Save and Compile, then
close the hardware configurator and return to the SIMATIC Manager.



Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 6 of 17
4. The SIMATIC now creates containers for an S7 Program (Sources and Blocks, see
Fig. 2.2). The container Sources contains the sources of SCL and Graph programs.
The container Blocks contains the compiled user programs for the PLC including
LAD, FBD and STL blocks as well as the compiled blocks of the SCL and Graph
sources.

5. Editing user program objects: Select the container Blocks in the container S7
Program. Afterwards you can insert organization blocks OBxx, Functions FCxx,
Function Blocks FBxx or Data Blocks DBxx by selecting Insert S7 Block
appropriate Block. The empty OB1 is automatically created.
































Contains a list of variables which shall be
monitored and controlled



Figure 2.2: Object hierarchy in a STEP 7 project


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 7 of 17
Figure 2.3: Hardware Catalog

This example is
not the hardware
configuration of
the training
system in the
laboratory!
Figure 2.4: Example for a Hardware Configuration


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit


2.2 Editing a program

This part shows the development of a simple program in the form of a Statement
List (STL) and its realization and testing on the PLC.
The program shall realize the logic plan shown in Figure 2.5.



I 0.0
I 0.1
I 0.3
Q 4.0
&
> 1


Figure 2.5 Logic plan of the first task


For the realization of this program you have to program the organization block OB1.
Open the project container in the SIMATIC manager and select the container Blocks.
Open the Organization Block OB1 by double clicking on the icon in the right part of the
window.

The program can then be edited in the LAD/FBD/STL editor. The finished STL
program with one network has the following form:



Choosing View from the menu you can automatically view the program in Ladder
diagram (LAD) or Function block diagram (FBD). Save your programmed organization
block OB1 (File Save).
Having saved it, the OB1 is stored on the PC hard-disk. The finished program shall
now be transferred into and tested on the PLC.
Page 8 of 17


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 9 of 17


2.3 Deleting programs on the PLC

Before downloading the newly developed programs into the PLC you should delete all old
programs in the PLC. Do this by choosing the item PLC Clear/Reset from the
menu. Resetting is only possible in the operation modes STOP or RUN-P of the CPU (Use
operation mode switch).

2.4 Transferring (downloading) a program from the programming unit (PC) into the PLC

The program OB1 shall now be transferred (downloaded) into the PLC.
Open the OB1 or select it in the project window of the SIMATIC Manager. Choose PLC
Download from the menu or click on the Icon Download below the menu bar, see
Figure 2.6.
After the download the programs can be run (tested) on the PLC.




Choose Download or click on download icon Monitor (on/off)

Figure 2.6: Menu bar of the LAD/SL/FBD-Editor: Downloading and monitoring a user
program


2.5 Program Test

To run the downloaded program on the PLC switch the operation mode switch to RUN or
RUN-P. You can monitor the behavior of the program running on the PLC with the
programming unit (PC).

Open the organization block OB1 and click on the icon Monitor (on/off) below the menu
bar (Figure 2.6). After that you can see on the PC display the status of inputs, outputs,
flags and so on.

For a deeper introduction into the STEP 7 program development system read the
SIEMENS manual S7gsv54_e.pdf.


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit


Page 10 of 17
3. Tasks

Document all your programs in the laboratory report by using the menu item File
Print to print out each program.

Briefly discuss the results of your tests (include a short test report with test cases and their
results).


3.1 An example in Ladder diagram (LAD)

Program the logic function of Fig. 2.5 in a ladder diagram (LAD). Before you start delete
the old program in the PLC.


3.2 An example in Function block diagram (FBD)

Program the logic function of Fig. 2.5 in a function block diagram (FBD). Before you start
delete the old program in the PLC.


3.3 Cooling fluid pump of a machine tool

The cooling pump of a tooling machine can only be turned on, if the machine (spindle) is
rotating. It should always be possible to switch off the coolant system. The following
schematic diagram shows the hard wired control circuit.

Use symbols .e.g. the contact symbols S11S22, S0, K1 and K2 instead of the absolute
addresses I0.0I0.4, Q4.0 and Q4.1. The assignment of the symbols to the absolute
addresses is defined in a symbol table. You can open the symbol table in the
LAD/STL/FBD-Editor by choosing the menu item Options Symbol Table.




Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 11 of 17


M
3 ~
M
3 ~
L1
L2
L3
N
S0
(I 0.0)
S12
(I 0.2)
S11
(I 0.1)
K1
K2
K1 K2
K1
K1
K2
S22
(I 0.4)
S21
(I 0.3)
Spindle
motor
Pump
motor
(Q 4.0) (Q 4.1)

Fig. 3.1 Schematic of a coolant control system of a tooling machine


Description Symbol
Button spindle motor on (NO) S11
Button spindle motor off (NC) S12
Button pump motor on (NO) S21
Button pump motor off (NC) S22
Button system stop (NC) S0
Relays K1, K2
Contactor spindle motor K1
Contactor pump motor K2


Table 3.1 Description of the symbols of the coolant control system



Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 12 of 17

S12 S21 S22
K1 K2
I 0.0 I 01 I 0.2 I 0.3 I 0.4 I 0.5 I 0.6 I 0.7
Q 4.0 Q 4.1 Q 4.3 Q 4.2 Q 4.4 Q 4.5 Q 4.6 Q 4.7
S7-300
+
S11 S0


Fig 3.2 PLC connection diagram for the machine tool control

Be careful with the switches S0, S12 and S22 because those are normally closed
connectors (NC).


a.) Design the logic diagram (plan), using RS-flipflops wherever possible.

b.) Realize the control function with the PLC S7-300. Develop the control program.

After testing, print your program out as a functional block diagram (FBD) program.


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 13 of 17

3.4 Rising edge triggered JK-FF

Develop a program for a rising edge triggered J K-flipflop. Use one RS-FF (Fig. 3.3).


&
& >1
S
R
C
J
R
K
(I 0.0)
(I 0.2)
(I 0.1)
(I 0.7)
M 1.5
Q
Q
(Q 4.0)
(Q 4.1)
&

Figure 3.3 Structure of a J K-FF


Be careful to realize the right sequence of the instructions. The S- and the R-input of the
RS-flipflop must be calculated with the old values of the outputs Q and Not-Q.

Use symbols for the inputs, outputs and the flags.

Test your program. It should realize the following transition table of a J K-flipflops (Table
3.2).


J K Q
n+1
0 0 Q
n
0 1 0
1 0 1
1 1
n


Table 3.2: Transition table of a J K-FF with R=0. For R=1, the FF has the state Q=0.


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit


3.5 Circuit with off-delay

The diagram of the circuit in figure 3.4 includes an off-delay-relay (K2).
L1
N
S 0
(I 0.0)
S 1
(I 0.1)
K 1 K 2
K 1 K 2
L
(Q 4.0)
K1

Figure 3.4: Hard wired circuit with off-delay-relay


Replace the hard wired realization with a PLC. Develop the PLC-program. Choose an off-
delay-time of 5 seconds for the test.


S 0 S 1
L
I 0.0 I 0.1 I 0.2 I 0.3 I 0.4 I 0.5 I 0.6 I 0.7
Q 4.0 Q 4.1 Q 4.3 Q 4.2 Q 4.4 Q 4.5 Q 4.6 Q 4.7
S7-300
+


Figure 3.5 PLC connection diagram
Page 14 of 17


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit


3.6 Oscillator with adjustable frequency and duty cycle

With the timer operations of the PLC is it possible to realize an oscillator. Write a program
for an oscillator with an adjustable frequency and an adjustable duty cycle.

Enable
(I 0.0)
I 0.0
Q 4.0
0
1
0
1
t
t
Q
(Q 4.0)
Oscillator

t t
v1 v2


Figure 3.6: Block structure and timing diagram of the oscillator

Frequency:
f =
1

Duty cycle:

=
1
t


Choose for your test: f =0.2 Hz and =0.3.
Page 15 of 17


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 16 of 17
3.7 Oscillator with counter

The oscillator of Figure 3.6 shall be completed with a counter, in a way that it is possible to
produce a preselected number of pulses with the oscillator.





Oscillator
Counter
Enable
Q
(Q 4.0)
Start
(I 0.1)
Number of
pulses



References:

Siemens AG: Automation & Drives Product Support:
SIMATIC S7 Manuals:
http://support.automation.siemens.com Product Support Automation Systems
SIMATIC Industrial Automation Systems PLC SIMATIC S7:
S7gsv54_e.pdf
S7gsv54_e.pdf
S7-300_IHB_Hardware_And_Installation_e.pdf
S7-300_IHB_Installation_e.pdf
S7-300_RHB ModuleData_e.pdf
Opli312cbis314c S7-300 Instruction List_e.pdf
AWL_e.pdf
FUP_e.pdf
KOP_e.pdf
SCL_e.pdf
Graph7_e.pdf
GS_SCL_e.pdf
GSGraph_e.pdf
SystemProg.pdf

Siemens AG: Siemens Automation Cooperates with Education SCE
Training Material:
http://www.automation.siemens.com/fea/html_76/down_module.htm


Computer Based Automation Systems
Programmable logic controller Laboratory
Task 1: Programming
MSc Electrical Engineering
Faculty of EE & IT
Prof. Dr. S. Simons
Dipl.-Ing. R. Petit

Page 17 of 17

Wellenreuther, G.; Zastrow, D.: Automatisieren mit SPS. Revised edition August 2002,
Vieweg-Verlag, Braunschweig

M. Habermann; T. Wei: STEP7-Crashkurs Extended. 5. Auflage 2006, VDE-Verlag,
Berlin

Berger, Hans: Automating with SINEMATIC; 3., revised edition - September 2006
Wiley-VCH, Weinheim / Publicis Corporate Publishing, Erlangen

Berger, Hans: Automating with STEP 7 in LAD and FBD; 3., revised edition- November
2005 Wiley-VCH, Weinheim / Publicis Corporate Publishing, Erlangen


Berger, Hans: Automating with STEP 7 in STL and SCL; 3., revised edition - Februar 2005;
Wiley-VCH, Weinheim / Publicis Corporate Publishing, Erlangen