NALCO E&A (A Govt. of India Enterprise) RISHIJIT PANIGRAHI 1041110289 ECE E 4 TH YEAR NALCO OVERVIEW Incorporated in 1981 ISO 9002 (QMS) ISO14001(EMS). Miniratna status. Largest integrated Aluminium plant in Asia Units ALUMINA REFINERY BAUXITE MINES SMELTER CAPTIVE POWER PLANT HOME BAUXITE MINES Koraput Panchpatmali hills 48 ltpa Open cast mining ( Computerised mine planning) Gibsite bauxite (Al 2 O 3 .3H 2 0) 14.6 km long single flight, multi curve cable belt conveyor of 1800 tph capacity.
HOME
d
ALUMINA REFINERY
One among top ten in worl 15.75 ltpa of calcined alumina Atmospheric digestion at low temperature Bayers process
Distributed control digital process T HOME CAPTIVE POWER PLAN 960 MW Capacity (8x120 MW) Microprocessor-controlled burner management, Computerised DAS, automated turbine run-up, brush less excitation of generators, islanding facility.
7 th 8 th DCS in and units. - I
ALUMINIUM SMELTER 180 KA cell technology of Aluminium Pechiney France Hall-Herauolt electrolysis process. Integrated 3.45ltpa of 3 pot-lines Aluminium plant Aluminium. with 240 electrolytic pot shell each. I CAST HOUSE Cast house Strip casting plant CARBON AREA Green anode plant Bake oven furnace Rodding shop
Rolled unit products ALUMINIUM SMELTER POT LINES Pot regulation system Fume treatment plant Alumina handling system
POT LINES Fume treatment plant Pot regulation system Alumina handling ystem HOME Laddle and pipe cleaning shop
SYSTEM ROOM Anodes connected in parallel(1 6) POT REGULATION Electrolytic pot cell connected in -A series 1050 180 KA V Cathode is carbon bar +Aluminiu m metal ROOM- B HOME - +
A001 A120
B001 B120 POT REGULATION SYSTEM SERVER 2 MAN-MACHINE INTERFACE SERVER 1 DIGITAL MULTI- SWITCHING DEVICE Communicator 1 Communicator 2 1 2 3 14 15 16 1 2 3 14 15 16 Group of 15 Electronic pot micro controller HOME FUME TREATMENT Alumina from SILO PLANT Fluorine gas from Electrolytic pot Dry scrubbing in filter reactors CLEAN GAS Fluorinated Alumina to Electrolytic pot shell HOME ALUMINA HANDLING SYSTEM Transfer of alumina through Bottom air fluidisation Storage of alumina in Primary SILO (6 no. each Supply to FTPs as quantity. of 13,500 t) per required
HOME Redundant RACKS
SYSTEM CONFIGURATION Man -Process
Interface PC-PLC Communication I/O processors HOME PROGRAMMABLE LOGIC CONTROLLER
Early control systems consisted of huge control boards consisting of hundreds to thousands of electromechanical relays.
An engineer would design the system logic, electricians would receive a schematic outline of logic then implement the logic with relays.
The schematic was commonly called Ladder Schematic
The ladder displayed all switches, sensors, motors, valves, relays etc in the system.
Problems: Long commissioning time, dependency on mechanical reliance, Any system logic design change required the power to the control board to be isolated stopping production.
History
General Motors was among the first to recognize a need to replace the systems wired control board
Hydramatic Division of GM specified the design criteria for the programmable controller in 1968.
Goal Eliminate the high cost associated with inflexible, relay controlled systems.
History
New Controller Specifications: Solid State System Computer Flexibility Operate in Industrial Environment (vibrations, heat, dust etc.) Capability of being reprogrammed Easily programmed and maintained by electricians and technicians. History
In 1969 Gould Modicon developed the first PLC. Strength Programmed with Ladder Logic Initially called Programmable Controllers PCs Now - PLCs, Programmable Logic Controllers PLCs have evolved from simple on/off control to being able to communicate with other control systems, provide production reports, schedule production, diagnose machine and process faults. History
Advantage of PLC Over Relay Style RELAY PLC
1-Hard wiring 1-Less wiring
2-Changes difficult 2-Easy modification
3-More power 3-Low power
4-More maintenance 4-Less maintenance
5-Difficult to expand 5-Ease of expansion
Control Systems Types Programmable Logic Controllers Distributed Control System PC- Based Controls
Programmable Logic Controllers
Sequential logic solver PID Calculations. Advanced Subroutines BIT Operations. Data Transfer. Text Handling.
Applications : Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control Advantages of PLC : They are fast and designed for the rugged industrial environment. They are attractive on Cost-Per-Point Basis. These Devices are less Proprietary ( E.g.. Using Open Bus Interface.) These Systems are upgraded to add more Intelligence and Capabilities with dedicated PID and Ethernet Modules. Disadvantages of PLC : PLC were Designed for Relay Logic Ladder and have Difficulty with some Smart Devices. To maximize PLC performance and Flexibility, a number of Optional Modules must be added PLC holds only one copy of program
Programmable Logic Controllers
PLC Types Nano (Small) Micro (Medium) Large
Basic criteria for PLC Types Memory Capacity I/O Range Packaging and Cost per Point
Programmable Logic Controllers
Sizing of PLC Micro PLCs: I/O up to 32 points Small PLC: I/O up to 128 points Medium PLC: I/O up to 1024 points Large PLC: I/O up to 4096 points Very Large: I/O 4096 Onwards
Most Basic of PLC Systems In the most basic of PLC systems, a self contained (shoe box) PLC has 2 terminal blocks, one for Inputs and one for Outputs Today, most PLCs in this category are know as Micros. Typically they provide front panel LED status indication of I/O and Processor states Inputs Outputs C R
Modular Chassis Based PLCs The vast majority of PLCs installed today are modular chassis based systems consisting of: 1. Processor Module (CPU) 2. Input & Output Modules 3. Chassis 4. Power Supply
Modular Chassis-less PLC Systems Also available from many vendors are Chassis less but still Modular PLC systems. These systems still require a Processor, I/O Modules, and Power Supply, but in place of a chassis these components mount directly onto a panel, din rail, and many use a tongue and grove system to allow easy insertion and removal
Central Processing Unit (CPU) Input Output Modules Power Supply Bus system Programming Device
P L C Components CPU PROGRAM DEVICE
IN OUT m MODULE MODULE
Basic PLC Schematic CPU Power Supply Memory Input Blocks Output Blocks Communications Expansion Connections
It is a micro-controller based circuitary. The CPU consists of following blocks : Arithmatic Logic Unit (ALU), Timing / Control ckt, Program memory, Process image memory (Internal memory of CPU) Internal timers and counters and Flags, Address stack and instruction registers
The Central Processing Unit (CPU) Module is the brain of the PLC. P L C : Central Processing Unit
CPU Module CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnostics. Self Check Execute Code Scan Inputs Update Outputs PLC Program SCAN Primary role to read inputs, execute the control program, update outputs.
Memory The memory includes pre-programmed ROM memory containing the PLCs operating system, driver programs and application programs and the RAM memory.
PLC manufacturer offer various types of retentive memory to save user-programs and data while power is removed, so that the PLC can resume execution of the user-written control program as soon as power is restored.
Memory Many PLCs also offer removable memory modules, which are plugged into the CPU module. Memory can be classified into two basic categories: volatile and non- volatile. Volatile memory loses state (the stored information) when power is removed. Nonvolatile memory, maintains the information in memory even if the power is interrupted.
Memory Some types of memory used in a PLC include: ROM (Read-Only Memory) RAM (Random Access Memory) PROM (Programmable Read-Only Memory) EPROM (Erasable Programmable Read-Only Memory) EEPROM (Electronically Erasable Programmable Read-Only Memory) FLASH Memory Compact Flash Can store complete program information, read & write text files
I/O Modules Input and output (I/O) modules connect the PLC to sensors and actuators.
Provide isolation for the low-voltage, low-current signals that the PLC uses internally from the higher-power electrical circuits required by most sensors and actuators.
Wide range of I/O modules available including: digital (logical) I/O modules and Analog (continuous) I/O modules.
These modules act as link between field input sensors and the CPU.
Analog input module : Typical input to these modules is 4-20 mA, 0-10 V, Ohms, mV Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)
Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Switches, Pushbuttons, Relays, pump valve on off status
PLC : Input module
PLC : Input module Transfer of data:-I/P sensor to CPU Conversion:- 24vdc/230vac to 5vdc Isolation :- By Opto Coupler
SOURCING vs. SINKING DC Inputs DC Power Supply Field Device DC Input Module + - DC COM IN1 C DC Input Module Field Device DC Power Supply + - +VDC IN1 IN1 VDC SINK SOURCE
Analogue Inputs/Outputs Analogue input cards convert continuous signals via a A/D converter into discrete values for the PLC Analogue output cards convert digital values in then PLC to continuous signals via a D/A converter. Resolution can be important in choosing an applicable card Example, for a temperature input of 0 to 100 degrees C For 8 bit resolution the value in the PLC is 0 to 255 For 12 bit resolution the value in the PLC is 0 to 4095 For 12.5 bit resolution the value in the PLC is 0 to 6000 For 13 bit resolution the value in the PLC is 0 to 8192 For 16 bit resolution the value in the PLC is 0 to 32768
These modules act as link between the CPU and the output devices in the field. Analog output module : Typical output from these modules is 4-20 mA, 0-10 V Ex : Control Valve, Speed, Vibration Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control
PLC : Output module
Relay type -For AC or DC Transistor Type Logic(TTL) - For DC Triac (Triode AC) type - For AC Isolated common type -For different device
PLC : Output module - Types
PLC : Output module
Output Devices Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns
Relays The most important consideration when selecting relays, or relay outputs on a PLC, is the rated current and voltage.
For transistor outputs or higher density output cards relay terminal blocks are available. Advantage of individual standard replaceable relays
I/O Specifications INPUT VOLTAGE Magnitude and type of voltage ON-STATE INPUT VOLTAGE RANGE voltage at which signal is recognized Nominal current per input Min. current to operate input circuit AMBIENT TEMP RATING Max temp of surrounding the I/O module INPUT DELAY Time duration for input signal to be on before known as valid input. ( 9-ms to 25ms) NOMINAL OUTPUT VOLTAGE It is min and max o/p operating voltage.e.g. Rated 120 v ac o/p ckt. Works in 92 to 138 v range. MAX O/P CURRENT RATING Max current a single o/p or module can safely carry under load OFF STATELEAK CURRENT PER O/P Max value of leak current flows through the o/p in OFF position ELECTRICAL ISOLATION Max volts between I/o and logic ckt.
The power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.
The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes.
As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.
P L C : Power Supply
It is path for the transmission of the signal . Bus system is responsible for the signal exchange between processor and I/O modules
The bus system comprise of several single line ie wires / tracks
Types of Bus P L C : Bus System Address bus - Location Data bus - Carries Data Control bus - Synchronization
Special Modules RF ID Voice Gas Flow Calculation Weigh Cell Hydraulic Servo ASCII Fuzzy Logic Temperature Sensor Temperature Control Heat/Cool Control Field Bus Cards DeviceNet, Profibus etc Lonworks, BACNet Fast Response (Interrupt) PID Loop Controller BASIC Cards RS232 Comms Modbus ASCII/RTU Ethernet Comms High Speed Counters Position Control Cards Peer to Peer Comms Controller Link DH+ Modbus Plus
Input Scan Program Scan Output Scan Housekeeping START Each ladder rung is scanned using the data in the Input file. The resulting status (Logic being solved) is written to the Output file (Output Image). The status of external inputs (terminal block voltage) is written to the Input image (Input file). The Output Image data is transferred to the external output circuits, turning the output devices ON or OFF. Internal checks on memory, speed and operation. Service any communication requests, etc. PLC Operating Cycle This scan cycle can be interrupted if required using interrupts
PLC Architecture Evolution Mid - 1970s : Discrete Machine Control Programming Terminal PLC I/O Programming Language :
- Relay ladder logic - Flexibility in altering Control system operation
Connection is Point to Point
Early - to - Mid 1980 : Discrete and Process Control PLC Architecture Evolution Reasonable Computer Running PLC Programming Software PLC I/O Programming Language :
- Ladder Program - PID - Data Storage
MS - DOS
PLC Architecture Evolution Late 1980s to early 1990s : Discrete and Process Control PC running PLC Programming Software PLC I/O Connection in networked allowing Multiple PLC PLC became a part of the developing enterprise resource system Windows PLC
Today : Distributed I/O Modules Distributed I/O modules PLC Distributed I/O scanner Data Communication Bus PLC Architecture Evolution
Remote I/O Network SPLITTERS FIBER OPTIC LINK TAPS Today : Hot Redundant System PLC Architecture Evolution
Level of redundancy Power Supply CPU I/O Communication
Remote Platform Wireless Modem / GSM Communication Wireless Modem / GSM Communication PLC H M I Display PC PLC Architecture Evolution Today : Wireless communication PLC
8 Analog Inputs 1 Analog Output Up/Down Fast Counter Up Counter Programming Terminal PC Connection Unitelway Port for connection of up to 5 Slaves PCMCIA memory expansion port PCMCIA communications port TSX37-22 Built in display for I/O (in-rack, AS-i) and Diag I/O Modules Configuration of PLC : Modicon
Configuration of PLC : Siemens CPU External Power Supply I/O Modules
Configuration of PLC : Allen Bradley CPU Power Supply I/O Modules
Configuration of PLC : GE FANUC
CPU I/O Modules Back plane
PLC Programming Standards The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application :
Ladder Diagram Statement List Instruction List Function Block Diagram Sequential Function Chart Structured Text
PLC : Terminology INPUT is referred by I OUTPUT is referred by Q / O TIMER is referred by T FLAGS are referred by M /B COUNTERS are referred by C
PLC : Communication Protocol It is a set of rules for data transmission when PLC is connected to network RS-232 (Recommended standard) RS-485 MPI(Multi point Interface) Profibus DH(Data Highway) Ethernet Controlnet Devicenet
Baud rate (Communication Speed) It is rate of data transmission on network Unit is bits/second Range:- 120 bits /sec to 100 Mega bits per second
Selecting a PLC Number of logical inputs and outputs Memory Number of special I/O modules Expansion Capabilities Scan Time Communication Software Support Cost
Manufactures Major Brands OMRON Allen Bradley Schneider GE Fanuc Siemens Automation Direct (Koyo) Toshiba Mitsubishi Hitachi Keyence VIPA
PLC Standardization IEC 61131 Based on IEC 1131 (1992) standard, developed to be a common and open framework for PLC architecture. IEC 61131-1 Overview IEC 61131-2 Requirements & Test Procedures IEC 61131-3 Data Types & Programming IEC 61131-4 User Guidelines IEC 61131-5 Communications IEC 61131-7 Fuzzy Control IEC 61131-7 Guidelines for the application and implementation of programming languages
PLC Programming The purpose of a PLC Program is to control the state of PLC outputs based on the current condition of PLC Inputs
Different PLCs support different languages, but the most popular PLC language is know as Ladder Logic.
IF input 4 AND input 5 have power THEN energize output 0 | | I/4 | | I/5 ( ) O/0 Logical Continuity T T T On
Logical AND Construction
IF input 4 OR input 5 have power THEN energize output 0 | | I/4 | | I/5 ( ) O/0 Logical Continuity F T On | | I/4 | | I/5 ( ) O/0 Logical Continuity T F On
Available Instructions Sequence Input Output Control Logic Timer and Counters Comparison Range Comparison Data Movement Data Shift Step / Step Next Serial Communications Text String Processing File Manipulation
Increment/Decrement Conversion ASCII Number Systems Math Floating Point Math Statistics Scaling PID PID with Auto tune Clock / Date Block Processing IF,THEN,ELSE,LOOP Table Processing LIFO, FIFO
Few more Instructions SEQUENCERS
SHIFT REGISTERS
DATA HANDLING
HIGH SPEED COUNTER
SUBROUTINES
Programmable Logic Controllers Siemens Types of SIEMENS PLC:-
Compact:- I/O number fixed
Modular :- I/O can be as per selection Siemens PLC
SIMATIC S7-300 within the System Family Mid- and low-end performance range S7-300
Micro PLCs S7-200 + Programming devices + STEP 7 software + Communication + Human-machine Interface High-end range / medium range S7-400
Highlights - Diverse applications ET 200S, ET200X Intelligent Interface modules, based on S7-300 or the standard S7-300 as PROFIBUS DP Slave Distributed Safety - S7-300F with fail safe I/O modules for central and distributed applications C7 control systems with integrated HMI on the basis of the S7-300
The C7 Systems are used where close integration with field, control and operation is required. For ex. Formulation and packaging in Pharma industry. These are costly systems and are used only for some high end applications. These are the remote I/O modules . Some of them have CPU inbuilt in them. The se I./Os are connected on Profibus network.
Siemens S7 Ranges
200 300 400 Series 212 to 226 312 to 318 412 to 418 Digital I/O 256 1024 16384 Analog I / O 38 256 4000 Programming S/W Micro win Simatic Manager
PS -Power Supply CPU -Central Processing Unit IM -Interface Module SM -Signal Module(I/O modules) Bus Connector Rack (rail) Eleven slot rail CP -Communication Processor FM -Functional Module
Siemens S7 PLC Hardware
The cost-effective entry into TIA The sophisticated solution for medium-range I/O configurations CP The standard CPU for a wide range of applications with integrated PROFIBUS DP Interface The new high-end CPU in S7-300 The high-performance CPU with system features of the S7-400 Siemens S7 300 CPU Overview
The new standard CPUs
Instr. / Data User memory DI / DO AI / AO Processingtime Bit instruction Wordinst. +/- I Floatingp.+/- R Flags Counters Timers Connections Interfaces
315-2 DP 128 KB
1024 256
0,1 s 1 s 3 s 16384 256 256 16 PROFIBUS- DP Master/ Slave
CPU 317-2 DP 512 KB
1024 256
0,05 s 0,2 s 1,0 s 32768 512 512 32 PROFIBUS-DP (Master/Slave) MPI also. DP
CPU 318-2 DP 84 K / 256 KB 512 KB 1024 256
0,1 s 0,1 s 0,6 s 8192 512 512 32 PROFIBUS-DP (Master/Slave) MPI also DP
CPU 314 48 KB
1024 256
0,1 s 1 s 3s 2048 256 256 12
CPU 312 16 KB
256 64
0,2 s 2 s 6 s 1024 128 128 6
The Compact CPUs - Highlights Integrated functions Count/measure, control, positioning Integrated I/O Digital, Analog Integrated communication interfaces In addition to MPI, also PROFIBUS DP and point-to-point
CPU 312C CPU 313C CPU 313C-2 PtP CPU 313C-2 DP CPU 314C-2 PtP CPU 314C-2 DP
Test and diagnostics functions System diagnostics Fault diagnostics from CPU to I/O internal CPU services (e.g. error message with time stamp) Process diagnostics ( Seperate PDIAG software is required) Monitoring critical process signals at the program level Simply assign parameters using S7-PDIAG and ProAgent CPU generates messages automatically for S7 HMI So that your service personnel can diagnose the problem sooner
MPI is used for PLC programming, inter CPU communication, SCADA/HMI communication
In addition to above Profibus is also used for remote I/Os and Drives communication . Now a days Profibus is implemented on industrial Ethernet as Profinet. Profibus can also be implemented using fibre optic technology. Modules for S7-300 Power Supplies classified according to capacity Signal modules for digital and analog signals and hazardous areas Point-to-Point CPs for I/O devices of all kinds Function modules for high-speed counting, positioning, closed- loop control and cam control
Siemens S7 300 - Digital modules
Voltage/ current range
Channels (optically isolated)
Sensors
Resolution
Encoding time
Ex (i)
Diagnostics
Digital outputs
DC 24 / 48...125 V AC 5...230 V 0,5 / 1 / 2 / 5 A
8, 16, 32 electr./ Relay
Namur / Ex(i)
yes
Digital inputs
DC 24...125 V AC 120 / 230 V
8, 16, 32
Switches, 2-wire Beros
Namur / Ex (i)
yes
Voltage/ current range
Channels (optically isolated)
Sensors
Resolution
Encoding time
Ex (i)
Diagnostics
Analog outputs
+/- 10 V, 0...10 V, +/- 20 mA, 0/4...20mA, u.a.
2, 4, 8
12 - 16 bit incl. sign bit
0.8 ms
Namur / Ex(i)
yes
Analog inputs
+/- 80mV...10 V, +/-3,2mA, 0/4...20mA u.a.
2, 4, 8 with integrated linearization
2-,3-,4-wire resistor (Pt100), thermocouples
9 to 16 bit incl. sign bit
2.5 ... 100 ms
Namur / Ex (i)
yes
Siemens S7 300 - Analog modules
Point-to-point CPs - for special interfaces 1 or 2 interfaces, up to 76 kbit/s Different physical transmission environment Standard or custom-specific protocols Programming device, PC, computers Robot controls Opto-electronics Printer SIMATIC S5 and also PLCs from other manufacturers Scanner, barcode reader, identification systems Weighing systems, controllers
Siemens S7 300 - Function Modules (FM) The FM are used when ... tasks have to be taken care of at top speed ... The very highest accuracy and reproducibility are required ... Special sensors or actuators are required ... technological tasks require practical solutions Counting, measuring, cam control, positioning, closed-loop control
Siemens S 7 300 Design Rugged, enclosed modules Integrated, easy-to-connect backplane bus High module density, up to 32 channels per module Minimum mounting depth due to recessed and covered connectors and plugs Power supply modules in the case of AC mains connection for supplying the S7-300 and sensors/actuators
Siemens S7 300 - Mounting Simply snap the module onto the mounting rail No slot rules No jumper settings required on the module Horizontal or vertical mounting Front connectors with in Screw- or Spring-loaded terminals Self-coding front connectros make sure that the right connector is plugged in after module replacement
CPU memory divided in blocks:-
OB -Organization Block(OB1-main block) FC -Functions(Subroutine user defined) FB Functional Block(defining function with memory) DB -Data Block(creating memory data) SFC -System Functions (syst. Block) SFB -System Function block(syst. Block)
CPU Memory organisation
Load memory:- User program stored, capacity can be changed by MMC up to 256k
Work memory:-Instructions required program execution
System memory:-Holds OS, Timer, Counter, memory bits, Process Image Memory, buffer diagnostics.
CPU Memory organisation
All the addresses are based on byte numbers. The Singnal Modules (I/O) can be put from slot no 4 onwards. When we do the I/O configuration byte numbers required for each module are defined by the system which we can use in the programming. In certain CPUs these Byte numbers can be changed by the user. Generally system defined addressing is preferred as it avoids memory holes. Siemens Addressing Concepts
The typical addressing in Siemens S7 300 compact PLCs is as follows Digital Input starts with I 124.0 (Byte No 124) , Digital Output starts with Q 124.0 (Byte No 124) Analog Input starts with PIW 256 or PIW 752 Analog Output starts with PQW 256 or PQW 752 Similar I/O mapping is followed for Profibus Dp based remote I/Os
I 0 . 0 (0 to 7) I 1 . 0 (0 to 7) Q 0 . 0 (0 to 7) Q 1 . 0 (0 to 7) Four Bytes are allotted for each slot 32 I/O are permitted in each slot One rail 8 slot are for SM,DP&FM 32 .8 =256 I/O in one rail Four rail configuration permitted 256 . 4 = 1024 I/O permitted in four rails Compact Module address is 124 to 127 INPUT or OUTPUT BYTE ADDRESS BIT ADDRESS Siemens I/O Addressing
M-Marker memory MB-memory byte MW-memory word MD-memory double word
If total memory bits 1024 then 1024/8=128 Memory byte no. - 0 to 127 Bit Level Address:- M0.0M0.7M1.0M1.7..M127.7 Byte Level Address:- MB0,MB1,MB2,MB3,MB127 8 BITS=255 OR -128 TO 127 Siemens Memory addressing
Siemens follows overlapping memory areas so user should be careful in using this addresses WORD Level Address:- MW0,MW2,MW4,..MW126 16 BITS = 65535 OR -32768 to 32767 Word address is used to display Timer & counter value and for Integer function within above limit DOUBLE WORD Level Address:- MD0,MD4,MD8,MD124 32 BITS = -2147483648 to 2147483647 Double Word address is used for Integer function value more than word limit Siemens Memory addressing
TIMER :-T0 T 511(depends on module) COUNTER :- C0 C 255 FC :- FC1.. FC 511 FB :- FB1. FB 511 DB :- DB1. DB 511
STL :- Structural Text Language A ( A I0.0 A I0.1 ) = Q0.0
Siemens Programming Language
FBD:- Functional Block Diagram
I0.0 Q0.0 I0.1
& = Siemens Programming Language
I(Integer) - MW(word address) W(Word) - ,,
D (Double) - MD (double word address) DI (Double Integer) - ,, DW (Double Word) - ,, R (Real) - ,, Siemens Syntaxes in programming
PLC MPI ADAPTER PC RS485 RS232 PLC USB ADAPTER PC RS485 USB Universal Serial Bus Siemens Types of MPI adapters
OB1 Main cuclic execution block. All other blocks must be called from here. OB10 - 17 Time-of-day interrupts Execution to be done on specific time can be called here. OB20 - 23 Time-Delay interrupts Keep repeating after delay time. OB10 &35 Cyclic interrupts Keep repeating aftre defined time interval OB40 - 47 Hardware interrupts Certain hardware moduels are capable of generating interrupts for ex. High speed counter. These blocks are executed when the hardware interrupts are triggered.
Siemens Organisational Blocks
These are interface between user program and operating system.
OB60 Multicomputing interrupt Used when multi cpu systems are used OB100 Warm restart - Memory retained but program starts from begining OB 101 Cold Restart Initialise memory and start from begining OB121, 122 Error interrupts When error happens it triggers these interrupts Siemens Organisational Blocks
im361 IM361 IM361 IM360 Cable upto 10 meter Siemens S7 300 Central Configuration With the 312 and 312C CPUs only a single structure is possible on one rack No restrictions to the selection of modules Central rack + max.3 expansion racks possible- 32 modules
----||----- NO ----|\|---- NC ----( )---- O/P COIL ----( S )---- SET COIL ----( R )---- RESET COIL ----( P)---- POSITIVE EDGE ----( N )---- NEGATIVE EDGE
Siemens Instructions
SF 1. Hardware faults 2. Programming errors 3. Parameter assignment errors 4 Calculation errors 5. Faulty memory card 6. I/O fault/error 7. Communication error BATF The backup battery is missing, faulty or not charged. It also is on when an accumulator is connected. The reason for this is that the user program is not back up by the accumulator. STOP Flashes When CPU is not processing a user program. The CPU requests a memory reset Siemens LED Description
5 V DC This must be ON. It shows CPU Logic power (5 V) available. FRCE If any I/O force exist in CPU it will glow Yellow. Run Solid green represents CPU in Run Mode
STOP Solid Yellow CPU in stop mode Siemens LED Description
Programmable Logic Controllers Allen Bradley PICO MicroLogix Compact Logix SLC PLC Obsolete (Control Logix is used) Flex Logix Discontinued Control Logix
Central Processing Unit Input Module Output Module Power supply Bus System Rack (chassis)
Chassis types:- 4,7,10&13 Slots (17 slots in Logix Platform) AB PLC Hardware
CPU memory divided in two parts:- Data Files Program Files
Data files:- System 0 -Manufacturer program System 1 -Reserve file Ladder 2 -Main user file -ladder 3 to 255 for subroutine program
AB PLC CPU Memory Organisation
Program files:- 0 -Output - O -- o/p status 1 -Input - I -- i/p status 2 -Status - S2 -- CPU data 3 -Binary - B3 -- Flag(memory bit) 4 -Timer - T4 -- Timer status 5 -Counter - C5 -- Counter status 6 -Control - R6 -- Specific data 7 -Integer - N7 -- whole no. data 8 -Float - F8 -- Decimal no.data 9 to 255 used to create new Program Files AB PLC CPU Memory Organisation
: . /
I : 1 . 0 / 0 (0 to 15) I : 1 . 1 / 0 ,, O : 2 . 0 / 0 ,, O : 2 . 0 / 0 ,, FILE LETTER SLOT NO WORD NO BIT NO AB PLC Addressing I/O
File Letter File Number Word Number BIT Number Addressing BINARY (Flag)
TIMER :- T4:0 . T4:255(as per PLC) COUNTER :- C5:0. C5:255 CONTROL :- R6:0. R6:255 INTEGER :- N7:0 N7:255 FLOAT :- F8:0. F8:255 Addressing of Programming Instructions
----||----- XIC NO ----|\|---- XIO NC ----( )---- OTE O/P COIL ----( L )---- OTL O/P COIL ----( U )---- OTU O/P COIL
Addressing of Symbols
DH+
DH485
Device Net
Control Net
Baud rate max
230.4 kbits/s
19.2 kbit/s
500 kbit/s
5 Mbit/s
No. of max. nodes
64
32
64
99
1
Network Length 3.048 km
1.2 km
0.487 km
30 km
15 m
Communications protocols are broadly distinguished by speed of the communication, number of nodes supported and length of network. Communication Protocols Comparison
AB_DF1 19.2 kb p/s
Allen Bradley : SLC system
System Components A modular-hardware SLC / 1746 control system at minimum consists of a processor module and I/O modules in a single 1746 chassis with a power supply. The 1746 power supply connects to the left end of each 1746 chassis. You can configure a system with one, two, or three local chassis, for a total of 30 local I/O or communication modules maximum. You connect multiple local chassis together with chassis interconnect cables to extend the backplane signal lines from one chassis to another.
Choose the processor module with the on-board communication ports you need. You optionally add modules to provide additional communication ports for the processor. For I/O in locations remote from the processor, you must add an I/O scanner module for ControlNet, DeviceNet, or Universal Remote I/O port.
The 1746/1747 platform provides a modular-hardware system for maximum flexibility. SLC 500 processors are single-slot modules that you place into the left-most slot of a 1746 I/O chassis. For 1746 I/O in a location remote from the processor, the I/O adapter is a single-slot module that you place into the left-most slot of a 1746 I/O chassis.
The 1746 I/O chassis are built for back-panel mounting and are available. Product Design : CPU
SLC 500 processors are available with 4096 Input and 4096 Output User memory 1K instructions with 64K words Local and Distributed I/O using I/O scanner module with Control / Devicenet or remote link Built in 1 or 2 communication ports Provision for expansion of memory
You can configure a system with one, two, or three local chassis, for a total of 30 local I/O or communication modules maximum. You connect multiple local chassis together with chassis interconnect cables to extend the backplane signal lines from one chassis to another.
For many modules, because you wire to a removable terminal block that unplugs from the module, you do not need to disconnect wiring to replace an I/O module.
Product Design : CPU
SLC 500 processors are available in a large range of forcible I/O (4096 inputs plus 4096 outputs maximum) and maximum user memory (1K instructions through 64K words). Several modular processors are capable of controlling remotely located I/O. By adding an I/O scanner module, you can use these processors to monitor/control these remotely located I/O across ControlNet, DeviceNet, and Universal Remote I/O links.
The 1746/1747 platform provides a modular-hardware system for maximum flexibility. SLC 500 processors are single-slot modules that you place into the left-most slot of a 1746 I/O chassis. For 1746 I/O in a location remote from the processor, the I/O adapter is a single-slot module that you place into the left-most slot of a 1746 I/O chassis.
Product Design : CPU
The 1746 I/O chassis are built for back-panel mounting. The 1746 I/O chassis is available in sizes of 4, 7, 10, or 13 module slots. The 1746 I/O modules are available in densities of a maximum of 32 I/O per module.
You can configure a system with one, two, or three local chassis, for a total of 30 local I/O or communication modules maximum. You connect multiple local chassis together with chassis interconnect cables to extend the backplane signal lines from one chassis to another. This same 30-I/O- module limit applies to a chassis remote from the processor with an I/O adapter module in the first slot.
Product Design : Chassis and I/O modules
Various models of SLC processors have various on-board ports for communication with other processors or computers. Also, separate modules are available to provide additional communication ports for communication with other processors, computers, and remotely located I/O.
Each SLC processor has one or two built-in ports for either EtherNet/IP, DH+, DH-485, or RS-232 (DF1, ASCII, OR DH-485 protocol) communication.
I/O adapter modules for 1746 I/O are also available for ControlNet and Universal Remote I/O links. Communication
Communication Protocols Comparison
DH+
DH485
Device Net
Control Net
Baud rate max
230.4 kbits/s
19.2 kbit/s
500 kbit/s
5 Mbit/s
No. of max. nodes
64
32
64
99
Network Length 3.048 km
1.2 km
0.487 km
30 km
Communications protocols are broadly distinguished by speed of the communication, number of nodes supported and length of network.