BEE2961

Industrial Electropneumatic

PLC
Configuration

PLC Introduction
--------------------------

What is PLC?
A Programmable Logic Controller (PLC) is a digital computer
used for automation of electromechanical processes, such as
control of machinery on factory assembly lines, amusement
rides, or light fixtures
PLCs are used in many industries and machines where it is
designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise,
and resistance to vibration and impact
Programs to control machine operation are typically stored in
battery-backed-up or non-volatile memory
A PLC is an example of a hard real-time system since output
results must be produced in response to input conditions
within a limited time, otherwise unintended operation will
result
In this subject, we will use PLC to control electropneumatics
system that has been learned previously

PLC Overview
MPI Interface
* Interface adapter
between PC and PLC

PLC CPU
* Processor of PLC

PLC I/O Board

* Input/Output pin for PLC

PC (Siemens STEP 7 Software)

PLC I/O Board

Toggle switch (digital input)

PLC ground

Digital input pin

Digital output pin

Analog I/O pin (we dont

use this in this course)

PLC I/O Board

All the hardware components will be
connected via PLC I/O board in order to
control them according to the ladder
programming written
Each hardware components needs to be
identified whether they acted as an input
or output for/from PLC
All the connected I/O pins must have the
same address assigned to them in ladder
programming

PLC CPU

Memory slot

CPU model/module
Status indicator

Reset switch

CPU order number

Input port indicator

Output port indicator

PLC CPU

The CPU controls all the input and output from PLC
I/O Board according to the program that has been
downloaded into it
The status indicator shows the status of the CPU
whether it is on RUN or STOP mode
The order number must be exactly the same as
the order number selected during the hardware
configuration to ensure that PC recognize the PLC
CPU
The input and output port indicator must be
monitored regularly to ensure that the
programmed system is working according to the
ladder programming written

MPI Interface

Power and active indicator

FLIP

RS232 connecter from PC

Transmission rate selector

MPI Interface

MPI Interface acts as a connector between PC

and PLC CPU
The transmission rate selector must be set to
the exact same value set in hardware
configuration
Power indicator must be shown in order for
PC and PLC CPU to interact with each other
Active indicator will be lighted whenever
theres a download or monitor activity
going on in that period of time

Siemens Step-7 Software

Siemens Step-7 Software is used to write
ladder programming that will be transferred to
PLC CPU in order to control the
electropneumatics system
Before writing a ladder programming,
hardware configuration must be set first as
the hardware cannot be detected
automatically
A misconfigured setting will results in failure
or error of the electropneumatics control
system

The Flowchart of PLC

Configuration Process
Setup a new
project

Interface
setup

Hardware
configuration

Download to
PLC CPU

Hardware
monitoring test
(optional)

Setting Up a Project
--------------------------

Starting Procedures
Start up your PC
Start up your PLC

1.
2.

3.
4.

PLC doesnt have a start switch, just switch on

after plugging the cable to an electric socket

Push the CPU switch to RUN

Wait for the status indicator LED
to stop blinking
Only DC5V and RUN indicator will
light on

5.

Double click SIMATIC Manager

in your PC

STEP 7 Wizard

A New Project Wizard will pop-up. Click Next

STEP 7 Wizard
Select CPU: CPU313C
MPI address: 2
Click Next

Inspect the PLC CPU model

STEP 7 Wizard
Select Blocks: OB1
Language for Selected Blocks: LAD
Click Next

OB1 is the main program,

we dont use others in
this subject
LAD for ladder
programming

STEP 7 Wizard
Write in a new project name
Click Finish

Write your project

name here

SIMATIC Manager Window

A new project has been created

Make sure the SIMATIC Manager

window display your project name

Interface Setup
--------------------------

SIMATIC Manager
In order to transfer hardware configuration or
ladder
programming to
PLC CPU, MPI
Interface needs to
be setup first
Usually, we will
use the default
setup, however we
will learn to
inspect the setup
Click Options Set PG/PC Interface

SIMATIC Manager

Double click PC Adapter [MPI]

SIMATIC Manager

The default setting should be:

Address: 3
Timeout: 10s
Transmission Rate 187.5 Kbps
Highest Station Address: 31

Next, click on Local

Connection tab

Never change this number, it will results

in hardware error if it is changed

SIMATIC Manager

The default setting should be:

Connection to: COM1
Transmission Rate: 19200

Lastly, click OK

Ensure that the transmission rate

selector on MPI interface is
selected at 19.2

Hardware
Configuration
--------------------------

SIMATIC Manager

Double click Hardware

Click + to expand the subfolder view

HW Config

A HW Config will pop-up

Rack with individual slot

Configuration settings

Hardware catalog

HW Config
Expand these columns to have a clear view of each settings

If the order number is not the same as the one

written on your PLC CPU, change it by searching
the correct order number from Hardware Catalog

HW Config

Click Yes

A warning message will pop-up

confirming the changes of
CPU order number

HW Config

The order number has been changed

Make sure the order number is correct

HW Config

Double click on DI24/DO16 row

Double click here to change the address

for input (I) and output (Q)

HW Config

A Properties window will pop-up

Click the Addresses tab to

change the input and
output address

HW Config

The PLC address needs to be started from 0

for input and output. This is due to the I/O
port numbering in PLC I/O Board

Deselect System Default as we

want to key-in our own address

HW Config
Change both the starting address to 0
Click OK

The end address will be

automatically set

HW Config
To save the settings, click Save and Compile
Then, to download the settings into PLC
CPU, click Download
A message will
pop-up confirming
the target module.
Click OK

HW Config

Another message will pop-up informing the

node address selection. Click OK

HW Config
In order for the new settings to take place,
all the previous activity in PLC CPU will be
stop during the downloading process
A message will pop-up, click OK

HW Config

After stopping, the module needs to be restarted

A message asking for a module restart will be
prompt. Click Yes

Congratulation, the PLC CPU has been downloaded

with a hardware configuration settings

Hardware Monitoring
Tests
--------------------------

HW Config
After the new settings have been
downloaded, all PLCs activities can now be
monitored by STEP-7 Software
To test it, we need
to setup the STEP-7
Software in an
online mode
Click Station
Open ONLINE

HW Config (ONLINE)
Right click on DI24/DO16 row
Then click Monitor/Modify

Notice that the window now

prompting that it is in online
mode

HW Config (ONLINE)

A new Monitor/Modify window will pop-up

These are all the input (I) address

that we have set in
hardware configuration

The input that has been setup is

digital only. As for that, it is
in Boolean format (BOOL)

HW Config (ONLINE)

Check the Monitor checkbox

In Boolean format,
0 will be stated as FALSE
and 1 will be stated as TRUE
During running or online activity,
notice that the active indicator on
MPI Interface will light on

HW Config (ONLINE)
Now, test the monitoring effects by playing
around with the toggle switch on PLC I/O Board
Any toggle switch that is
select to ON position will
result in TRUE on the
Monitor/Modify window
After finish, click CLOSE

The results
must be
the same