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THEME 2_
PLCs: how to program?
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Wired Logic CONTROLLERS Programmable Logic
Controllers: before, now and after
9
18
6 10
14
2
Centralized^ Relays
control Low speed
15
3
16
(n) Suggested Roadmap
Scalable^ High speed
Modular
Architecture
Scan cycle
Low flexibility Low High cost
lifetime
PLC
1
4 7
5
13
17 19
20 High
lifetime
High flexibility
Centralized or distributed
control
History Now and future
GRAFCET
Command law
Metalanguage
Language
Wire contacts schematics
Schematics using IEC symbology
Language
Wire contacts schematics
IEC standard- 61131 - 3
KOP AWL FUP
Structured
Not scalable
Compact
applications^ Low size Low/high size applications
8
11 12 21 22 2423 26 25
27 28
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IEC NEMA
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2 Motor 2 ON 3 SW
(^1) SW
(^0) SW1^ M·P Motor 1 ON
PROGRAM (1ST APPROXIMATION)
M0.
M0.
M0.
M0.
PLC (^) M P M0.1 M0.2 M0.3 M0.
M0.0^ M0.0 SW1^ M0.2 M0.
M0.
M0.
M0.1 SW2 M0.3 M0.
M0.
M0.2 SW1 M0.1 M0.
M0.
PLC
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HOW USE MARKS? As we say, when we work with PLCs we assign a mark toevery stage.
2 Motor 1 ON 3
SW
SW
1
0
M·P SW
Motor 2 ON
Motor 1 ON
M0. M0. M0. M0.
Typically uses M0.0, M0.1, and so on. Remember: after M0.7 we have M1.
(M0.8 not exists; in general, marks >Mx.7 not
exists)
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HOW USE MARKS?
2 Motor 1 ON 3
SW
SW
1
0
M·P SW
Motor 2 ON
Motor 1 ON
M0. M0. M0. M0.
Now, we assign for every transition (typically a sensor) an input point. M I0. P I0. SW1 I0. SW2 I0. SW3 I0.
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HOW USE MARKS?
2 Motor 1 ON 3
SW
SW
1
0
M·P SW
Motor 2 ON
Motor 1 ON
M0. M0. M0. M0.
And every action (typically an actuator) to an output point. M I0. P I0. SW1 I0. SW2 I0. Motor 1 Motor 2 QQ0.00.1^ SW3^ I0.
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
M P M0.0 S
I0.0 I0.
Stage 0: SET M AND NOT PRESET Stage 1
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
Stage 2: SET Stage 1 AND SW2RESET Stage 3
M P M0.0 S
R
M0.1^ I0.0^ I0.1M0.
M0.0 SW1 M0.1 S
M0.3^ I0.
M0.2 M0.1 R
M0.1 SW2 M0.2 S
I0.
M0.3 M0.2 R
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
Stage 3: SET Stage 2 AND SW3RESET Stage 1
M P M0.0 S
R
M0.1^ I0.0^ I0.1M0.
M0.0 SW1 M0.1 S
M0.3^ I0.
M0.2 M0.1 R
M0.1 SW2 M0.2 S
I0.
M0.3 M0.2 R
M0.2 SW3 M0.3 S
I0.
M0.1 M0.3 R © EEBE/UPC
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
Now, we canwrite outputs:
M P M0.0 S
R
M0.1^ I0.0^ I0.1M0.
M0.0 SW1 M0.1 S
M0.3^ I0.
M0.2 M0.1 R
M0.2 SW3 M0.3 S
I0.
M0.1 M0.3 R
M0.1 SW2 M0.2 S
I0.
M0.3 M0.2 R
M0.
M0.
Q0.
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
Now, we canwrite outputs:
S
R
M0.1^ I0.0^ I0.1M0.
M0.0 SW1 M0.1 S
M0.3^ I0.
M0.2 M0.1 R
M0.2 SW3 M0.3 S
I0.
M0.1 M0.3 R
M0.1 SW2 M0.2 S
I0.
M0.3 M0.2 R
M0.
M0.
Q0.
M0.2 Q0.
M P M0.
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2 EV1 ON
SW
1 SW
M·P
SW1 Motor 1 ON
M0.
M0.
M0.
M0.
M P II0.00.
SW1 SW2 II0.20.
SW3 I0.
Motor 1 Motor 2 QQ0.00.
Other structures
5 EV2 ON
4 SW
SW1 Motor 2 M0.4 ON M0.
Motor 1 ON
SW M0.
SW
SW5^ Motor 1^ ON
SW4 SW5 II0.50.
EV 1 EV 2 QQ0.50.
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Other structures
(^2) EV1 ON 3 SW
SW2^1
0 M·^ P SW1 Motor 1 ON
M0. M0. M0. M0.
5 SW4EV2 ON
M0.4^4 SW1^ Motor 2 ON M0. 6
Motor 1 ON M0.6^ SW
SW2 Motor 1 ON SW
M P II0.00. SW1 SW2 II0.20. SW3 SW4 II0.40. SW5 I0.
P S
M0.1 M0.0 R
M0.0 SW1^ M0.1 S
M0.
M0.2 M0.1 R
M0.2 SW3 M0.3 S
M0.6 M0.3 R
M0.1 SW2 M0.2 S
M0.3 M0.2 R
M0.
M^ M0.
M0.1 SW
M0.0 SW1 M0.4 S
M0.
M0.5 M0.4 R
M0.3 SW5 M0.6 S
M0.1 M0.6 R
M0.4 SW4 M0.5 S
M0.6 M0.5 R
M0.
M0.
M0.
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(^2) EV1 ON 3 SW
SW2^1
0 M·^ P SW1 Motor 1 ON
M0. M0. M0. M0.
5 SW4EV2 ON
M0.4^4 SW1^ Motor 2 ON M0. 6
Motor 1 ON M0.6^ SW
SW2 Motor 1 ON SW
Motor 1 Motor 2 EV 1 QQQ0.50.00. EV 2 Q0.
P S
M0.1 M0.0 SW1M0.0 R M0.
M0.6^ S
M0.2 M0.1 R
M0.2 SW3 M0.3 S
M0.6 M0.3 R
M0.1 SW2 M0.2 S
M0.3 M0.2 R
M0.
M^ M0.
M0.1 SW
M0.0 SW1 M0.4 S
M0.
M0.5 M0.4 R
M0.3 SW5 M0.6 S
M0.1 M0.6 R
M0.4 SW4 M0.5 S
M0.6 M0.5 R
M0.
M0.
M0.4^ Outputs Q0.
Motor 2
M0.2 Q0.5 EV
M0.5 Q0.6 EV
M0.
M0.2 M0.
Q0.0 Motor 1
P
P
P
P © EEBE/UPC
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(^2) EV1 ON 3 SW
SW2^1
0 M·^ P SW1 Motor 1 ON
M0. M0. M0. M0.
5 SW4EV2 ON
M0.4 4 SW1^ Motor 2 ON M0. 6
Motor 1 ON M0.6^ SW
SW2 Motor 1 ON SW
P S
M0.1 M0.0 SW1M0.0 R M0.
M0.6^ S
M0.2 M0.1 R
M0.2 SW3 M0.3 S
M0.6 M0.3 R
M0.1 SW2 M0.2 S
M0.3 M0.2 R
M0.
M^ M0.
M0.1 SW
M0.0 SW1 M0.4 S
M0.
M0.5 M0.4 R
M0.3 SW5 M0.6 S
M0.1 M0.6 R
M0.4 SW4 M0.5 S
M0.6 M0.5 R
M0.
M0.
Outputs
PE M0.
RESET_BF 7
Motor 1 Motor 2 EV 1 QQQ0.50.00. EV 2 Q0.
M0.4 Q0.1 Motor 2
M0.2 Q0.5 EV
M0.5 Q0.6 EV
M0.
M0.2 M0.
Q0.0 Motor 1
P
P
P
P © EEBE/UPC
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(^1) t/5s
M·P
SW
EV1 ON
M0.
M0.
M0.
M P II0.00.
SW1 SW2 II0.20.
Timers
M0.3^3 t/8s M0. M0.5^5 SW
EV 1 EV 2 QQ0.50.
TIM1 ON^ TIM2 ON^ EV2^ ON
P S
M0.1 M0.0 SW1 M0.0 R
M0.5^ S
M0.2 M0.1 M0.1 R M0.
S
M0.5 R
M^ M0.
M0.
M0.0 SW1 S
M0.
M0.4 M0.3 M0.3 R M0.
S
R
M0.2^ M0.4^ M0.5 S
M0.1 M0.3^ M0.5 R
M0.1 Q0.5 EV
M0.3 Q0.6 EV
PE M0.
RESET_BF 6
P
P
M0.
M0.
SW
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t/5s
M·P
SW
EV1 ON
M0.
M0.
M0.
M P II0.00.
SW1 SW2 II0.20.
Timers
t/8s
M0.3^3
M0.
M0.5^5 SW
EV 1 EV 2 QQ0.50.
TIM1 ON TIM2 ON^ EV2^ ON
M0.0 SW1 S
M0.
M0.2 M0.1 R
M0.2 S
M0.5 R
M0.0 SW1 S
M0.
R
M0.4 S
A more compactsolution (fraction):
M0.
M0.
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Slopes In many applications it is more interesting to know if a sensorgoes from zero to one if a state has zero or one. In this case, we use positive slopes (from zero to one) and negative slopes (fromone to zero).
M0.0^ P M0.0^ N
SW1 SW
In previous case, SW1 is the input under inspection (for to knowif changes form zero to one – P contact– or from one to zero – N contact–. M0.0 is the previous value from SW1. This contact in series with a line, passes to one only during onescan cycle, sufficient for memorize if necessary.
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Always true In many applications isnecessary (for example, for not have Boole problems) tohave a forced transition called ALWAYS TRUE or =1. Inwired controllers there is a wire, connected in serieswith previous stage instead of a sensor. In PLC programs,we use a special mark. This mark is configurable by theuser but in this subject, we use usually M100.0 specified for your teacher). (or other
M0.1^1 SW
M0. M0.
M0.0 SW1 M0.1 S
M0.
M0.2 M0.1 R
M0.2 M100.0 M0.3 S
M0.1 M0.3 R
M0.1 SW2 M0.2 S
M0.3 M0.2 R
SW
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Counters
1 C3>
M·P
SW
EV1 ON
M0.
M0.
M0.
M P II0.00.
SW1 SW2 II0.20.
EV 1 EV 2 QQ0.50.
C3=C3- 1
The number of counters in the S7-1200 only is limited by available memory size in DB area. Are typeIEC (standard format), his format is 16 bit and resides in DB (Data Block) memory area.
Counters in a GRAFCET have the double condition ofsensors and actuators at same time (as timers).
Example
C3=
SW
M0.3^3
Yes, there are a Boole error but C3=
this is only an example
about counters.
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Have 3 counter types: • CTU is an UP counter.
- • CTDCTUD is a down counter. is an up/down counter. In lab practices you know more details about counters.
All of them arecommonly used.
CU = Count up, CD = count down, R = Reset to initial value, LOAD = initial value,
PV = preset value.
Q = true when final count or zero, CV 0 count value.
See programming manual for more information.
Counters (^) Counter_Name CU R PV^ CTU CV Q Counter_Name CD LOAD PV^ CTD CV Q Counter_Name CU LOAD
CTUD CV Q PV
2 C3>0^ CD^ R
M·P
SW
EV1 ON
M0.
M0.
M0.
C3=C3- 1
C3=
SW
M0.3^3
C3=
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M P II0.00.
SW1 SW2 II0.20.
EV 1 Q0.
P S
M0.1 M0.0 SW1 M0.1M0.0 R
M0.3^ S^ R
M0.2 M0.
M0.1 M0.2 S
M^ M0.
M0.
M0.1 M0.3 R
M0.2 Q0.5 EV
P M0.
RESET_BF 4
Counters
C3>
M·P
SW
EV1 ON
M0.
M0.
M0.
C3=C3- 1
C3=
SW
M0.3^3
C3=
C
CD
LOAD
Q
CV
CTD
PV
M0.
M0.
M0.
C3 >
M0.3 M0.2 R
M0.2 SW2 M0.3 S
M0.1 C3 ==
0 Yes, is a Boole error
P
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CONSIDERATIONS
About Stop, Emergency Stop, programming and PLC connection
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2 Motor 1 ON 3
SW
1 SW
M·P
SW
Motor 2 ON
Motor 1 ON
M0.
M0.
M0.
M0.3 M I0.
P SW1 II0.10.
SW2 SW3 II0.30.
Motor 1 Motor 2 QQ0.00.
M P M0.0 S
I0.
This connection to open contact the implies that P button I0.1 input of the PLC, P, must be a normally closed contact. If will act on the given input signal PLC not press P, being normally closed, and allowing only depend SET M0.0 press M, which is normally open.
1M 0.0 0.1 0.2^ S-7 1200 CPU 1214
M P
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For RESET_BF, is the same: you must program a closed contactand must be consistent with pushbutton type. P
I0.
M0. RESET_BF 4
1M^ S-7 1200 CPU 1214 I0.0 I0.1 I0. M (^) P
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While P pushbutton is used to stop the process, for example, atthe end of the cycle, PE is the emergency stop pushbutton and comes attached to an European Norm. EN 60204-1:1992 9.2.5.4 norm, says: Emergency stop Emergency stop functions should be wired so as to remove power from all actuators, and an electromechanical directly drop Controller power should not be removed.-out relay may be used for this function, but the The Controller and input circuit via a secondary contact on the Emergency should be informed of this action by using Stop.
What happen with PE pushbutton?
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In this scenario, we can choose very few things ... Manufacturershas independent double section, NO+NC, NC+NC, etc.^ What happen with PE pushbutton?
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