Programmable Logic Controller S7-1200

SIMATIC TIA PORTAL

Eng. Ahmed Elsayed

Contents

Module (0) Introduction

Module (1) Programming Startup

Module (2) Function Blocks

Module (3) Timers and Counters

Module (4) Math, Comparator and Conversion Operations

Module (5) Diagnosis & Analog Value Processing

Module (6) Closed Loop Control

Module (7) Networking

Module (8) Human machine Interface

Module (9) Graduation Project

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Objectives Module (0) Introduction

1. Describe the major components of a common PLC.

2. Relay Ladder Logic.

3. Introduction to Siemens PLCs (S7-1200 family).

4. Hardware Configuration of S7-1200.

5. Introduction to SIMATIC TIA PORTAL.

Module (1) Programming Startup

1. Getting familiar with Programming.

2. CPU Connection & Resetting Factory Mode.

3. Addressing System.

4. Data Types.

5. Bit Logic Operations.

6. Configuring and Operating the SIMATIC S7-1200.

7. Tasks: Relay Diagrams to Ladder and FBD, Motor Start/Stop, ……

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Module (2) Function Blocks

1. Types of Blocks

2. Linear Programming

3. Structured Programming

4. User Blocks Organization Blocks, Functions, Function Blocks, Data Blocks

5. Set/Reset Operation

6. Tasks: Stamping System, Belt Control.

Module (3) Timers & Counters

1. Types of Timers.

2. Types of Counters.

3. Operation of each type.

4. Tasks: Practical Start/Stop Motor, Practical Stamping Machine, Production Line.

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Module (4) Math, Comparator and Conversion Operations

1. Math Operations

2. Comparator Operations

3. Conversion Operations

Module (5) Diagnosis & Analog Value Processing

Diagnosis.

1. Open Project Online

2. Device Diagnosis

3. Offline/Online Comparison

4. Monitoring, Controlling and Forcing Variables

Analog Value Processing.

1. Analog Signals.

2. Reading/Writing Analog Values.

3. Scaling / Un-scaling

4. Task: Tank Level Control.

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Module (6) Closed Loop Control

1. Fundamental of Closed Loop Control.

2. PID in SIMTIC.

3. Tasks: Water Level and Temperature Control.

Module (7) Networking

1. Networking Basics.

2. Adding another Controller to the Network

3. Communication Blocks.

4. Tasks:

a. Programming for 1st Controller: Conveyer Control.

b. Programming for 2nd Controller: Conveyer Data Logging.

c. Programming of Communication Blocks.

d. Final Project.

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Module (8) Human Machine Interface

1. Display Data on HMI Screens.

2. Sending Data from HMI Screens.

Module (9) Graduation Project

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Module (0) Introduction

1.What is the word “PLC”?

2.The major components of a common PLC.

3.Basic Definitions.

4.Relay Ladder Logic.

5.Introduction to Siemens PLCs (S7-1200 family).

6.Hardware Configuration of S7-1200.

7.Introduction to SIMATIC TIA PORTAL.

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What is meant by PLC?

PLC is an abbreviation for “Programmable Logic Control”.

It is simply a special computer device used for industrial control systems.

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Advantages of PLCs

Less wiring.

Wiring between devices and relay contacts are done in the PLC program.

Easier and faster to make changes.

Trouble shooting aids make programming easier and reduce downtime.

Reliable components make these likely to operate for years before failure.

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PLC like any PC, consists of:

1. Central Processing Unit.

2. Input/Output (I/O) interface system.

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The central processing unit (CPU) governs all PLC activities.

The following three components form the CPU:

1. The Processor.

2. The Memory System.

3. The System Power Supply.

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Final Block Diagram of CPU interacting with I/Os

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Functional interaction of a PLC system

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The major components of a common PLC.

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Physical Components

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Power Supply (PS) A separate power source for a PLC that converts the standard incoming 220VAC to the low voltage DC that the CPU requires, around 24V or 5V. General Advantages of Primary PS - stabilized output voltage. - high efficiency. - compact design. Main Advantages - Disconnect automatically if short circuit or over-current occurred. - Return a fault signal if short circuit or over-current occurred.

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Central Processing Unit (CPU)

The brain of the whole PLC is the CPU module. This module typically lives in the slot beside the power supply.

The CPU consists of a microprocessor, memory chip and other integrated circuits to control logic, monitoring and communications. The CPU has different operating modes, In programming mode it accepts the downloaded logic from a PC. The CPU is then placed in run mode so that it can execute the program and operate the process.

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I/O System

The I/O system provides the physical connection between the equipment and the PLC.

Provides signal conversion and isolation between the internal logic- level signals inside the PLC and the field’s high level signal.

Input modules converts signals from discrete or analog input devices to logic levels acceptable to PLC’s processor.

Discrete Input (digital input), is an input that is either ON or OFF are connected to the PLC digital input. Analog Input, is an input signal that has a continuous signal.

Output modules converts signal from the processor to levels capable of driving the connected discrete or analog output devices. Discrete Output(digital output), is an output that is either ON or OFF are connected to the PLC digital input. (Contact or Transistor) An analog output, is an output signal that has a continuous signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.

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Discrete input AC/DC INPUTS

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Physical Wiring in Field

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AC input module DC input module

DC INPUTS (SINK/SOURCE)

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Sinking input module/sourcing input device

Sourcing input module/sinking input device

Field device connections for a sink/source DC input module

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Analog Input

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Physical Wiring in Field

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Discrete Output

AC Output

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Logic 1– ON (“Switch” Closed)

Logic 0– OFF (“Switch” Open)

Physical Wiring in Field

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DC Output

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Analog Output

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Physical Wiring in Field

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Rack

The rack is the component that holds everything together. Depending on the needs of the control system it can be ordered in different sizes to hold more modules.

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Addressing on Rack

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Case Study Process Control System (Tank Control System)

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Control System

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SP: Set Point PV: Process Variable E: Error CV: Control Variable Controller: Control Technique implemented in PLC. Process: Our Tank Control System (Temperature).

Actual Control System

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Introduction to Siemens PLCs (S7-1200 family)

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Family of S7-1200

1. CPU 1211

2. CPU 1212

3. CPU 1214

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AC/DC/RLY DC/DC/RLY DC/DC/DC

1. Type of Supply (DC/AC).

2. Type of input signal.

3. Type of Output; DC means the out put will be only DC via transistor RLY means the output may be DC or AC via relay

Supply/Input/Output

1) Power Connector.

2) I/Os Wiring Connectors.

3) I/Os Status LEDs.

4) PROFINET Connector.

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Features of S7-1200

controller with integrated PROFINET interface for communication with programming device, HMI or other SIMATIC controllers.

powerful, integrated technology functions such as counting, measuring, closed-loop control, and motion control integrated digital and analog inputs/outputs

signal boards for direct use in a controller

signal modules for expansion of controllers by input/output channels

communication modules for expansion of controllers by communications interfaces

accessories, e.g. power supply, switch module or SIMATIC Memory Card

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Communication with Programming device

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Architecture Layout

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Addressing System

Input

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Output

Introduction to SIMATIC TIA PORTAL

STEP7 is the Programming Software of Programmable Logic Controller (PLC) of the SIMATIC S7 family of Siemens.

TIA is an abbreviation for “Totally Integrated Automation”

TIA is a strategy (architecture) in the automation technology, which defines the interaction of extensive single components, tool (SW) and the services (spare part service, etc.) to achieve an Automation solution.

The interaction performs integration across the four automation levels of the automation pyramid:

1. Management level

2. Operator’s level

3. Controller’s level

4. Field level

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Moving to TIA Software !

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