Programmable logic controller - Siemens S7-1200


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Programmable logic controller - Siemens S7-1200

  1. 1. Programmable Logic Controller S7-1200 SIMATIC TIA PORTAL Eng. Ahmed Elsayed
  2. 2. 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 Eng. Ahmed Elsayed
  3. 3. 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, …… Eng. Ahmed Elsayed
  4. 4.  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. Eng. Ahmed Elsayed
  5. 5.  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. Eng. Ahmed Elsayed
  6. 6.  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. Eng. Ahmed Elsayed
  7. 7.  Module (8) Human Machine Interface 1.Display Data on HMI Screens. 2.Sending Data from HMI Screens.  Module (9) Graduation Project Eng. Ahmed Elsayed
  8. 8. 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. Eng. Ahmed Elsayed
  9. 9. 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. Eng. Ahmed Elsayed
  10. 10. 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. Eng. Ahmed Elsayed
  11. 11. PLC like any PC, consists of: 1. Central Processing Unit. 2. Input/Output (I/O) interface system. Eng. Ahmed Elsayed
  12. 12.  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. Eng. Ahmed Elsayed
  13. 13. Final Block Diagram of CPU interacting with I/Os Eng. Ahmed Elsayed
  14. 14. Functional interaction of a PLC system Eng. Ahmed Elsayed
  15. 15. The major components of a common PLC. Eng. Ahmed Elsayed
  16. 16. Physical Components Eng. Ahmed Elsayed
  17. 17. 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. Eng. Ahmed Elsayed
  18. 18. 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. Eng. Ahmed Elsayed
  19. 19. 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. Eng. Ahmed Elsayed
  20. 20. Discrete input  AC/DC INPUTS Eng. Ahmed Elsayed
  21. 21. Physical Wiring in Field Eng. Ahmed Elsayed AC input module DC input module
  22. 22.  DC INPUTS (SINK/SOURCE) Eng. Ahmed Elsayed Sinking input module/sourcing input device Sourcing input module/sinking input device
  23. 23. Field device connections for a sink/source DC input module Eng. Ahmed Elsayed
  24. 24. Analog Input Eng. Ahmed Elsayed
  25. 25. Physical Wiring in Field Eng. Ahmed Elsayed
  26. 26. Discrete Output  AC Output Eng. Ahmed Elsayed  Logic 1– ON (“Switch” Closed)  Logic 0– OFF (“Switch” Open)
  27. 27. Physical Wiring in Field Eng. Ahmed Elsayed
  28. 28.  DC Output Eng. Ahmed Elsayed
  29. 29. Analog Output Eng. Ahmed Elsayed
  30. 30. Physical Wiring in Field Eng. Ahmed Elsayed
  31. 31. 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. Eng. Ahmed Elsayed
  32. 32. Addressing on Rack Eng. Ahmed Elsayed
  33. 33. Case Study Process Control System (Tank Control System) Eng. Ahmed Elsayed
  34. 34.  Control System Eng. Ahmed Elsayed SP: Set Point PV: Process Variable E: Error CV: Control Variable Controller: Control Technique implemented in PLC. Process: Our Tank Control System (Temperature).
  35. 35.  Actual Control System Eng. Ahmed Elsayed
  36. 36. Eng. Ahmed Elsayed
  37. 37. Introduction to Siemens PLCs (S7-1200 family) Eng. Ahmed Elsayed
  38. 38. Family of S7-1200 1. CPU 1211 2. CPU 1212 3. CPU 1214 Eng. Ahmed Elsayed 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
  39. 39. 1) Power Connector. 2) I/Os Wiring Connectors. 3) I/Os Status LEDs. 4) PROFINET Connector. Eng. Ahmed Elsayed
  40. 40. 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 Eng. Ahmed Elsayed
  41. 41. Communication with Programming device Eng. Ahmed Elsayed
  42. 42. Eng. Ahmed Elsayed
  43. 43. Architecture Layout Eng. Ahmed Elsayed
  44. 44. Addressing System  Input Eng. Ahmed Elsayed  Output
  45. 45. 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 Eng. Ahmed Elsayed
  46. 46. Eng. Ahmed Elsayed
  47. 47. Moving to TIA Software ! Eng. Ahmed Elsayed