DEPT.

OF ELECTRONICS AND AUTOMATION

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

Input Devices
Pushbuttons
Selector Switches
Limit Switches
Level Switches
Photoelectric Sensors
Proximity Sensors
Motor Starter Contacts
Relay Contacts
Thumbwheel Switches

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

Analogue Cards
Typical Analogue Input
signals are:
Flow sensors
Humidity sensors
Load Cells
Potentiometers
Pressure sensors
Temperature sensors
Vibration


Analogue Output signals
control:
Analogue Valves
Actuators
Chart Recorders
Variable Speed Drives
Analogue Meters

Typical Analogue Signal Levels
4-20mA
1-5 Vdc
0-10 Vdc
-10 10Vdc


PLC : Input module


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
120 VAC/VDC
240 VAC
24 VAC/VDC
Triac
120/230 VAC
Transistor MOSFET
24 VDC

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 Signal Flow
Programming Terminal
O:0/7
O:0/7
O:1/5
Output Devices
Output Modules
Processor Memory Input Module
Input Devices
Ladder Program
O:0/7
O:1/5
I:0/6
I:1/4
O:1/5
I:0/6
I:1/4
I:0/6
I:1/4
Data
Input
Image Table

Output
Image Table

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


Controller Controller
Controller
Controller
Workstation Workstation Workstation Workstation
Switched Hub
PLC Architecture Evolution
Today : Ethernet Technology in PLCs

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.

PLC Ladder Logic purposely resembles Relay Logic


| | |/|
Read / Conditional
Instructions
Write / Control
Instructions
| | |/|
| | |/|
| |
| | |/| ( )
| |
( )
( )
( )
( )
| |
Start (Rung #1)
End (Rung #5)
Ladder Logic Concepts


Read / Conditional
Instructions
Write / Control
Instructions
No Logical Continuity
|/| | |
True False False
|/| |/|
( )
( )
True True True
Logical Continuity

Ladder Logic Concepts

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

Logical OR Construction

|/|
I/11
| |
I/5
|/|
I/7
|/|
I/1
| |
I/3
| |
I/2
| |
I/4
|/|
I/0
| |
I/1
| |
I/1
|/|
I/8
| |
I/9
( )
O/0
| |
I/10

Typical Construction

L1 L2
PB1 LS1 PS2
SOL6
DEVICE

PB1

LS1

PS2

SOL6
| | ( ) | | | |
I/5 I/6 O/0 I/7

HHP
I/5

I/6

I/7

O/0

Logix
I:0/5

I:0/6

I:0/7

O:0/0
ADDRESS

Addressing Examples
INPUT Address Assignment:
PB1- I/4 PB2- I/5
LS1- I/6 LS2- I/7
LS3- I/8 LS4- I/9

OUTPUT Address Assignment:
SOL2- O/0 M1- O/1
|/|
CR3
CR3 M1
PB1 LS1
SOL2
PB2 LS1
LS3
LS4
I/8
I/4 I/6 O/0
O/1
| | | | ( )
I/5 I/7 B/0
| | | | ( )
| |
|/|
B/0
( )
Relay Logic to Ladder Logic
| |
I/9

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



CPU Communication ports



MPI Profibus
Baud rate
max

1.5 Mb PS Default
187.5 KbPS
12 Mb PS
No. of max.
nodes

32 126
Network
Length
4000 Ft
without
repeater

4000 Ft
without
repeater

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

Siemens Memory addressing

I0.0 I0.1 Q0.0
Ladder :- ------||-----||-----------( )----


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


PLC Ranges Available





PLC S/W I/O capacity
Pico Pico soft 32
Mirco Logix RS logix500 156
SLC 500 RSlogix500 4096/4096
Logix platform RSlogix5000 1,28,000
Communication s/w:-
RS linx :- With variety of software drivers

Allen Bradley PLC

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


: /

B3 : 0 / 0 (0 to 15)
B3 : 1 / 0 ,,
. . .
. . .
. . .
B3 : 15 / 15


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.

PLC Programming Software