Automation

The process or system which is control through

logic gates, relay logic, PLCs, or computer.

Automation
The process or system which is control through
logic gates, relay logic, PLCs or computer

Automation
Application
1.
2.
3.
4.

Quantity
Safety
Quality
Coast saving

Quantity
1. Bottle filling industry use automation system to
increase their quantity. If human fill 1 bottle in 5
second.
1 minute: 1/5*60=12 bottles
1 Hour= 12*60=720 Bottles
2. While the machine fills 40-60 thousand in 1
hours

Safety
1. For the filling of 40,000 bottles human strength
is required, so risk factor is involved for filling of
bottles may be some of them will be damaged
similarly for so many human safety is required.
2. While machine will automatically fill the bottles
so less number of bottles will be damage.

Quality
1. If human fills the bottles, some of them will be
fill more then the required level, some of them
will be less than the required level.
2. While the machine fill the bottles exactly up to
the required level. Machine scans the level and
then pass it other wise it will be rejected and
will be pull out from the system.
3. Similarly in production system machine will
produce the same parts each time, however
there will be error chances while process
through human.

Coast saving
1. In case of human how much quantity are filled,
so the net income will be according to the
quantity.
2. While filling through machine, imagine how
much quantity in increased, so it will increase
the net income.

Disadvantages of Relay
logics
1. Due to Huge size and complex circuits, for simple
circuit a huge network of wires are connected .
2. Reprogramming. If someone wants to change the
logic so he will reproduce the whole wiring system.
3. Troubleshooting is difficult, fault occurs often due
to which machine down time is increases
4. It support only digital values i.e. high and low, it
cannot support analogue values

Simatic
1. In Siemens, PLC and automation are called simatic
2. Simatic are Siemens PLC and automation
equipment.
3. Siemens produce siamtic in 1970
4. In first ranking ,33% Siemens PLC are used in the
world
5. In second ranking,13% Allen Barley PLC are used in
the world

Continued
1.
2.
3.
4.

China also produce Siemens PLC.

S7-200 CN, CN shows it is from china
Simatic controller is PLC
Simatic software is the software which is used
for programming of PLC.

PLC Families
1. Step 5 which is also called S-5, it is old PLC from
1970-1980. Its external case color is white and
EPROM are orange color. It also have a cell
cartridge.
2. Step 7 which is also called S-7

Advantaged of S5 over
relay logic
1. It supports both analogue and digital values
2. High speed counting

Disadvantaged of S5
1. If battery is drained then reload PLC program
from EPROM. It occurs mostly in S5
2. Low level language Program (Assembly
Language is used for its programing)
3. Not fully online. PLC inputs and outputs can not
monitored fully, some of them can be
monitored.

Logo
1. Siemens launch S7 family in 1990 which was
called logo, it was the first PLC of S7 family
2. Logo PLC have screen and keys (External case)
3. Software for logo programing is Logo Soft
comfort
4. Its internal memory was 22kb only
5. Programming cable is Logo PC cable

Continued..

1. 1-module have 8 digital inputs and 4 digital outputs

2. Logo support 8 Analogue inputs and 2 Analogue
outputs
3. I/O s can be increased up to 100. logo supports
maximum 100 inputs and outputs.
4. For stand alone system or independent system logo
is the best solution.
5. Logo is cheaper price is only 12-15 thousand
6. Mostly sale out PLC of Siemens is logo.

Continued..
1. Logo have its own HMI.
2. Disadvantage is only less number of inputs and
output i.e. 100

Application
1. Traffic signal, 90% in traffic signal logo is used
2. Mostly used in ATS, automatic transfer switch. It is
used to transfer load from WAPDA to generator or
vice versa.
3. Used in Textile industry
4. For stand alone system logo is the best solution
5. In new logo PLC Ethernet port is available
6. Logo can be interfaced or communicate with
external Siemens HMI

S7-200
1.
2.
3.
4.
5.

Launched after Logo

Internal Memory 32Kb
Its memory can be extended with memory card
Supported Memory cards: 64kb, 128kb, 256kb
On board 14 Digital inputs and 10 digital
outputs
6. 200 I/Os are supported by expansion of module

Continued..
1. Software for PLC Programming: Micro win
2. Communication cable: PPI cable (point to point
interface) Apr. price: 20,000/
3. S7-200 can be interface with Siemens and non
Siemens HMI.
4. S7-200 can not support SCADA (Supervisory
control and data acquisition) system

Interfacing of Siemens PLC

with Non Siemens Modules
1. To interface Siemens PLC with non Siemens
Modules, GSD (general system description) file
is required.
2. Every module have their own GSD file
3. It act like a translator, without installation of this
file CPU will not recognize the module

S7-200
Application
1.
2.
3.
4.
5.

Every CNG station in Pakistan

Textile industry
Pharmaceuticals
Packaging
Mostly used in Pakistan, china equipment
mostly have S7-200 PLC.
6. Basic Module start from Rs. 70,000/

S7-300
1. S7-300 have separate CPU and Signal modules.
2. CPU do not have memory for data storing
3. PLC program is stored into external memory
card
4. External Memory card: Mini card (supported up
to 8MB)
5. Programing software: Simatic Manager
6. Programing cable: MPI (Multi point interface)

Continued
1. CPU Price: 3,50,000/ (Memory card and SM are
not included)
2. S7-300 support Profi bus, fiber optic and
ethernet.
3. Maximum number of input/output supported:
1024
4. S7-300 also support master-slave configuration

Continued
1. Total 32 number of S7-300 can be supported in
network.
2. This is called Dazy chain topology
3. When more then 31 slave is required then
repeaters are required
4. Maximum Supported I/Os in master-slave
configuration: 17700

Continued
1. Always program master CPU
2. In case of breakage in communication b/w
master-slave or fault occurs in any network,
whole system will be shutdown
3. S7-300 support SCADA (Supervisory control and
data acquisition)

S7-300
Application
1.
2.
3.
4.
5.
6.

Power Houses
Nuclear Power plant
Cement Industry
Food Industry
Fertilizer Industry
Oil & gas sector

S7-400
1.
2.
3.
4.
5.
6.
7.

CPU price: 8 Lakh

Software: Simatic Manager
Support Profi bus communication
Support Master-slave configuration
Supported I/Os: 2048
Support 31 slave network
Support DCS (Distributed control system)

Continued
1. Siemens called DCS, PCS7 (Process control
system-7).
2. S7-400 is redundant system
3. When one system fails, another system starts
working

S7-1200
1. 2-3 years ago, Siemens launched, replacement
of S7-200
2. All features are of S7-200
3. Software: TIA portal (Total Integrated
Automation portal)
4. HMI can be designed in TIA portal
5. Support 250 I/Os Expansion

Continued
1. Internal memory: 256Kb
2. Memory extended by using Mini SD card up to
1MB
3. Programming cable: Ethernet
4. Module have 14 DI, 10 DO, 2 AI
5. Price is less than S7-200
6. Support Master-slave configuration through
Ethernet cable

S7-300

CP
Communication
processor

4-11 (8 SM)
Signal Module
Digital Input/output
Analogue Input/output

FM
Functional Module

CPU

IM
Interface module

Power Supply

1. Slot rule

Continued
1. PS, IM, FM and CP are optional
2. Functional module: when special function is
required like encoder, closed loop control for
positioning
3. Communication processor: when Ethernet
supported drives are communicated with CPU,
then Ethernet CP is used.

Rack configuration
1. Two types: Horizontal and vertical
2. In hot weather country horizontal configuration
is used due to easy heat transfer
3. In cold weather country vertical configuration is
used.

Digital Module address

P0
I0.0-I0.7

P2
I2.0-I2.7

DI

P1
I1.0-I1.7

P3
I3.0-I3.7

Digital Module address

P4
q4.0-I0.7

P6
q6.0-q6.7

DO

P5
q5.0-q5.7

P7
q7.0-q7.7

Digital Module address

P0

P1

P2

P3

P4

P8

P12

P14

P5

P9

P13

P15

Power Supply

CPU

IM-S

SM
8*32=256

IM-R

SM
8*32=256

IM-R

SM
8*32=256

Continued
1. IM used for communication with racks
2. S7-300 support 1024 I/Os so IM-S and IM-R is
used

Module
Model No.

Order number

Model No
SM331

A18*12BIT

Order No
AI

6ES7 331-7KF02-0AB0

SM322
DO16*RelAC120/230

DO

6ES7 322-1HH01-0AA0

SM322
DO16*RelAC120/230

DO

6ES7 322-1HH01-0AA0

SM321 DI32*DC24V

DI

6ES7 321-1BL00-0AA0

CPU

6ES7 315-2AF02-0AB0

PS

6ES7 307-1EA00-0AA0

CPU315-2DP

PS307, 5A

Continued
321- Digital input Module
322- Digital output Module
323- Digital input/output module
331- Analogue input module
332- Analogue output module
333- Analogue input/output module

Profibus
1.
2.
3.
4.
5.

Industrial communication protocol

Decentralized Peripheral (DP) mean profibus
2 wire communication
Purple color
Profibus communicate through RS485, Shielded
cable
6. Red-green wires
7. Red-A1, green-B1
8. Profibus can be used for interfacing PLC with
NCU and HMI

Continued..
1. Profibus connector have termination switch (ON
& OFF)
2. When the switch is ON, it means terminate the
communication
3. Diagram for Master CPU interfacing with slave
CPU
4. First and last PLC module switch should be ON,
other will be OFF

Gates Basic
1. AND Gate: Z=X*Y
2. OR Gate: Z=X+Y
3. NAND Gate: Z=X+Y
4. NOR Gate: Z=X*Y
5. XOR Gate: Z=X*Y+X*Y
6. XNOR Gate: Z=X*Y+X*Y
7. In English Language I: Input, Q: output
8. In German language E: Input, A: Output
9. Solve above Examples in Ladder
10. Next Presentation will be about Simatic Manager

Thank you