Siemens Simatic S7 Series User manual

Siemens

Simatic S7

Manuals and Guides

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Table of Contents

Introduction ..............................................................................2

PLCs .........................................................................................4

Number Systems......................................................................8

Terminology ............................................................................ 12

Basic Requirements................................................................18

S7-200 Micro PLCs.................................................................20

Programming a PLC................................................................33

Discrete Inputs/Outputs .........................................................41

Analog Inputs and Outputs.....................................................48

Timers.....................................................................................51

Counters .................................................................................58

High-Speed Instructions .........................................................61

Specialized Expansion Modules .............................................65

Review Answers.....................................................................72

Final Exam .............................................................................. 74

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Introduction

Welcome to another course in the STEP series, Siemens

Technical Education Program, designed to prepare our

distributors to sell Siemens Industry, Inc. products more

effectively.This course covers Basics of PLCs and related

products.

Upon completion of Basics of PLCs you should be able to:

• Identify the major components of a PLC and describe

their functions

• Convert numbers from decimal to binary, BCD, and

hexadecimal

• Identify typical discrete and analog inputs and outputs

• Identify key differences of the various S7-200 models

• Identify the types of expansion modules available for

S7-200 PLCs

• Describe the types or programming available for S7-200

PLCs

• Describe the operation of commonly used program

functions such as timers and counters

• Identify the proper manual to refer to for programming or

installation of an S7-200 PLC

This knowledge will help you better understand customer

applications. In addition, you will be better able to describe

products to customers and determine important differences

between products.You should complete Basics of Electricity

before attempting Basics of PLCs. An understanding of many

of the concepts covered in Basics of Electricity is required for

this course.

After you have completed this course, if you wish to determine

how well you have retained the information covered, you can

complete a final exam online as described later in this course. If

you pass the exam, you will be given the opportunity to print a

certificate of completion.

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Siemens is a trademark of Siemens AG. Product names

mentioned may be trademarks or registered trademarks of their

respective companies. Specifications subject to change without

notice.

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PLCs

A programmable logic controller (PLC), also referred to as

a programmable controller, is the name given to a type of

computer commonly used in commercial and industrial control

applications. PLCs differ from office computers in the types of

tasks that they perform and the hardware and software they

require to perform these tasks. While the specific applications

vary widely, all PLCs monitor inputs and other variable values,

make decisions based on a stored program, and control

outputs to automate a process or machine.This course is

meant to supply you with basic information on the functions

and configurations of PLCs with emphasis on the S7-200 PLC

family.

SF/DIAG

Motor

Pump

Pushbutton

Sensor

Indicator Light

Basic PLC Operation The basic elements of a PLC include input modules or points,

a central processing unit (CPU), output modules or points,

and a programming device. The type of input modules or

points used by a PLC depends upon the types of input devices

used. Some input modules or points respond to digital inputs,

also called discrete inputs, which are either on or off. Other

modules or inputs respond to analog signals.These analog

signals represent machine or process conditions as a range of

voltage or current values. The primary function of a PLC’s input

circuitry is to convert the signals provided by these various

switches and sensors into logic signals that can be used by the

CPU.

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The CPU evaluates the status of inputs, outputs, and other

variables as it executes a stored program.The CPU then sends

signals to update the status of outputs.

Output modules convert control signals from the CPU into

digital or analog values that can be used to control various

output devices.

The programming device is used to enter or change the PLC’s

program or to monitor or change stored values. Once entered,

the program and associated variables are stored in the CPU.

In addition to these basic elements, a PLC system may also

incorporate an operator interface device to simplify monitoring

of the machine or process.

Programming

Device

Operator

Interface

Central Processing Unit

(CPU)

Input

Module

Output

Module

In the simple example shown below, pushbuttons (sensors)

connected to PLC inputs are used to start and stop a motor

connected to a PLC output through a motor starter (actuator).

No programming device or operator interface are shown in this

simple example.

Motor Starter

Start

Pushbutton

Stop

Pushbutton

Inputs

Output

PLC

Motor

SF/DIAG

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Hard-Wired Control Prior to PLCs, many control tasks were performed by

contactors, control relays, and other electromechanical devices.

This is often referred to as hard-wired control. Circuit

diagrams had to be designed, electrical components specified

and installed, and wiring lists created. Electricians would then

wire the components necessary to perform a specific task. If

an error was made, the wires had to be reconnected correctly.

A change in function or system expansion required extensive

component changes and rewiring.

Motor

Start

Stop

460 VAC

24 VAC

Advantages of PLCs PLCs not only are capable of performing the same tasks as

hard-wired control, but are also capable of many more complex

applications. In addition, the PLC program and electronic

communication lines replace much of the interconnecting wires

required by hard-wired control. Therefore, hard-wiring, though

still required to connect field devices, is less intensive.This also

makes correcting errors and modifying the application easier.

Some of the additional advantages of PLCs are as follows:

• Smaller physical size than hard-wire solutions.

• Easier and faster to make changes.

• PLCs have integrated diagnostics and override functions.

• Diagnostics are centrally available.

• Applications can be immediately documented.

• Applications can be duplicated faster and less expensively.

Siemens Modular PLCs Siemens SIMATIC PLCs are the foundation upon which our

Totally Integrated Automation (TIA) concept is based.

Because the needs of end users and machine builders vary

widely, SIMATIC PLCs are available as conventional modular

controllers, embedded automation products, or as PC-based

controllers.

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Modular SIMATIC controllers are optimized for control tasks

and can be adapted to meet application requirements using

plug-in modules for input/output (I/O), special functions, and

communications. Examples of products in this category include:

LOGO!, S7-200, and S7-1200 micro automation products,

S7-300 and S7-400 modular system PLCs, C7 combination

controller and panel, and ET 200 distributed I/O system with

local intelligence.

SIMATIC S7-400 SIMATIC S7-300

SIMATIC S7-200 LOGO!

SF/DIAG

SIMATIC

S7-1200

SIMATIC S7-1200

Other SIMATIC Controllers SIMATIC embedded automation products are available in

a microbox, panel PC, or multi-functional PC-based system.

All products utilize rugged, fan-free, diskless hardware

platforms with an operating system optimized for each

platform. Examples of products in this category include:

Microbox 420-RTX, Microbox 420-T, Panel PC 477-HMI/RTX, and

WinAC MP.

SIMATIC PC-based controllers are available as software that

can run on standard PC systems or in a plug-in card (slot PLC)

for increased reliability.This category includes WinAC software

and WinAC slot PLC.

SIMATIC Software SIMATIC software is the universal configuring and

programming environment for SIMATIC controllers, human

machine interface systems, and process control systems.

SIMATIC software with STEP 7 and numerous engineering

tools supports all phases of product deployment, from

hardware configuration of the system and parameterization

of modules to service of the installed system. A variety

of programming options are available.This includes basic

programming languages (Instruction List, Ladder Diagram,

and Function Block Diagram), high-level languages (Structured

Text and Sequential Function Chart), and engineering tools

(S7 Structured Control Language, S7-Graph, S7-PLCSIM, S7-

HiGraph, and Continuous Function Chart).

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Number Systems

Because a PLC is a computer, it stores information in the form

of on or off conditions (1 or 0), referred to as bits. Sometimes

bits are used individually and sometimes they are used

to represent numerical values. Understanding how these

bits can be used to represent numerical values requires an

understanding of the binary number system.

Decimal System In order to understand the binary number system, it is

first useful to recall some of the basics of the decimal

number system. All number systems have the same three

characteristics: digits, base, weight. For example, the decimal

system has the following characteristics:

Ten digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9

Base 10

Weights Powers of base 10 (1, 10, 100, 1000, ...)

Binary System The binary system has the following characteristics:

Two digits: 0, 1

Base 2

Weights Powers of base 2 (1, 2, 4, 8, 16, ...)

The binary system has a base of 2 and uses only two

characters, 1 and 0. Each bit is associated with a power of 2

based on its position in the number. The further to the left,

the higher the power of 2.The number in the far left-hand

column is referred to as the most significant bit or MSB and

the number in the far right-hand column is referred to as the

least significant bit or LSB. A 1 is placed in a position if that

power of 2 is used in the number. Otherwise, a 0 is placed in a

position.

128 64 32 16 8 4 2 1

0 0 0 1 1 0 0 0

Most Significant Bit (MSB) Least Significant Bit (LSB)

2726252423222120

00011000 in binary = 24 in Decimal

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The process of converting a binary number to an equal decimal

value is as simple as adding the equivalent decimal value

for each position in the binary number where a 1 is shown.

Positions with a 0 do not add to the number value.

128 64 32 16 8 4 2 1

0 0 11 0 0

2726252423222120

1 0

Decimal Value = 32 + 8 + 1 = 41

Bits, Bytes, and Words Each position in a binary number is called a bit. The number

of bits used to represent numbers varies with the device.

However, instructions and data are usually grouped in bytes and

eight bits make up one byte.Two bytes, or 16 bits, make up one

word.

Word

Byte

Bit

Logic 0, Logic 1 While PLCs are capable of sensing and generating analog

values, programmable controllers internally use signals that are

on or off. These on and off conditions correspond to the binary

values 1 and 0. For example, a binary 0, also called logic 0, can

be used to indicate that a switch is off, and a binary 1 (logic 1)

can be used to indicate that a switch is on.

PLC

Input 1

24 VDC

Off

Logic 0

Logic 1 PLC

Input 1

24 VDC

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