Implementation of An 8 Floor Control System With A PDF

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Implementation of an 8 Floor Control System with a PLC
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Seyedreza Fattahzadeh
© 2015 Seyedreza Fattahzadeh
www.plc-doc.com
www.helpme@yahoo.com
No part of this book may be reproduced, in any form or by any means, without the written
permission from the author / publisher.
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NOTICE TO THE READER
All rights reserved. No part of this book may be reproduced, in any form or by any
means, without permission in writing from the publisher.
Every effort has been made to ensure our books are as accurate as possible. However,
there may be mistakes, both typo and in content. This content should be used as a general
guide and not as the solution. The author does not warrant or guarantee any of the
products described herein. Also, the author does not warrant or guarantee any of the
equipment or programs described herein or accept liability for any damages resulting from
their use. The reader is warned that both electricity and the construction of electrical
equipment can be dangerous. It is the responsibility of the reader to use common sense
and safe electrical and mechanical practices.
SIMATIC STEP7, LOGO! Soft Comfort software, SIMATIC S7-300, and LOGO! PLCs
are trademarks of SIEMENS AG Inc.
PanelMaster ® is a registered trademark of Cermate Technologies INC.
EasyView ® is a registered trademark of MKS instruments.
VFD-004M series ® is a registered trademark of Delta Electronics.
Please be informed that:
This book contains many images. Since eReaders don’t always display images well,
upon request, I will provide you with the PDF file which contains the complete e-Book,
including the images, if you need an easier-to-read format. To receive a PDF version of
this e-book or any other software which is mentioned in the content of this text, you can
email me the proof of your purchase of the kindle version of the book from Amazon.com
to srfattah@yahoo.com. Upon receipt of that proof, a PDF version will be sent to your
email address.
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Table of Contents
Preface
About the author
How to use this book
Read me first
Chapter 1
Project scope
Car sliding door mechanism
Schematic diagram of the 7-segment display
Binary-coded decimal
Chapter 2
SIMATIC S7-300 PLC and its wiring
The Voltage Divider circuit
Chapter 3
Recognize position (FC1)
Manual State (FC2)
Auto state
Record all requests (FC3)
Detect direct (FC4)
Detect Service (FC5)
Turn Motors on (FC6)
Change Speed (FC7)
Update some LEDs in auto (FC8)
Exit from Auto (FC9)
Update outputs in every scan (FC10)
Monitoring (FC11)
Initializing (OB100)
Chapter 4
Introduction
Basic wiring
Driver Keypad
Change setting
Chapter 5
What is a “Human Machine Interface (HMI)” device?
Programming the PanelMaster display
Programming WinCC
Making a Connection
Designing a monitoring screen
Appendix A
Appendix B
Question and Answers about this project
Conclusion
My e-book product list
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Preface
The purpose of this manual is to design and implement an eight-floor elevator control
system. This project is an upgraded version of my previous one, which was published
about a year ago: Programming a 4 Floor Elevator with SIMATIC S7-300 and LOGO
Programmable Logic Controllers (PLC).
The five most important features of this version, compared to the previous version are
as follows:
1. The upgraded version control software is more complicated than the previous one,
since it has been prepared for an Elevator System with 8 stops as opposed to that
with 4 stops.
2. Two different car-traveling speeds are being used in this version to ensure smooth
picking and dropping of a passenger.
3. Permanent magnets and a hall sensor are used to detect current location of the car
as opposed to the application of 5 limit switches employed to detect current
position of the Elevator Car.
4. This version has two modes of operations: Automatic and Manual. In Manual
mode, an operator can move the car up/down or open/close the car's door, just by
depressing four related push-buttons.
5. The Control program of the 4 Floor System was prepared using STEP7 SIMATIC
MANAGER software as opposed to the current version, which also comes with a
second control software developed using LogixPro. This second Control Software
allows the developer/programmer to download even a trial version of LogixPro
and use the code to master his/her programming a PLC,the instructions being fully
supported by RSLogix 500 developed for Allen Bradley family of PLCs.
The final aspect of this experiment is to organize the ladder logic intelligently, to make the
troubleshooting easier. Hence the purpose behind developing a manual like this is to make
the learning of programming aspect of PLCs more enjoyable. Learning to understand the
familiar control systems, such as a full functional eight-floor-elevator brings out how and
why latches, timers, limit switches, sensors, and relays are used. Although the programs in
this manual are written for SIMATIC S7-300 PLC Simatic Manager and LogixPro
software to develop the control software, the ideas and program layouts are universal to
any PLC.
About the Author
Seyedreza Fattahzadeh holds a Bachelor of Science in Electrical Engineering from
the University of Texas at Arlington. His main expertise is in digital systems, electronics,
and computer engineering.
Seyedreza has extensive experience in the field of programmable controllers. He has
worked for a few industrial manufacturers as a prime part of programmable controller
consulting firm. His industrial experience includes designing and implementing mid-class
automation systems, based on PLC.
Seyedreza has authored several other books on programmable controllers. You can
find more information on these, at the end of this book.
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How to use this Book
This book details programming a SIMATIC S7-300 PLC as an 8 Floor Elevator
Control System. In other books of mine, I have talked about the basics of Programming
with different models of PLCs. This book has been prepared for those who are already
familiar with the basic PLC instructions, and maybe have already developed some PLC-
based programs for different purposes. Therefore, this text is prepared for those who want
to challenge their PLC programming knowledge to generate even more complex industrial
PLC programs with enhanced features: in this case, preparing a control program for a
SIMATIC S7-300 PLC to control an 8 Floor Elevator System.
The project specification is presented to you. It contains all the aspects including
goals, functionalities, and details required for the development of this controller system to
fulfill the project's typical minimum requirements. Study the project requirements
presented in this text carefully. Your job is to generate the main control program, to fulfill
the project's requirements. Take your time as much as you think it is needed. You can use a
pen and paper, a PLC simulator software, or your own PLC (any brand!) hardware to
develop the control program. Once you have done this, review and compare it with the one
presented in this text. If your solution works right, then you can celebrate the
accomplishment, as you have learnt something new about your level of capability when it
comes to PLC programming. If the solution you came up with, has some problems and
somehow does not function as it is intended to be, then you can compare your solution
against mine. In this case, you know that you did your best, and tried it on your own. You
can use my solution to find out what went wrong with yours. Once you find it out, you can
resolve the issue and make your solution function correctly. And, that is the whole purpose
of this text. It is indeed to motivate you enough, and make you enthusiastic towards
completing a relatively complex PLC program.
The Main Control Program solution is prepared in LDA formats using STEP7
software, developed by SIEMENS. In addition, the schematic of all hardwires used in
project is given. The amount of effort you want to invest in implementing this project, is
completely up to you and depending on your interest. If you wish, you can build your own
controller hardware similar to the one presented in this text, or even tailor it to the one
with more features as you prefer. In either case, just by simulating the presented program
and checking its performance, you can improve your programming knowledge, and
ultimately, this is the whole purpose behind developing the text from my side.
Seyedreza Fattahzadeh
Winter of 2015
Read me first – list of different application programs developed for this
project
In the chapter 1, we are going to develop the main circuit program for S7-300 PLC,
which when executed, controls an 8 Floor Elevator System based on a defined project
specification given. It also establishes a communication path with two HMI devices, to
show all related process data on either a PC's monitor or a stand-alone HMI device.
You are assumed to be able to develop a circuit diagram of this project with even extra
features on your own. Just in case, if you wish to have the code I developed for this
project, you only need to email me the proof of your purchase from any online websites
such as eBay, Amazon, etc. to my email address srfattah@yahoo.com. Upon receipt of that
proof, the software will be sent to your email address. The following table shows the
folder and file names that I have used, to develop my circuit programs or the application
programs for HMI or PC based displays devices.
Program description Folder name File name
Main PLC program Step7_Program Insert file from step7 software
HMI settings HMI_Panel Master 8elevator.pm2
Wincc settings HMI_Wincc Test.mcp
LogixPro control code LogixPro_Program All files in “.rsl” format
To see the project in action, please click on the following link:

http://youtu.be/H6-Ksj25mQ0
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Chapter 1
Project Scope of an 8 Floor Elevator Control System
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Project Scope
In this project, we want to develop a PLC program to control an eight floor elevator
with two main modes of operation: Auto and Manual.
In the Manual mode, the operator can move an elevator car up\down or open\close the
elevator car door. All other push buttons available on the keypad, are disabled in Manual
mode. Change of mode from Auto to Manual and vice versa, is done by a small hammer
switch and is indicated with two Green and Red LEDs. In the Auto mode, a Green LED is
turned on and in the Manual mode, the Red one. In Figure 1-2, the Hammer switch and
LEDs are designated with # 1.
In the Auto mode, at the startup time, the car door closes (and it takes about 5 seconds)
and the elevator car is moved to the first floor. PLC saves the last position of the car. Then
for the next runs, the car is not directed to go to the first floor anymore.
The elevator has a main keypad consisting of 21 push buttons, 21LEDs, one Hammer
switch, and a 7-segmnet display to show the floor number. Figure 1-1 displays a very
simplified block diagram of the prototype of 8 Floor Elevator system.
Figure 1-2 displays an exploded view of the main keypad. In figure1-2, when any floor
call button is depressed (designated with # 7 in yellow color), after a delay of about 5
seconds to let any additional key to be pressed, the car door closes (moves to left), the car
travels to the called floor, the elevator car door opens, and it awaits providing a next
pickup service. After completing any service, the car door will open and the control goes
to its standby mode and becomes ready to handle next call service.
Figure 1-1
When any call button related to the group designated with # 6 is pressed, control code
reacts the same way as it does when any call button designated with # 7, but this time code
assumes that the service call is coming from the car internal keypad and therefore shows a
image of a human inside the elevator cabin on the HMI display.
Notice that all call buttons have LEDs embedded on the top left. The main purpose of
each LED is to confirm whenever any related button is depressed. Upon depression of any
call button, the related LED turns either on solid or remains blinking till the car reaches
the related floor.
Let's say a call button # 5 (group # 6) is pressed and elevator car is stationed at floor #
1. Since the call button is related to the keypad which is installed inside the car, the control
code assumes that someone is inside the car now and wants to be dropped off at the 1st
floor. Control code executes the following steps:
1. It shuts the car door (after 5 seconds from the time of the call button depression)
2. Green LED is turned on (blinking)
3. Hoist motor is tuned on to move the car upward
4. The Red LED # 1 turns on (solid) related to group 6 and the Red LED #1 on group
# 7 turns on (blinking)
5. Green blinking LED and two other call buttons are turned off after the car gets to
its destination which is 1st floor
6. The 7-segment display # '1', Hoist Motor is turned off and car door is opened.
Figure 1-2
Any of the four push buttons in group # 4 is used to move the elevator car upward or
downward and or move the car sliding door to the left (to close) or to the right (to open) it
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respectively (when the system is being operated in Manual mode).
free
In Figure 1-2, the 9 ebooks ==> www.ebook777.com
th push button is called Emergency Button, which is activated
when there is an emergency situation inside the Elevator. For example, if somebody is
trapped inside the elevator, he/she wants to inform others about the occurrence of any fault
in the system. By depressing the Emergency Button momentarily, a horn or blinking light
turns on (usually located outside the system) to ensure that any trapped person will receive
the help. Depressing the same Emergency Button again, turns off the light.
Figure 1-3 displays some field devices installed on the fixture of the prototype
Elevator System. Three limit switches installed on the fixture are EMS_UP, EMS_DOWN
and the 1st floor limit switches whose outputs are connected to PLC at addresses I1.3, I1.2
and I1.1 respectively. Notice that output of Hall sensor is connected to I1.0 of PLC.
Hoist motor is a 3~phase motor whose power terminals are wired and connected to the
output terminals of 1/3phase (@0.4 KW) VFD drive.
Figure 1-3
In Figure 1-3, notice that detection of the current location of the Car of the 'elevator' is
implemented by the application of 16 pieces of permanent magnets and a Hall Effect
sensor. Anytime the tip of the sensor is located right across of any N pole, its output is set
to 1 (High), and when it is passing by an S pole, the sensor output is set to (Low). PLC can
detect the current location of the 'elevator car' by counting the number of '1s' or '0s'
coming from the sensor output while the Car is moved either upward or downward.
In Figure 1-3, the outputs of two other limit switches named “EMS_DOWN” and
“EMS_UP” are going to be tied to the PLC input terminals to stop the car movement if it
goes beyond the upper or lower limit, avoid damage to the Hoist motor or elevator fixture.
When the code is executed for the first time (startup case), if the car is not at the first floor
already, it is automatically directed downward and when it hits the 1st Floor limit switch, it
is stopped. The system PLC saves the location of the Car as 1st floor, and based on the
next signals arising from the movement of the sensor over permanent magnets it
determines exact location of the car in next trips.
Figure 1-4 displays the wiring diagram of VFD drive, 7-segment display, Auto/Manual
Hammer switch and 4 push buttons that are housed on the top right side of the Main
keypad. Addresses which are used to connect each of the components specified, to Input
or Output modules of the system PLC are also given.
Figure 1-4
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Figure 1-5 displays the detailed drawing of the Elevator fixture. Notice that in Figure
1-5 B it is very important to know 'where' to install 1st floor and EMS_DOWN limit
switches, to ensure that the Elevator detects any floor number and Emergency limit
switches correctly.
Figure 1-5
Car Sliding door Mechanism
Figure 1-6 displays the schematic diagram of the “car door and a DC motor
controller”. According to the Figure1-6, a few electronic components and two 12 DC
relays are used to construct the controller. The schematic is self-explanatory where two
relays are used to change the polarity of the dc motor, and the transistors are used to drive
the relays. We do need to have a source of 12 V DC power supply to turn on the relays,
but I used a 2 AAA battery holder to energize a small toy DC motor which is used here to
move the car door to left (to close the door) or right (to open the door). Based on the
schematic diagram in Figure 1-6, to turn on the circuit and move the door CW (to close the
door), PLC outputs to green terminals need to be set to '1' and '0'. To revolve the motor in
the opposite direction, 'CCW signal' input terminals need to be set to '1' and '1', causing
the door to move in the opposite direction (to open the door).
The car door can be moved back and forth by a small 3 volt DC motor. Figures 1-7 and
1-8 display the status of the physical door and limit switches with their related addresses,
which are connected to PLC inputs and locations where they are installed to control the
door movement when it is being opened or closed.
To open or close the car sliding door using controller shown in figure 1-7 works
perfectly; however, in this project, I used a small stepper motor and a related controller to
simulate the DC motor's function. You may view the performance of the sliding door
using a stepper motor, by clicking the following link: http://youtu.be/XBWCsl512Lc.
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Figure 1-6: displays driver schematic to control the car small door
Figure 1-7
Figure 1-8
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Schematic diagram of the 7-segment display
According to the figure 1-9, the input of a 7- segment display is tied in parallel to PLC
output terminals. Assuming that (4 PLC outputs) Q0.2 tied to A, Q0.3 to B, Q0.4 to C and
Q0.5 to D output terminals of the main keypad, to show that the car is located at for
example third floor, the PLC output terminals must be set to the following states:
Q0.2 = A =1 (high), Q0.3 = B =1(high), Q0.4 = C = 0(Low), Q0.5 = D = 0(Low)
Figure 1-9
Binary-coded decimal
In computing and electronic systems, binary-coded decimal (BCD) is a class of binary
encodings of decimal numbers where each decimal digit is represented by a fixed number
of “bits”, usually four or eight (in our case, just 4 bits will do).
In byte-oriented systems (i.e. most modern computers), the term uncompressed BCD
usually implies a full byte for each digit (often including a sign), whereas the packed BCD
typically encodes two decimal digits within “a single byte by taking advantage of the fact
that four bits are enough to represent the range 0 to 9 (since our elevator is serving only 8
floors, the four bits will do the job for us). BCD takes advantage of the fact that any one
decimal numeral can be represented by a four-bit pattern. Table 1-1 shows how setting of
input pattern can create a Decimal digit that corresponds to the floor number, which is
related to the current location of the Elevator car.
Table 1-1
Figure 1-10 displays detail push buttons of the Main keypad with their related
addresses, which are connected to PLC input ports.
Figure 1-11 displays detail LED circuit of the Main keypad with their related
addresses, which are connected to PLC output ports. Notice that since a typical bias
voltage of a LED is about 2 to 3 V DC, then each Anode of LED must be connected to
PLC output port using a 1 K Ohm resistor otherwise, 24 V DC voltage of a PLC output
port can easily burn the LED.
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Figure 1-10
Figure 1-11
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Chapter 2
Presentation of the 8 floor Elevator with SIMATIC S7_300 PLC
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SIMATIC S7-300 PLC and its wiring
In rewriting the 4 floor elevator with STEP7 V.5 software, I used the following
hardware and Software:
1 × PLC SIMATIC S7-300 model CPU 315 – 2DP
2 × Digital Input modules model SM 321 ~ DI 16×DC24 V
Siemens part number 321 – 1BH01-0AA0
2 × Digital Outputs modules model SM 322 ~ DO 16×DC 24 V/0.5 A
Siemens part number 322 – 1BH01-0AA0
Figure 2-1 displays the PLC CPU, two digital input modules and two digital output
modules.
Figure 2-1
Figure 2-2 displays how elevator floor call buttons are connected to the first Digital
Input module #1.
Figure 2-3 displays how elevator car call buttons are connected to the second Digital
Input module # 2.
Figure 2-4 displays how elevator Car call button LEDs and 7-segment display inputs
are connected to the third Digital Output module # 3. All Resistors connected in series
with each LED are 1000 Ohm @ 1 Watt.
Figure 2-5 displays how elevator floor call button LEDs and car door motor are connected
to the screw terminal of the forth Digital Output module
Figure 2-2
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Figure 2-3
Figure 2-4
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Figure 2-5
Remark
The voltage at output terminals of PLC is 24 VDC. In Figure1-6, notice that you need
to use a 5 V DC supply source, to energize the lift motor (to open or close Car door). To
power this 3V DC toy motor, I used a 4.7 Ohm Resistor @ 10 W in series with the supply
source to drop about 2 volts from the main input 5V DC input terminal.
The Voltage Divider Circuit
The two-resistor voltage dividers are most often used to supply a voltage, which is
different from that of an available battery or power supply. In application the output
voltage depends upon the resistance of the load it drives. Also, to activate the A, B, C
inputs of the 7-segment display, we need to use a conditioning circuit. We can use a
resistance voltage divider, along with a 5.1 volt Zener diode to clamp 24 V DC to 5.1 volt.
See Figure 2-6 representing the final schematic of voltage conditioning circuit, which is
used in this project.
Figure 2-6
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Chapter 3
Programming PLC with Step7 software
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Introduction
Before anything, it is necessary to say that we’ve defined the byte MB0 as clock
memory in hardware configuration of CPU. For doing that after defining your hardware,
perform the following steps:
1. Run step7 software.
2. Double-click Hardware.
The HW Config window appears.
3. Double-click on your CPU.
The Properties dialog box of your CPU appears.
4. Click Cycle/Clock Memory tab.
5. Click Clock Memory check box ( clock memory changes to clock memory).
6. In memory text box, type 0.
7. Click OK.
So we will be able to use the bits of this memory for LEDs and lights that should be turned
on in the flickering mode. We are going to write any section of our program in a separated
FC, so that we will be able to understand the whole of the program easier. Also, we
defined symbols for most of the memories, Inputs and Outputs in the program and you can
see all of them in appendix A. The Location of the Step7 program is marked with a blue
box in figures that show each section of the program. In addition, the final point to note is
that the lower bit of the memory MW1 is MB2.0 not MB1.0.
In the following, each section of the program will be presented and analyzed.
Recognize position (FC1)
Before PLC dose any work, it needs to recognize the position of the cabin. Therefore,
we use this function to write a program to detect the position of the cabin (Figure 3-1).
Figure 3-1: FC1 in OB1

For detecting the position of the cabin, it is necessary the cabin going to floor1 till the
“Floor1 Limit Switch” will be activated. So now, we have a base calculating and we will
able to calculate the position of the cabin with the received pulse from “Cabin Sensor”.
Such as the figure 3-2 we can set a bit memory (“Active_7seg”) with “Floor1 Limit
Switch” input to understand that if cabin has gone to the first floor in our program. If
“Active_7seg” bit memory has set, then our calculated position has been valid and we’ll
be able to update the PLC outputs that they are connecting to the 7 segment inputs.
Figure 3-2: Network1 in FC1

Now we use the “Active_7seg” memory for the other active and reactive Networks in
FC1. In network2 of FC1, we used a CUD1 block to calculate the position (Figure 3-3).
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According to the above figure, whenever the cabin arrives at the first floor, the value
of “Floor1 Limit Switch” changes to 1 and then the number 1 gets loaded in the counter.
If the “Motor_Up” output is active, then with any pulse received from “Cabin Sensor”
the value of the counter gets incremented by one unit. The second line in figure 3-3
represents a similar work performed, when the cabin is being moving down.
So with the above program, the position of the elevator is calculated and stored in
MW14 and MW10 with two format Word and BCD code respectively. Remember that we
can use this BCD code for the inputs of a 7segment. In the next network, we are going to
store the position in Integer format with a BCD_I2 block such as the one shown in the
following figure:

Also, we set a bit in the first eight bits of MW16 (Figure 3-5) respectively with the
position of elevator.

In this Network at first, the number 0000-0000-0000-00001 is copied in MW16 and
then shifted so as to make it the same as the position of the cabin that is stored in MW14.
For example, if the position was 1 then MW16 is equal to 0000-0000-0000-0010, and if
the position was 5 then MW16 is equal to 0000-0000-0010-0000. But if you see the
results, they show for position 1 the 2nd bit and for position 5 the 6th bit of MW16 having
been set. To modify this result, we should use a SHR_W block to shift MW16 right by one
bit. So the last result in this Network becomes 0000-0000-0000-0001 for position 1 and
0000-0000-0001-0000 for position 5.
Now the position of the elevator is stored in memory in different format and when we
need them, we will able to use them in our program.
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Manual State (FC2)
We can switch between manual and automatic modes with “Auto/Manual” input. If it
was reactive then the system is in manual mode such as Figure 3-6. According to this
figure, we can write the control program of elevator in FC2 when the system works in
manual mode.

In the manual mode, the operator can move the cabin up/down with two push button
input (“Up P.B” and “Down P.B” in the program). As depicted in the next figure, we can
move the cabin down with “Down P.B”. But it’s necessary to consider some safely points
in any program, such as using a fuse in hardware circuit. So we insert the red box to
program for more safety.

According the Figure 3-7, if two push buttons (“Down P.B” and “Up P.B” are for
moving cabin down and up respectively) were depressed at the same time or
“Ems_Down” sensor was active or “Floor1 Limit Switch” or cabin is moving up
(“Motor_Up” output is active) then even “Down P.B” was activated, the cabin can’t
move down. We wrote a similar program for moving cabin up in Networ2 in FC2.
Now we’re going to write a program for controlling the cabin door. A simple program can
be such as Figure 3-8. The state of M1.7 memory isn’t important such as its symbol. It is
used just for ending the program because the program didn’t finish with a coil; otherwise
the software shows an error dialog box when you want to store your program.

The above program needs to take care of more safety. So we insert some contactor
between inputs and outputs (Figure 3-9).
See the first line in the above figure. “Left Close Sensor” ensures that the “To close
door_P.B” input is effective as long as the cabin doors are not closed. If the cabin door
has closed, then the motor can’t turn on for closing the door. Using of normally closed
contact of “To open door_P.B” in this line ensures that the operator can’t close and open
the cabin door simultaneously. The second and third lines are similar to the first line.
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Auto state
We are going to start writing the auto part of our program with several functions (FC3
to FC9). The auto part is active with “Auto/Manual” input. But by any reason one of two
emergency sensors (“Ems_Up” or “Ems_Down”) change its state and become active,
then the auto part of our program will disable (Figure 3-10)
Figure 3-9: Networks in FC2

Record all requests (FC3)
In auto part of our program before turning motors for moving cabin we need to detect
direct of moving that the elevator need it. To do this we need to compare the position of
the elevator (it is done in FC1) and the all floor requested from all passengers. So at the
first step in auto part of our program, we use FC3 to record all requests from all
passengers in PLC memory (Figure 3-10).
Figure 3-10: Network3 in OB1

Such as Figure 3-11 we can store the request from “Floor Key1” (the key that it’s on
floor1 for passengers) in M4.0 Memory and reset it when the elevator’s cabin arrive to
first floor. With the same way we can store all requests from the other keys in other floors
(second floor to 8th floor) in eight bits of MB4. MB3 is reserved for future. So now MW3
that consist of MB3 and MB4 can store the request from all floors.
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With the same way we wrote a program to record all requests from keys in elevator
cabin in first eight bits of MW5.
For detecting the direct of moving that the elevator needs it, we have to compare the
position of elevator with two types of request in two previous networks (request from the
cabin and from floors). So in Network3 of FC3 we used a WOR_W block to store the two
types of request in MW7 (Figure 3-12).
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Detect direct (FC4)
Now we have to detect the direct of moving cabin the elevator needs it. This part of
our program wrote in FC4 that placed in Network3 after FC3 (Figure 3-13).
Figure 3-13: FC4 in Network3

In start time of moving, the elevator should wait 5second for record all requests and
then detect the direct (Figure 3-14)

Before explaining the FC4, there is a point to remember it. It’s according De Morgan's
rule the below equation are true.
The first line in Figure 3-15 represent that when a request was received, a bit memory
(M2.0) change to set active a timer and then after 5s a bit memory (“Out of Timer1”) is
set. The M2.0 and then the timer are active until the all request clear from memory (MB8
in second line). Now we can use the “Out of Timer1” for active the program that its task
is to detect direct of moving in next networks in FC4 and reactive it when this bit is
reactive because there isn’t any request.
According Figure 3-15 if the out of previews network (“Out of Timer1”) is active
then a program to check if cabin need to move down is run.

In this program if the position of the cabin is 2 (second bit in MB17 was true) and
there is a request for first floor (first bit of MB8 was true) a bit in memory (“Need to
Down”) change to 1 or when the position is 3 and there are requests from the first or
second floor. We can understand when cabin need to move down with this method for
other floors too. Such as Figure 3-15 we wrote a program in network3 to set a bit memory
(“Need to up”). We wanted to give a priority for requested that are from passengers. For
example, if the cabin is moving up, the elevator should answer the requests that are in
above floors of position cabin and then moving down. To do it, we can use normally close
contact of “Need to Down” and “Need to UP” in front of together such as Figure 3-16.
When “Need to UP” is set and cabin need to move up, then the bit memory with name
“Need to Down” can’t be set.

The other priority that we need it to add to our program is in the start time of moving.
After 5 second (Network1) the request for moving down has upper priority. To do it, we
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have to place the program of “Need to down” (it is in network2) upper than the program
of “Need to up” (it is network3). So now if the both of these bit memory were zero (such
as in the start time of cabins move) the program first checks if the cabin needs to move
down and then if cabin doesn’t need to move down check if cabin needs to move up. The
last point of this section is about this question: when will these two bit memories reset? To
reset these two bit memories suppose that the cabin was in 2nd floor (MB17.1 was set in
memory) and we have a request for first floor (MB8.0 was set). Now the program detects
that the cabin need to move down. So we have to write a program with these two bits to
move cabin down in next FCs and when the position of cabin (MB17.1 change to zero and
MB17.0 change to one) is equal to the passenger request(MB8.0),then the correspond
request in memory (second bit in MB8,MB6 and MB4 for floor 2 – go FC3) reset. Now,
because we don’t need to move down the bit memory “Need to Down” will change to
zero.
Detect Service (FC5)
Until now we can control the cabin moving with two bits in the previous section
(“Need to Down” and “Need to Up”) according from request and position of the elevator.
But if the position of elevator arrived to one requested floor the cabin is moving should
stop to give service to passengers and then continue her moving if there are another
requests. So we used FC5 after FC4 in OB1 (Figure 3-17) to write on it a program to
detect available services when cabin arrived at requested floor.

So we’re going to write a program to set a bit memory when elevator needs to give
service at a requested floor that arrived that in the first network of the FC5. In FC3 when
the cabin arrived to a request floor, the corresponding bit memory (8 bits of MB8)
changed to zero and make a negative pulse. So such as Figure 3-18 we can use this
negative pulse from 8 bits of MB8 to detect cabin needs to give service and set the bit
memory with name “Need to Service” to prevent of moving cabin until the service is
done.
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When the cabin door open with next Networks and then closed and give a service at
requested floor, the “Need to Service” will be reset. Be Careful that when the door is
closed absolutely means end of service not a closed door. So this memory (“Need to
Service”) active the program part of giving service such as open and close cabin door
when it’s active and when it’s reactive prevent the moving cabin up and down.
In network3 we wrote a first part if control programming for the cabin door. According
Figure 3-19 if “Need to Service” memory generate a positive pulse. Then a bit memory
(“open_Endopening”) is set to understand that the cabin door needs to open and When
the sensor “Right Open Sensor” change to active, the “open_Endopening” memory will
reset.

If the “Right Open Sensor” generates a positive pulse (when the door is absolute
close) the “Open_EndOpening” memory changes to zero. So with this memory we can
control the closing cabins door.
Now we‘re going to write the condition of closing the cabin door in network3. Three
conditions are considered. The first condition is when the elevator opens the door (“End
of opening door” _see previous network) to give its service and we need to move up or
down. Then a timer active and after 5 second with its negative pulse, we set a bit memory
with name “Close_EndClosing”. If the “Left Close Sensor” sensor is active then we do
not need to set “Close_EndClosing” to show we need to close the cabin door. The second
condition is at start of moving up-down that we need to close the door before that. Another
condition was considered to have more safely is when the position of cabin is not valid. Its
means is with any reason that the position of elevator isn’t between 1 and 8, then the cabin
door should be closed.
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Turn Motors on (FC6)
Now we have the condition of moving cabin up-down and opening-closing cabins
door in memory with two functions FC5 and FC4. So we’re going to write a program for
active and reactive outputs that turn motors on in FC6 after FC5.

We can write the simple below program for control of cabin door.
Figure 3-21: Network in FC6

In next network we wrote a program to move down cabin according “Need to Dow”
bit in memory that Determined in FC4.
The bit “Need to Down” turn on “Motor Down” output. But it’s necessary to insert
some safely condition between two contactors such as red box in Figure 3-22. So,
according to the first line.
1. If the cabin door was closed
2. and if cabin wasn’t opened (use both of door sensors for more security)
3. and if 5second has passed
4. and if the elevator doesn’t need to give service
5. and the “Motor UP” wasn’t on at the same time
Then the “Motor Down” output for moving cabin down is on if bit memory “Need to
down” was active.
We also add the green box in Figure 3-23 that it’s make to move cabin down when the
position of elevator isn’t valid. The moving cabin down continues until the floor 1 sensor
active and a valid position stored in memory. It’s so useful for first time running for our
system.
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In network3 we wrote a program such as Figure 3-23 for move cabin up as you see in
Figure 3-24
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Change Speed (FC7)
A circuit can be designed that can turn on a motor with two outputs “Motor_Up” and
“Motor_Down” in two direct. In this project we used a driver produced by Delta
Company. So by doing a few settings (that introduced in the next chapter) we can have
two speeds for moving cabin just with two digital outputs that determine speeds. In FC7
We‘re going to write a program to determine two outputs “Slow Speed” and “Fast
Speed”. We want to have Slow Speed until 2 second after start moving and from one floor
is to requested floor. In other times of moving we want to have speed fast. We wrote a
program (Figure 3-25) to do that.

In the above figure, first line of the first green box says if cabin is moving up and the
cabin was first floor(M17.0) and we have a request for another floor we need slow speed
and the correspond bit set. This rule is used for the position was floor7 and there is request
for floor8 at the time of moving up. Such as this rule, we wrote a program for time of
moving down in the second green box. In third box when moving down-up started until 2
second program set “Slow Speed” and we’ll have slow speed. If we don’t need slow
speed, the “Fast Speed” is set all time. There is a point that these outputs are effective if
one of two outputs “Motor_UP” or “Motor_Down” turn on Motor. Although this
program is working correctly but you can insert here a contactor for more safely. Do you
know what it is?
Update some LEDs in auto (FC8)
In FC8 that inserted in our program after FC7 we‘re going to write a program to
determine the state of some LEDs, Lights,… that relative auto part according the states of
PLC memory that we used them. In first Network (Figure 3-26) we want to write a
program for cabin LEDs that they all show requested floors.

According to Figure 3-26 if we have request for first floor from inside cabin (M6.0)
the “CabinLED1” is changed to 1 and the correspond LED is always turned on until the
requested in M6.0 is reset. Also, if we have a request for first floor from out of the cabin
(from in floors) “Cabin LED1” changed to turn on but in flickering form according green
box. If you remember, we define MB0 as clock memory in hardware configuration of
CPU. We wrote a similar program for Floor LEDs that are in floors in network2.
In network3 we’re going to write a program for cabin lights that it should turn on
when a passenger is in the cabin. To detect passenger we need all requests that stored them
in memory. If we have a request from inside the cabin (M6.0 to M6.7) then cabin has
passengers. In the first line of Figure 3-27 when each of bits in MB6 was 1 then a bit
memory (“Cabin has passenger”) is set and then the “Cabin Light” Turn on
immediately. If we don’t have any request and the cabin door was opened for outing
passengers, the “Cabin has passenger” is reset and “Cabin Light” turn off after 5
second because of using an On delay Timer.
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And in the last Network in FC8, by the program in Figure 3-28 we play music with
“Music” outputs when a passenger is inside the cabin (“Cabin Light”) and cabin is
moving.

Exit from Auto (FC9)
Now the main programs for auto state are written. Here is an important point. When
the program exit from auto mode if the all memory that used for this part are valid
continually? Of course not. So such as Figure 3-29 we use FC9 after M2.3 that it detects a
negative pulse when the program is exiting from auto mode.

In FC8 we reset these memories and outputs that we used them in auto state. In FC9
we reset the following memories and outputs. QD1, MW1, MW3 ( All Request_from
Floors (, MW5 )All Request_from cabin), MW7 (ALL Request_ Floor&Cabin), MB9,
MB20, M21.0.
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Update outputs in every scan (FC10)
Such as FC8, we’re going to write a program for LEDs, Lights and etc in FC10. But
FC10 is run every scan (Figure 3-30).

In first network, we wrote a program for our 7 segment. Remember that we store the
position of elevator in MW10 in BCD code form. So now we can easily use these
memories to update a 7 segment such as Figure 3-31. Also, we use bit memory
“Active_7seg” that make turn on 7segments when the position is valid (return FC1)
Figure 3-31: Network in FC10

In network2 we want to turn on two lamps for showing the moving cabin up-down
(Figure 3-32). In red box we can generate different frequencies for flickering lamps. In
this program two contactors with time period 1 and 0.5 second are flickering. Because
they are AND together the output is turned on for 0.25 second and turn off 0.75 second.

In two next networks, we want to write a program for emergency light in the cabin.
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In network 3 with each positive pulse from “Cabin Key9_Emergency” switch one of
two bit M2.4 or M21.1 is set according previous state of Emergency lamp (M20.6). If in
network3 we receive a positive pulse and Emergency lamp was flickering (red box in
Network4) M21.1 set one for reactive M20.6 and if lamp wasn’t on, the M2.4 is set to
active lamp in network4.
Monitoring (FC11)
In our project we try to store the all states in PLC memory. So now we can use these
memories to make a connection between a monitoring device (such as a panel Master or
WinCC) to show the status of elevator. When the cabin door is absolute open or close we
can understand from two sensors for monitoring device. But how do we understand door is
closing or opening? So we wrote a program in FC11.

In the first line if Q3.1 is active and Q3.2 is reactive the door is closing and we store
this state in two form constant and flickering in two bits on PLC memory that use them in
monitoring device. Second line is similar to the first line.
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Initializing (OB100)
In OB100 that run at once time in start running of PLC, we reset MW3, MW5, MW7
that record all passenger requests. Also, we can write other initializing setting here.
________
1Counter UP and Down
2BCD code to Integer

Chapter 4
VFD_M Driver
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Introduction
With growing industry, the needing of Motor soft starter is increasing. So some soft
starter designed and used in circuits of motors. A motor soft starter used to reduce the load
and torque in the power train and electrical current surge of the motor during startup. This
way reduces the mechanical stress on the motor and shaft. So the system lifespan will
extend. Motor drivers are more complete. They have additional features such as speed
control, voltage and frequency control. Today it’s important for any electrician to learn
working with drivers.
In this project we use a VFD_M driver produced by Delta Company (Figure 4-1).
There is an advice that before using any driver, you can download and read its user
manual from the internet.
Figure 4-1: Delta Driver – VFD-M Series
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Basic wiring
A diagram of drives terminal is shown. In this figure, 3 important parts of our project
are indented. In first red box we connect three terminals R/L1, S/L2 and T/L3 to 3-phase
AC power. If you don’t have 3phase power, you can connect a single phase and null to
R/L1 and S/L2. Don’t forget to use fuse for more circuit protection. In second red box, we
connect the AC drive terminals U/T1, V/T2 and W/T3 to the motor terminals. To reverse
direct motor rotation, switch over any of the two motor inputs. The driver can be
controlled by different ways, such as its keypad, AVI or ACI Analog input, its digital input
(M0 to M5), etc. In this project we use its digital input to control driver with PLC that it
will be explained in end of this chapter and before that we need to understand the way of
using keypad for changing some setting.
Figure 4-2: Basic Wiring of VFD_M Driver (courtesy of DELTA electronic)

Driver Keypad
The driver has a digital keypad includes two parts: Display panel and keypad (Figure
4-3).
Figure 4-3: Digital Keypad

The display panel provides the feature display and shows the status of the AC drive. The
keypad provides programming and control interface.
The panel displays some modes such as Table 0-1:
Table 0-1: Some modes of the Driver
You can appear any mode by a few pressing mode-key. Then by pressing Enter-Key
you can select it. Now you can change the value of the selected parameter with two key
and . To enter your new value in driver, press Enter-key and then if appear
it's mean your setting was saved successfully and this message
appears if your setting is invalid. To return or exit from the selected mode without any
saving, just press the Mode-key.
By pressing the run-key on keypad if the factory setting of driver hasn’t changed, first
motor turning slowly and after 10-second reached to its speed. To stop motor we need to
press the stop-key and then the motor stopped slowly.
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Change setting
Consider the driver has its factory setting. In this project we first change the value of
Pr.00 from 00 to 04 (Table 0-2). So we will be able to change the motor speed by the
potentiometer on digital keypad. Now we will be able to find two suitable frequencies for
our two motor speeds with rotating potentiometer.
Table 0-2: Pr.00
In this project we need to control motor from external logical signals. We can use two
terminals M0-M1 by GND terminal to turning motor clockwise and anticlockwise
direction (Table 0-3). But for using these terminals, we must change the parameter P.01
from 00 to 01 (Table 0-4) .So the control of the motor changed from keypad to the its
digital terminals. With this setting the stop key on the keypad is effective too.
Table 0-3: Pr.38
Table 0-4: Pr.01

To stop motor quickly we can change the Pr.02 from 00 to 01 (Table 0-5).
Table 0-5: Pr.02
If you want to limit the maximum voltage at the motor output, we should use Pr.05. our
drive model is 230 volt, so we can change this parameter from 0.1 to 255 volts (Table 0-
6).
Table 0-6: Pr.05
Pr.10 and Pr.11 determine the time required for starting and stopping. If we don’t change
these parameters, the motor reached its speed after 10 second and stopped after 10 second.
For quicker, we change them from 10 second to 0.1 second (Table 0-7)
Table 0-7: Pr.10 and Pr.11
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By above setting, we can turn on driver and use it. And then by several running and
change the frequency with potentiometer, we select two 20hz and 60hz frequency for our
slow and fast speed. Now we have to store these frequencies in driver memory. The driver
can store 7 different speeds on Pr.17 to Pr.23. We store them on two first parameter Pr.17
and Pr.18 (Table 0-8)
Table 0-8: Pr.17 and Pr.18
We can select each of 7 frequencies in Pr.17 to Pr.23 just with 3 bit such as Figure 4-4
Figure 4-4: select a speed with 3 bits

In Table 0-9 we can see some setting for Digital inputs (M2 to M5) that store in Pr.39
to Pr.42. So we can use M3, M4 and M5 without changing their factory setting to select 7
different frequencies on Pr.17 to Pr23. In this project we just use M3 and M4 and connect
“Slow speed” and “Fast speed” outputs them, because we need to select two speeds in
Pr.17 and Pr.18.
Table 0-9: Pr.39 to Pr.42
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Chapter 5
Human Machine Interface (HMI)
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What is a “Human Machine Interface (HMI)” device?
Human Machine Interfaces are devices that enable operators to check the present
condition of the operational machine, and if needed, impose changes in the operation of
the machine at hand. For example, HMI Series Air Compressor Control System is a touch
screen-based control system. As a new touch screen human-machine interface, from the
appearance of a concern, easy to use, powerful features and excellent stability make it well
suited for industrial environments. The use of man-machine interface can clearly instruct
and tell the operator the current status of machinery and equipment, allowing operation
becomes simple, vivid, and can reduce operational errors, even if the novice can easily
operate the machinery and equipment. As long as operator gently points, he can enter the
interface he wants. To get information about parameters such as real-time data, tens of
fault records, allowing the compressor to be used more efficient and stable.
Usually, General Operators, simply input the required loading and unloading pressure
can allow air compressor running, easy operation, and fast.
To protect related data security, one can change the parameters, he need to enter a
password to prevent other people to change parameters, resulting in unnecessary air
compressor failures.
To use an HMI device, usually, it has to be programmed before connected to a PLC.
Different HMI manufactures have developed software to suitable for their devices.
For example, one can use WinCC software developed by Siemens AG to program MP
277 8 or 10 inch key or touch models. Other software such as LabVIEW, EasyBuilder
8000, or PanelMaster are also among those could be used to program HMIs. Functionality
of this software is very similar thus, one learns how to work with one, he usually should
be able to use different for the same task. In this chapter, we are going to use PanelMaster
software to program a product name PT070-WST which is a 7 inch HMI device.
We had said that HMI devices are used for control as well as monitoring. But how
does an HMI Device change the inputs of a PLC that are coming from sensors, switches,
… from inside factory? An HMI device can read the value of memory, outputs and inputs
for monitoring and change them except inputs for control. So if we want to have a switch
on HMI device that its operate is similar a switch inside a factory, we must use memory
instead inputs in the PLC program. For example, refer to the program that wrote in
network1 of FC1 (Figure 3-7). Now we want to set “Motor_Down” output from HMI
device such as two inputs Down P.B and UP P.B. So we used two bits M21.5 and
M21.6(Monitoring_Down P.B and Monitoring_UP P.B) respectively two these inputs
(Down P.B and UP P.B) such as Figure 5-1. So if we change Monitoring_Down P.B from
an HMI device, it's similar to change the Down P.B from inside factory.
Figure 5-1: Modify Program to use an HMI Device

We need to use some other memories for other PLC inputs and modify the program
such as Figure 5-1. You can see the used memories in our program that operate such as
other inputs in appendix A. To detect these memories in our program, the name of all
started with “Monitoring” word and ending with the name of its equal PLC input such as
Down P.B input and Monitoring_Down P.B memory
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Programming the PanelMaster display
We used PMDesigner for Programming our HMI Device. If you want to learn the way
of connecting between the panel master and PLC and other initial information about this
HMI device, you can see www.plcgoods.net or www.plc-doc.com websites.
The first step is about insert an object and changes its setting. So
1. Run the PMDesigner software.
2. Click Object menu.
3. Click an object that you want to use such as Bit Button.
4. Click on a place that you want to insert your object
With this way you’ll be able to insert any objects from the PMDesigner library to your
design. Then:
5. Double-click on your object.
Its properties window with the name of your object appears. You can change its setting on
this window.
You can see an overview of wrote programs in Figure 5-2 that we‘re going to explain each
its part.
Figure 5-2: An overview of HMI interface

Now we’re going to set the setting of Manual-Auto key in above the figure. We used a
Toggle-Switch from PMdesigner library so insert a Toggle-Switch and open its properties
window. Now:
6. Click general tab
7. In the Write Address box, type I1.4(“Auto/Manual”)
8. Click Monitor Address identical to Write Address ( changes to )
Although this element operates such as a switch in HMI but in fact it can't change I1.4. So
it can just monitor the state of I1.4 from PLC program.
In its label Tab we can choose two pitchers or text respectively two states on and off for
I1.4. For example
9. Click Label tab.
10. Click OFF Picture
11. In front of the Name text box, click .
The Select/Import from Library dialog box appears. Select a suitable picture such as
Slide Switch (left). Repeat the three above step for On Picture and select a suitable picture
such as Slide Switch (right). Now if the value of I1.4 changes from 0 to 1 then the Slide
Switch (left) picture changes to Slide Switch (right) picture on the monitor screen.
The next part is programming four bit button key that we are using them when we are
in manual mode (Figure 5-3).
Figure 5-3: Manual Keys

We use these four keys to move cabin up-down and to close-open cabin door. The
settings of these are similar together and we’re going to explain Key UP setting) So:
1. Insert a Bit Button.
2. Double-click Bit Button.
The Bit Button dialog box appears.
3. In Bit Button dialog box, click General tab.
4. In Operation box, click Momentary ON.
5. Use the Address Type list to select Bit type.
6. In the Write Address text box, type M21.6 (“Monitoring_UP P.B“)
7. Click Monitor ( changes to ).
8. Click Monitor Address identical to Write Address ( changes to ).
By these setting when we are pressing this key on screen, its make the M21.6
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(“Monitoring_UP P.B“) memory is set. This key make to move cabin UP like I1.6 (“Up
P.B “). So This Bit-Button change the value of “Monitoring_UP P.B” and monitor it.
Now:
9. Click Label tab.
In label tab you can define your suitable texts or pitchers for the Bit-Button such as said
steps for previews Toggle-Switch. We select two 3D buttons from the library (3-D black
button (not pressed) and 3-D green button (pressed)) in the same size and position but
different in their color and shape. So when the value of M21.6 changed the operator see
the change of key shape and color.
The next part is programming floor keys that are in the cabin or in different floors. We just
explain setting of M23.0 (“Monitoring_Cabin Key1“). The operating of this memory like
I2.0 (“cabin Key1“). The settings of other floor keys inside or out of cabin are similar
together. So:
10. Insert a Bit Button.
11. Double click the Bit Button.
12. Click General tab.
13. In Operation box, click Set ON Pulse.
14. Use the Address Type list to select Bit type.
15. In the Write Address text box, type M23.0.
16. Click Monitor ( changes to )
17. Click Monitor Address identical to Write Address ( changes to ).
18. In the Monitor Address text box, type Q1.0 (“Cabin LED1“)
19. Click Label tab.
20. Define your favorite pictures for monitoring.
21. Click OK.
According above settings and a modify our program in PLC, The action of this bit will
be similar I2.0 but this Bit-Button monitor another address (Q1.0) from PLC outputs.
Another section is about showing the position of Elevator. We have the position of the
elevator in MW11 in PLC memory. So
1. Insert “Advanced numeric display” to screen
2. Use the Data Type list to select 16-Bit unsigned integer.
3. Use the Display Type list to select 16-Bit unsigned Decimal.
4. In the Monitor Address text box, type MW12.
Another part is about showing the state of the cabin door. We can use two sensors “Left
Close Sensor” and “Right Open Sensor” to detect the door is absolute close and open. If
you remember we wrote a program in FC11 to detect door is opening or closing (Figure 3-
33). Then we can use the state of these sensors and M106.0 to M106.3 in our HMI to show
the state of our door. At first we insert four pictures respectively four door states. All
These pictures are hidden except one of them that show the state of the door. For example:
1. Insert Garage door, closed from the library.
2. Double-Click Garage door, closed.
3. Click Fit to Object ( changes to ).
4. Click Visibility Controlled By Bit ( changes to ).
5. In the Control Bit text box, type I3.0 (”Left Close Sensor“).
6. Change Visible State OFF to ON.
So if the door was absolute close, then the “Left Close Sensor” changes to 1 and then
appears Garage door, closed on Monitor screen.
The settings of indented parts in the Figure 5-4 are similar previous examples. Any by,
you can see their settings in program that given by this document.
Figure 5-4: Other parts in PM Designer program
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Programming WinCC
We’ve used WinCC software to monitor Elevators states, such as PanelMaster in the
previous section. In the first step we have to make a connection between WinCC software
and PLC to use the states of memories, inputs and outputs of our PLC. Then we will
explain the program that wrote by WinCC.
Making a Connection
To have a connection with PLC, we must define our hardware in WinCC. So:
1. Run SIMATIC WinCC Explorer.
2. Click File.
3. Click Active ( Active changes to Active).
For doing some setting in WinCC we have to do above steps. Now for defining our
hardware:
1. Click Tag Management.
In Tag Management you will see all configured Tags and communication channels. In firs
time You will just see the Internal Tag on your right hand. You can define your local
variables in it. But we want to use PLC states, then we need to make a connecting channel.
So
2. Right click on blank area (Project Window).
3. Click Add New Driver… .
The Add New Driver dialog box appears. In this dialog box You will find the
communication drivers supported by WinCC. In this project we used a Simatic PLC series
300. So:
4. Double-Click SIMATIC S7 Protocol Suite.chn
“SIMATIC S7 Protocol Suite” appears in the WinCC Explorer Project Window.
5. Double-click SIMATIC S7 Protocol Suite
You will see types of connection that you can make it between WinCC and PLC series 300
produced by Siemens company. We use MPI connection. So
6. Double-Click MPI.
7. Right click on blank area.
8. Click New Driver Connection… .
The connection Properties Dialog box appears. Then
9. In the Name text box, type a suitable name (for example simatic300)
10. Click properties.
The “Connection Parameter-MPI” appears, check showed numbers by CPUs setting in
HW configuration that you had done in step7 software
11. Click OK twice time.
Your connecting channel has made. Now WinCC can access to states of inputs, outputs,
and memories of your PLC.
Now you can define your external tags in Wincc from your PLC. For example, we
want to use a bit memory, such as M21.3 in our PLC program. So
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1. Double-click simatic300.
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3. Click New Group… .
A Properties of the Tag Group dialog box appears.
4. In the Name text box, type a suitable name such as Memory.
5. Click OK
In above step you can define different groups to sort your tags. For example, you can
define three groups with three name Input, Output, Memory and define each tag in
suitable group. Now:
6. Double-click Memory Group.
7. Right click on blank area.
8. Click New Tag… .
The Tag properties appears.
9. In the Name text box, type a name.
10. Use the Data Type list to define type of your tag. Select Binary Tag.
11. Click select.
12. Define your Data type and Address.
13. Click OK.
Now you can use the state of M21.3 in WinCC software. In a similar way you can use
inputs, outputs and other type of memories. In Appendix B you can see the all tags that
we‘ve defined them in WinCC software.
Designing a monitoring screen
Now we‘re going to design monitoring screen to show the states of elevator white WinCC
software. So:
1. Double-Click Graphic Designer
A Graphic Designer Window appears. At first time you won’t see anything in it. But we
designed a monitoring screen such as Figure 5-5.
Figure 5-5: Designed screen to show states’ elevator

First part in our program is about how we show the elevator states (Manual or Auto).
For this we used four Rectangles such as Figure 5-6.
Figure 5-6: Auto or Manual

In our program two green rectangles were moved on two gray rectangles. All time two
gray rectangles are shown. When we are in auto mode the left green rectangle is shown
and left gray will be hidden. So when one of these green rectangles is shown, the its under
gray box disappear and an operator will see we are in Auto or Manual mode. For example,
we want to make left green rectangle, so:
1. Insert a rectangle from Object Palette.
2. Right-Click on rectangle.
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3. Click properties
The object properties dialog box appears. That you can change the setting of this
rectangle.
4. Click effects.
5. Change global color scheme from Yes to No
Now you can change the color of this box
6. Click Colors.
7. Select your favorite color (we selected green).
8. Click miscellaneous
9. Change static parameter of Display from Yes to No
So this object disappears when the program is run.
10. Right-Click on Dynamic parameter of Display.
11. Click Dynamic dialog… .
The Dynamic dialog box appears
12. In Expression/Formula select or type “M-Auto/Manual” Tag
13. In the Data Type, Click Boolean.
Two rows appear In Result of Expression/Formula.
14. Change first row of Display to Yes.
15. Change second row of Display to No.
Now the rectangle appears if the value of “M-Auto/Manual” changed to 1.
Another part is four keys for the operator when elevator is in manual mode (Figure 5-
7).
Figure 5-7: Four keys

We’re going to explain just the setting of UP key because the Setting of these push-
buttons is similar. So
1. Insert a Button from Object Palette.
2. Right-Click on it.
3. Click Properties
The Object Properties dialog box appears. We want to set “M-UP” memory when the
operator presses the Up Button and reset when the operator releases the Button. So:
4. Click the Events Tab.
5. Click Mouse
6. Right-click Action of Press left
A Direct Connection dialog box appears.
7. In Source box, In text Constant box, type 1
8. In Target section, In the Tag box select your target tag (“M_Up.PB”)
9. Click OK
10. Again Click Mouse
11. Right-click Action of Release left
13. In Target section, In the Tag box, select your target tag (“M_Up.PB”)
14. Click OK
Another part is set the setting of floors push-buttons. The setting of pushbutton keypad
inside the car and the floor key are similar. So we explain just setting of Cabin key1. So
for creating a cabin key and change its setting:
1. Insert a circle
2. Right-click it
3. Click properties
4. Click Properties tab
5. Click Color
6. Right click on dynamic tab of background color
7. Click dynamic
A Dynamic value ranges appears.
8. In expression/Formula type ‘Cabin_LED 1’ or select from your external tags
9. In Data Type, click Boolean.
Two rows appear In Result of Expression/Formula that you can select two colors for two
states of parameters.
10. Change first row of Background Color to red.
11. Change second row of Background Color to gray.
If you remember, according to program in FC8, CABIN_LED1 output may flickering with
0.5s Period. So we offer you for flickering outputs change the time of scan it. We mean
that you had better change the scanning time by Wincc for this PLC output so:
12. In event name, click
13. Click cabin_LED1 to appear this name in Tag name
14. Change the default “Upon change” to 250ms.
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15. Click OK
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So now your external tag updates every 250ms on operator screen and it monitors the state
of ‘Cabin_LED 1’. Also, by this circle we can have a floor request to make an order for
PLC program such as I2.0 So
17. Click Events Tab.
18. Right-click on Action of Press Left
Such as the setting of UP Key, we can change the setting set and reset M_Cabin key1
Memory in PLC program that its task is like I2.0.
19. Click the Events Tab.
20. Click Mouse
21. Right-click Action of Press left
A Direct Connection dialog box appears.
23. In Target section, In the Tag box select your target tag (M_Cabin key1)
24. Click OK
25. Again Click Mouse
26. Right-click Action of Release left
28. In Target section, In the Tag box, select your target tag (M_Cabin key1)
29. Click OK
We also want to know the state of the elevator when is move up-down and opens-close
door. Since we use three angles respectively in our program (Figure 5-8).
Figure 5-8: four three angles

Such as the previous setting in their color properties we use two bit Memory
“Flashing closing” and “Flashing open” from PLC memory for showing the state of the
car door.
We want to have a flickering alarm when the motor is up or down, but two outputs
Motor_Up and Motor_Down are constant. So we use these outputs on flashing part of
properties instead of Color. So:
1. Insert a Threeangle from Object Pallete.
2. Right-click on it.
3. Click properties.
4. Click Effects.
5. Change global color scheme from Yes to No.
6. Click Flashing.
7. Change Flashing Background active from No to Yes.
8. Select Two favorite color on Flashing Background color.
9. Right-click The Dynamic of Flashing Background active.
The dynamic value range appears. Then;
10. In Expression/Formula select or type “Motor_UP” Tag
11. In the Data Type, Click Boolean.
Two rows appear In Result of Expression/Formula.
12. Change first row of Display to Yes.
13. Change second row of Display to No.
14. Click OK.
15. Click OK.
Another part is way of showing the position of the elevator. So:
1. Insert an I/O Field from Object Palette.
2. Right-click on it.
3. Click Configuration Dialog… .
An I/O field Configuration dialog box appears.
4. In Tag box text, select or type “Position_INT“.
5. Change color and font to your favorite.
6. Click OK.
Other Objects setting in Wincc are similar together and you can understand them inside
the Program.
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Appendix A
All symbols that defined in Step7 program
- Symbol Address Data Type
1 Recognize_Position FC1 FC
2 Manual FC2 FC
3 Record AL request in MW7 FC3 FC
4 _Detect Direct FC4 FC
5 _detect service FC5 FC
6 Turn Motors on FC6 FC
7 _change speed FC7 FC
8 Update some LEDs in auto FC8 FC
9 Exit From Auto FC9 FC
10 Update output every Scan FC10 FC
11 Monitoring FC11 FC
12 Floor Key1 I 0.0 BOOL

20 Cabin Sensor I 1.0 BOOL
21 Floor1 Limit Switch I 1.1 BOOL
22 Ems_Down I 1.2 BOOL
23 Ems_Up I 1.3 BOOL
24 Auto/Manual I 1.4 BOOL
25 Down P.B I 1.5 BOOL
26 Up P.B I 1.6 BOOL
27 Cabin Key9_Emergency I 1.7 BOOL
28 Cabin Key1 I 2.0 BOOL
36 Left Close Sensor I 3.0 BOOL
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37 Right Open Sensor I 3.1 BOOL
38 To close door_P.B I 3.2 BOOL
39 To open door_P.B I 3.3 BOOL
40 For Floor Keys IB 0 BYTE
41 For Cabins Keys IB 2 BYTE
42 clock_Mememory-0.1s M 0.0 BOOL
43 clock_0.5s M 0.3 BOOL
44 clock_1s M 0.5 BOOL
45 clock_2s M 0.7 BOOL
46 Active_7seg M 1.0 BOOL
47 Used M1.1 M 1.1 BOOL
49 Need to Down M 1.3 BOOL
50 Need to up M 1.4 BOOL
53 Not important M 1.7 BOOL
55 Out of Timer1 M 2.1 BOOL
56 out of timer0 M 2.2 BOOL

60 Need to Service M 2.6 BOOL
61 used M2.7 M 2.7 BOOL
62 Open_EndOpening M 20.0 BOOL
63 Close_EndClosing M 20.1 BOOL
66 End Of opening door M 20.4 BOOL
67 End of closing door M 20.5 BOOL
68 before state of EM Lamp M 20.6 BOOL
72 Monitoring_toclosedoor M 21.3 BOOL
73 Monitoring_Toopen door M 21.4 BOOL
74 Monitoring_Down P.B M 21.5 BOOL
75 Monitoring_UP P.B M 21.6 BOOL
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76 Monitoring_CabinKey9_E M 21.7 BOOL
77 Monitoring_Cabin Key1 M 23.0 BOOL
85 Monitoring_Floor Key1 M 25.0 BOOL
93 cabin has pasenger M 30.1 BOOL
94 Door is closing_Flashing M 106.0 BOOL

95 Door is opening_Flashing M 106.1 BOOL
96 Door is closing_NoFlash M 106.2 BOOL
97 Door is opening_NoFlash M 106.3 BOOL
98 Clock memory MB 0 BYTE
99 Used MB9 MB 9 BYTE
100 All Request_from Floors MW 3 WORD
101 All Request_from cabin MW 5 WORD
102 ALL Request_ Floor&Cabin MW 7 WORD
103 Position of Elevator_BCD MW 10 WORD
104 Position of Elevator_Int MW 12 INT
105 Position of Elevator_W MW 14 WORD
106 Position of Elevator_bit MW 16 WORD
107 Door was Closed MW 100 WORD
108 Door was Opened MW 102 WORD
109 door isnt open or close MW 104 WORD
110 COMPLETE RESTART OB 100 OB 100
111 Motor_Up Q 0.0 BOOL
112 Motor_Down Q 0.1 BOOL
113 7Seg_A Q 0.2 BOOL
114 7Seg_B Q 0.3 BOOL
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BOOL
116 7Seg_D Q 0.5 BOOL
117 Red Down LED Q 0.6 BOOL
118 Green UP LED Q 0.7 BOOL
119 Cabin LED1 Q 1.0 BOOL
127 Floor LED1 Q 2.0 BOOL

135 Music Q 3.0 BOOL
136 For OC DoorA Q 3.1 BOOL
137 For OC DoorB Q 3.2 BOOL
138 Cabin Light Q 3.3 BOOL
139 Slow speed Q 3.4 BOOL
140 Fast speed Q 3.5 BOOL
141 Out Cabin Emergency LED Q 3.6 BOOL
142 In Cabin Emergency LED Q 3.7 BOOL
143 For Cabin LEDs QB 1 BYTE
144 For Floors LED QB 2 BYTE
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Appendix B
All external tags and their symbols are defined in the WinCC program. We define All
Tags in 4 groups in the following tables. For the Inputs group, we select 5 PLC inputs in
our WinCC program.
Inputs Symbol Address in PLC Data Type
1 M_Auto/Manual I1.4 Bool
2 LeftCloseSensor I3.0 Bool
3 RightOpenSensor I3.1 Bool
4 EMSDown I1.2 Bool
5 EMSUP I1.3 Bool
In Outputs group, we chose the following PLC outputs in Our Wincc program.
In Memory group, we chose the following PLC Memories in Our Wincc program
Memory Symbol Address Data Type
1 Flashing_In_Closing M1060 Bool
2 Flashing_In_Opening M106.1 Bool

3 Position_INT MW12 Integer
In Memory_As_Input group we chose the following PLC Memories in Our Wincc

program. The operate of these memories are like some PLC inputs such as Keys.
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Questions and Answers related to this project
This section of this manual is reserved for you. I would be very happy if you would
like write to me with any questions (hardware or software wise) that you have related to
this well designed industrial project.
I shall answer you question ASAP and also, will include your question in this section of
the manual, as I believe that it might be also somebody else's question, as well.
Thanks for your comments and concerns regarding this design!
Conclusion
Now you have the information you need to become a successful PLC programmer.
This is a moment for you to take the information you’ve been given and not be afraid to
put it to use.
The primary thing that keeps people from becoming successful is fear. If you can
overcome this fear then you will succeed and prosper.
All you need to do at this point is to stop putting things off and just do it. Start working
and you will find it becomes easier as you go along.
Once you accomplish any new skill or task, you will realize just how easy it is. That is
when you want to kick yourself for not starting sooner.
So don’t hesitate. Start right now. Start today. Break that cycle of doubt and enjoy your
newfound skills and succeed in exploiting them.
To your success and happiness,
Seyedreza
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3. Basics of Programmable Logic Controllers (PLC)
4. Programming Allen-Bradley series of PLCs using RSLogix 500 software compiler
5. Introduction to programming Allen-Bradley series of PLCs (Second Edition)
Design and Implementation of typical end year college projects using a PLC with
youtube.com site links to watch the projects in action:
1. Programming a 4 floor elevator with SIMATIC STEP 7 and LOGO! SoftComfort
http://youtu.be/dqkeHD5WNcc
2. Programming SIEMENS LOGO! PLC as a dyeing machine temperature controller
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5. Implementing a PLC-based temperature controller with PID algorithm
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6. Implementation of an 8 Floor Elevator Control System with a PLC
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Design and Implementation of typical end year college projects using AVR
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http://youtu.be/q0eWsX2kMeU
2. Microcontroller based 4 Floor Elevator System
http://youtu.be/UQbGcntcVP4
3. Analog LED clock with chime, alarm, calendar and temperature display
http://youtu.be/Mi5zAdctp4g
4. Implementing an Arduino based temperature controller with PID algorithm
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5. Simple Arduino based 4 Floor Elevator Project:
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Program description Folder name File name

Main PLC program Step7_Program Insert file from step7 software

HMI settings HMI_Panel Master 8elevator.pm2

Wincc settings HMI_Wincc Test.mcp

LogixPro control code LogixPro_Program All files in “.rsl” format

To see the project in action, please click on the following link:

Figure 3-1: FC1 in OB1

Figure 3-2: Network1 in FC1

Figure 3-3: Network2 in FC1

Figure 3-4: Network3 in FC1

Figure 3-5: Network4 in FC1

Figure 3-6: FC2 in OB1

Figure 3-7: Network1 in FC2

Figure 3-8: Network3 in FC2

Figure 3-9: Networks in FC2

Figure 3-10: Network3 in OB1

Figure 3-11: Network1 in FC3

Figure 3-12: Network3 in FC3

Figure 3-13: FC4 in Network3

Figure 3-14: Network1 in FC4

Figure 3-15: Network2 in FC4

Figure 3-16: Network2 in FC4

Figure 3-17: FC5 in OB1

Figure 3-18: Network1 in FC5

Figure 3-19: Network2 in FC5

Figure 3-20: FC6 in OB1

Figure 3-21: Network in FC6

Figure 3-22: Network2 in FC6

Figure 3-23: Network3 in FC5

Figure 3-24: Network3 in FC6

Figure 3-25: Network1 in FC7

Figure 3-26: Network1 in FC8

Figure 3-27: Network3 in FC8

Figure 3-28: Network4 in FC8

Figure 3-29: FC9 in OB1

Figure 3-30: FC10 in OB1

Figure 3-31: Network in FC10

Figure 3-32: Network2 in FC10

Figure 3-33: Network1 in FC11

2BCD code to Integer

Figure 4-1: Delta Driver – VFD-M Series

Figure 4-2: Basic Wiring of VFD_M Driver (courtesy of DELTA electronic)

Figure 4-3: Digital Keypad

Table 0-4: Pr.01

Figure 4-4: select a speed with 3 bits

Figure 5-1: Modify Program to use an HMI Device

Figure 5-2: An overview of HMI interface

Figure 5-3: Manual Keys

Figure 5-4: Other parts in PM Designer program

Figure 5-5: Designed screen to show states’ elevator

Figure 5-6: Auto or Manual

Figure 5-7: Four keys

Figure 5-8: four three angles

- Symbol Address Data Type

3 Record AL request in MW7 FC3 FC

4 _Detect Direct FC4 FC

5 _detect service FC5 FC

6 Turn Motors on FC6 FC

7 _change speed FC7 FC

8 Update some LEDs in auto FC8 FC

9 Exit From Auto FC9 FC

10 Update output every Scan FC10 FC