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PROGRAMMABLE LOGIC CONTROLLER

Siemens-S7-200

Lab Manual

Department of Electrical Engineering

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PROGRAMMABLE LOGIC CONTROLLER

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Siemens S7-200

LAB MANUAL
Supervised By

MR. SAJJAD DURRANI

Department of Electrical Engineering COMSATS ABBOTTABAD

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This Manual describes the operation and function of the Siemens PLC. Read this carefully to ensure maximum performance from your PLC.

Objectives
To install the PLC in systems To construct PLC programs in LAD To run and debug the programs on Siemens S7-200 PLC.

Introduction to PLC
The S7-200 is referred to as a micro PLC because of its small size. The S7-200 has a brick design which means that the power supply and I/O are on-board. The S7-200 can be used on smaller, stand-alone applications such as elevators, car washes, or mixing machines. It can also be used on more complex industrial applications such as bottling and packaging machines.

PLC consists of three main parts: CPU Memory I/O units. CPU is the brain of PLC. It reads the input values from inputs, runs the program existed in the program memory and writes the output values to the output register. Memory is used to store different types of information in the binary structure form. I/O units provide communication between PLC control systems.

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How Plc Works

PLC reads the INPUTS then executes the program burned in it accordingly and then updates the OUTPUT respectively.

Installation Programming Practical Getting familiar with Siemens S7-200 PLC

Installation:
Installing software Download the software. Download the communication cable driver. Run the software and follow following steps Install the PC/PPI cable Go to device manager

:->my computer>properties>hardware>device manager

Double click the PPI port Change the port setting to the COM1 COMSATS ABBOTTABAD

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**Remember** if Com1 is already assigned to some other port like communication port then change that one to any other COM but PPIs port must be COM1.For laptops check by selecting one by one. Connecting the plc with the computer. Use PC/PPI cable to connect plc with the PC. Place the knob at TRM position of the PLC. Plc can be connected to PC in standalone as well in operational mode.

Connecting the plc with the inputs and load.

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Programming:
**Remember** Connect the PLC to the Power supply before programming. Ladder logic diagrams Ladder logic (LAD) is one programming language used with PLCs. Ladder logic uses components that resemble elements used in a line diagram format to describe hard-wired control. The left vertical line of a ladder logic diagram called rail represents the power or energized conductor. The output element or instruction represents the neutral or return path of the circuit. The right vertical line represents the return path on a hard-wired control line diagram. Ladder logic diagrams are read from left-to-right, top-to-bottom. Rungs are sometimes referred to as networks or horizontal lines. A Rung may have several control elements and output coils.

The user-friendly design allows data entry from a mouse. You can select and specify a device type. This ensures error-free entry of target symbols.

Addresses

S7-200
Inputs
Outputs I0.0 I0.7 Q0.0 Q0.3

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Basic Ladder Logic Programming

Running PLC Programs When the program is compiled successfully, click on the Download button on the taskbar to transfer the compiled program to the PLC. During this operation, be sure that PLC is STOP or TERM mode. When the transfer is completed, switch the PLC to RUN mode or click RUN button in the toolbar. Now, PLC is running. Switch the inputs ON and OFF, and observe the change on outputs of the PLC module. Check if your program works correctly. You can also transfer the existed program in PLC to PC. In a similar way, when the PLC is STOP mode, click on the Upload button on the taskbar. When the operation is completed, you can see the program code existed in PLC on computer screen. Now you can modify the program if it is necessary.

Building Program(e-g. latch) Start -> Programs -> Keyence Applications ->Ladder Builder for KV Sample Ver.

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Create a new file. Select the KV10 model.

The new window will bw like this.

Place an N.O contact and give it address of the desired input contact.

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Now place an N.C contact.

Extend the rung by placing horizontal lines(F9).

Now place an output (F7) and address it accordingly.

Connect the circuit to the right power line. COMSATS ABBOTTABAD

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Place the cursor below the contact of relay 0001 add a Branch with a NO contact (OR logic), Select relay 0500

Place the cursor below the NO contact of relay 0500. Type END -> for end of routine . Click OK.

Place the cursor below on line 0004. Type ENDH -> for end of program. Click OK. COMSATS ABBOTTABAD

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Compile and Execute the program for continuous scan. Then simulate.

Compile Simulator PLC Monitor

Simulator Its a quick debugging without a PLC. Even without a PLC connected, the Ladder Builder for KV can simulate program execution. The execution can be checked without transferring the program to the PLC. By providing a single-step execution function (forward or reverse) in addition to a regular scan execution function, debugging efficiency is increased. PLC Monitor Real time monitoring without stopping the machine Ladder diagram and element on/off stands can be monitored real time. Timing charts can be monitored simultaneously. Simulation of above build program

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Practical:
Develop a relay based controller that will allow three switches in a room to control a single light. Develop a simple ladder logic program that will turn on an output X if inputs A and B, or input C is on. Develop basic logic gates on PLC. Develop a motor forward/reverse program using interlock circuit with 5 sec delay on PLC. Develop a program which counts subjects on a conveyor belt. Develop time delayed security alarm program using relay. Develop a pressure and level controller program of a boiler having self fault identifier. Experimental Work An automatic stamp system shown in Figure 2 works as follows: When start switch is turned on, system gets ready to run. When the operator puts a box at the beginning of the conveyor (on LS1) the motor runs and conveyor moves. Upon reaching the mid point of the conveyor (on LS2) the conveyor motor stops. Then the stamp comes down and puts the stamp on the box. When this process is finished, the stamp goes up and conveyor moves again to the other end of the conveyor. After box reaches to end of the conveyor (on LS3), the motor stops. The system waits for the box to get and COMSATS ABBOTTABAD

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another box to be placed at the beginning of the conveyor. If start switch is turned off, the system can not run even if there is a box on conveyor. The light on the start box indicates that the system is active whereas UP and Down lights indicate that the stamp is UP and DOWN position respectively. Develop a LAD to control the stamp system.

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