This document outlines a training course on programmable logic controllers (PLCs) using the Siemens S7-1200 PLC and TIA Portal software. The course consists of 9 modules that cover topics such as PLC hardware components, programming basics, function blocks, timers and counters, math operations, diagnostics, closed-loop control, networking, and human-machine interfaces. The introduction module describes the major PLC components, relay ladder logic, and provides an overview of the S7-1200 PLC and TIA Portal software. The course objectives are to teach students how to program and configure the S7-1200 PLC to automate various industrial processes and systems.
2. Contents
Module (0) Introduction
Module (1) Programming Startup
Module (2) Function Blocks
Module (3) Timers and Counters
Module (4) Math, Comparator and Conversion Operations
Module (5) Diagnosis & Analog Value Processing
Module (6) Closed Loop Control
Module (7) Networking
Module (8) Human machine Interface
Module (9) Graduation Project
Eng. Ahmed Elsayed
3. Objectives
Module (0) Introduction
1. Describe the major components of a common PLC.
2. Relay Ladder Logic.
3. Introduction to Siemens PLCs (S7-1200 family).
4. Hardware Configuration of S7-1200.
5. Introduction to SIMATIC TIA PORTAL.
Module (1) Programming Startup
1. Getting familiar with Programming.
2. CPU Connection & Resetting Factory Mode.
3. Addressing System.
4. Data Types.
5. Bit Logic Operations.
6. Configuring and Operating the SIMATIC S7-1200.
7. Tasks: Relay Diagrams to Ladder and FBD, Motor Start/Stop, ……
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4. Module (2) Function Blocks
1. Types of Blocks
2. Linear Programming
3. Structured Programming
4. User Blocks
Organization Blocks, Functions, Function Blocks, Data Blocks
5. Set/Reset Operation
6. Tasks: Stamping System, Belt Control.
Module (3) Timers & Counters
1. Types of Timers.
2. Types of Counters.
3. Operation of each type.
4. Tasks: Practical Start/Stop Motor, Practical Stamping Machine, Production Line.
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5. Module (4) Math, Comparator and Conversion Operations
1. Math Operations
2. Comparator Operations
3. Conversion Operations
Module (5) Diagnosis & Analog Value Processing
Diagnosis.
1. Open Project Online
2. Device Diagnosis
3. Offline/Online Comparison
4. Monitoring, Controlling and Forcing Variables
Analog Value Processing.
1. Analog Signals.
2. Reading/Writing Analog Values.
3. Scaling / Un-scaling
4. Task: Tank Level Control.
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6. Module (6) Closed Loop Control
1.Fundamental of Closed Loop Control.
2.PID in SIMTIC.
3.Tasks: Water Level and Temperature Control.
Module (7) Networking
1.Networking Basics.
2.Adding another Controller to the Network
3.Communication Blocks.
4.Tasks:
a. Programming for 1st Controller: Conveyer Control.
b. Programming for 2nd Controller: Conveyer Data Logging.
c. Programming of Communication Blocks.
d. Final Project.
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7. Module (8) Human Machine Interface
1.Display Data on HMI Screens.
2.Sending Data from HMI Screens.
Module (9) Graduation Project
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8. Module (0) Introduction
1.What is the word “PLC”?
2.The major components of a common PLC.
3.Basic Definitions.
4.Relay Ladder Logic.
5.Introduction to Siemens PLCs (S7-1200 family).
6.Hardware Configuration of S7-1200.
7.Introduction to SIMATIC TIA PORTAL.
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9. What is meant by PLC?
PLC is an abbreviation for “Programmable Logic Control”.
It is simply a special computer device used for industrial control systems.
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10. Advantages of PLCs
Less wiring.
Wiring between devices and relay contacts are done in the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming easier and reduce downtime.
Reliable components make these likely to operate for years before failure.
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11. PLC like any PC, consists of:
1. Central Processing Unit.
2. Input/Output (I/O) interface system.
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12. The central processing unit (CPU) governs all PLC activities.
The following three components form the CPU:
1. The Processor.
2. The Memory System.
3. The System Power Supply.
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17. Power Supply (PS)
A separate power source for a PLC that converts the standard incoming
220VAC to the low voltage DC that the CPU requires, around 24V or 5V.
General Advantages of Primary PS
- stabilized output voltage.
- high efficiency.
- compact design.
Main Advantages
- Disconnect automatically if short circuit or over-current occurred.
- Return a fault signal if short circuit or over-current occurred.
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18. Central Processing Unit (CPU)
The brain of the whole PLC is the CPU module.
This module typically lives in the slot beside the power supply.
The CPU consists of
a microprocessor, memory chip and
other integrated circuits to control logic,
monitoring and communications.
The CPU has different operating modes,
In programming mode it accepts the
downloaded logic from a PC.
The CPU is then placed in run mode so
that it can execute the program and
operate the process.
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19. I/O System
The I/O system provides the physical connection between the equipment and the
PLC.
Provides signal conversion and isolation between the internal logic- level signals
inside the PLC and the field’s high level signal.
Input modules converts signals from discrete or analog input devices to logic levels
acceptable to PLC’s processor.
Discrete Input (digital input), is an input that is either ON or OFF are connected to
the PLC digital input.
Analog Input, is an input signal that has a continuous signal.
Output modules converts signal from the processor to levels capable of driving the
connected discrete or analog output devices.
Discrete Output(digital output), is an output that is either ON or OFF are connected
to the PLC digital input. (Contact or Transistor)
An analog output, is an output signal that has a continuous signal. Typical outputs
may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
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31. Rack
The rack is the component that holds everything together.
Depending on the needs of the control system it can be ordered in different
sizes to hold more modules.
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34. Control System
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SP: Set Point
PV: Process Variable
E: Error
CV: Control Variable
Controller: Control Technique implemented in PLC.
Process: Our Tank Control System (Temperature).
38. Family of S7-1200
1. CPU 1211
2. CPU 1212
3. CPU 1214
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AC/DC/RLY DC/DC/RLY DC/DC/DC
1. Type of Supply (DC/AC).
2. Type of input signal.
3. Type of Output; DC means the out put will be only DC via transistor
RLY means the output may be DC or AC via relay
Supply/Input/Output
39. 1) Power Connector.
2) I/Os Wiring Connectors.
3) I/Os Status LEDs.
4) PROFINET Connector.
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40. Features of S7-1200
controller with integrated PROFINET interface for communication
with programming device, HMI or other SIMATIC controllers.
powerful, integrated technology functions such as counting,
measuring, closed-loop control, and motion control integrated digital
and analog inputs/outputs
signal boards for direct use in a controller
signal modules for expansion of controllers by input/output channels
communication modules for expansion of controllers by
communications interfaces
accessories, e.g. power supply, switch module or SIMATIC Memory
Card
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45. Introduction to SIMATIC TIA PORTAL
STEP7 is the Programming Software of Programmable Logic Controller (PLC)
of the SIMATIC S7 family of Siemens.
TIA is an abbreviation for “Totally Integrated Automation”
TIA is a strategy (architecture) in the automation technology, which defines
the interaction of extensive single components, tool (SW) and the services
(spare part service, etc.) to achieve an Automation solution.
The interaction performs integration across the four automation levels of
the automation pyramid:
1. Management level
2. Operator’s level
3. Controller’s level
4. Field level
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