Setting Up the Profibus DP Using S7 300 PLC

The software of Siemens Simatic Manager is utilized to set up the S7 300 PLC.

Installing the GSD file
The opening stage is to set up the GSD file then Simatic is capable to map the blocks data to our appliance. Then Double-click the Hardware in the right hand of window. This will begin the HWConfig where mostly the work is done. The HWConfig demonstrates the recent PLC hardware design. Close up this configuration (NOT HWConfig) and select Options>Install GSD File. Click Browse to choose the folder were the file of GSD previously downloaded is, choose the file and click Install. The setup of PLC hardware can be released again by doing Station and picking the latest opened file which should be number 1, once the file of GSD is installed successfully. If this is a new installation, organize your PLC with the correct modules.

Setup the network of Profibus
The subsequent steps illustrate how to install the network of Profibus DP. Leave out these stages if your PLC application already acquires a network of Profibus DP. On the edge window that corresponds to the PLC, double click the area of DP to open the window properties.

Adding the G3 on the network of Profibus
Modular Controller to the network of Profibus, pull the MC/DSP/G3 Profibus Card from the Catalog navigation situated on the right hand side of HWConfig to the Master System of Profibus DP, to add the G3.

Now, The G3 is on the network of Profibus DP, and it preferred. HWConfig shows the slots existing under the G3 to organize the data blocks to exchange. Just pull and drop one of the data blocks existing under the DSP/G3/MC Profibus Card in the slot number 1. Simatic will allocate automatically a start address in the particular columns of Input and output depending of the block type selected.

Setup the Profibus Communication

The G3 can be configured to robust its configuration once the PLC is setup. Data Station Plus or Modular Controller to correspond on Profibus DP, a card of Profibus Option must be fitted in the device.

Setting up the Profibus communication
Go into the module of communication and choose the G3. Select the Edit key to choose the Option card on the right hand panel. Choose Profibus Option card and enter OK. The card option showed in the tree of communication. Choose the Interface of Profibus and click the Edit key to choose a driver. Click OK to select the driver of Profibus DP. Now Crimson displays the driver settings where the Station Address can be adjusted. This address is the address of G3 on the network of Profibus. No settings of Baud Rate as the option card of Profibus identifies the transmission rate automatically. Now a device called PLC1 is displayed under the Interface of Profibus.

Setting up tags
Tags can be made to contact the PLC block once the communication is set up. First, make a variable that communicate to the data type required. Choose the variable and change the name eventually. Next, click on Internal to mapping on the right hand side panel, and choose the PLC1, which is the Master of Profibus.

In the arise window, pick the type of block required. Two choices are offered:
• Input block: The input of terminology is from the Siemens standpoint. Consequently this will be the G3 block will write to. The mapped tag to an input block must be setup as Write Only.
• Output block: The output of terminology is from the Siemens standpoint. Consequently this will be the G3 block will read from. The mapped tag to an output block must be setup as Read Only.

Profibus Decentralized Peripherals Slave

Data Station Plus and enhanced master of Modular Controller now support Profibus communication using an optional card of communication. This article will give a description on Profibus DP and tell how to set up a G3 HMI with a CPU315-2DP, S7300 PLC using Profibus. An Enhanced Master of Modular Controller setup would be analogous. It is not be determined that this article offer a specify description of Profibus, but only a short introduction, necessary to identify the terms that are used all over the rest of this article.

Profibus DP means for “PROFIBUS for Decentralized Peripherals”. Profibus-DP is a tool level bus that applicable both discrete and analog signals. It has general usage for such items as variable speed drives, motor control centers, and remote I/O systems. Profibus-DP corresponds at speeds from 9.6 Kbps to 12 Mbps with distances from 100 to 1,200 meters. Profibus DP Slave is the protocol that supported by both G3 HMIs of Profibus DP option card (G3PBDP00) and Profibus DP option card for Data Station Plus and Modular Controller (XCPBDP00). Therefore, Red Lion Controls’ products must be connected to a Profibus network with a master device.

It is a short explanation on Profibus DP communication is working before the set up. The communication of Profibus DP gets the block exchange form. Profibus blocks are created of memory bytes where 2 bytes make a word and 4 bytes a double word, or Dword. A block is a consecutive bytes range of addresses and is unidirectional. This indicates the PLC will replace data write only and read only on DP slave unit blocks. Every device addresses are autonomous and only related to the device for its own program. This represents, for instance, that the first block address range in the master can begin at 256 with a 64 words block length and could effect in the slave with a range beginning from 0 with 64 words length.

PLC Control Builder Configurations and Functions

If the PLC is the aim for your applications which you need to download the application to the PLC from the Project Explorer. The code of programming is then run in the PLC. The Programmable Logic Controller Control builder is used to build control solutions. The solutions are made within projects of control builder, and several levels of structuring are existing inside one project. A project can work up to 256 applications where every application can work onto 64 programs at the most. 32 Control Builder PCs maximum can be operated together in multi-user environment and up to 32 PLCs can be built and handled within a project.

You can built self-defined libraries involving function block types, data types etc. Aside function block types, your Control Builder can also use for control modules, which are devices for object-oriented programming.

Not supported Functions
When you need to add functionality for creating DCS type of control solutions, control builder that available in the ABB 800xA DCS system offering can be used. The control builder of 800xA, to set of functions available in PLC Control Builder need to add the following functions
• High Integrity Controller for SIL applications
• The function of CI860 is for FF HSE, and the function of CI862 for TRIO I/O
• Security
• Batch handling
• HART protocol is for information routing
• Audit Trail
• SFC Viewer

Multi-User Engineering
Programmable Logic Controller Control Builder chains multi-user engineering with up to 32 separate engineering stations. All the OPC Server and Control Builder PCs have to have right of entry to the common project file in a multi-user configuration. This represents that a common Project folder must be made on a shared network server. The server of network can be put anywhere appropriate in your network; thus placed and handled by an OPC Server PC or in a Control Builder PC.

FATEK FBS Series PLC

The FATEK FBS Series PLC is a new micro PLC generation outfitted with outstanding functions compare to medium or large PLC, it contains up to 5 communication ports. The maximum numbers of I/O are 256 points for DI (Digital Input) and DO (Digital Output), 64 words for NI (Numeric Input) and NO (Numeric Output). The FBS Main Units are offered in three types: High-Speed NC Type (MN), High-Performance Type (MC), and Economy Type (MA). A total of 17 models are offered with the I/O point combination ranges from 10 to 60. 14 DI/DO and 12 NI/NO models are existing for Expansion Units or Modules. The peripherals communications are available with 14 modules and boards with interface options in Ethernet, USB, RS485 and RS232.

All the FBS-PLC Main Units have the same structure of physical. The difference is only the case width. There are 4 different case sizes, which are 175mm, 130mm, 90mm, and 60mm. The below is the Main Unit case of the FBS-24MC:
• Digital Input Indicator (Xn).
• Digital Output Indicator (Yn).
• System status indicator (ERR, POW, RUN,).
• I/O output expansion header cover, with esthetic purpose and capable of securing expansion cable.
• Board of FBS-CB22 Communication (CB).
• Cover plate of FBS-CB22 CB
• Communication board screw holes.
• Communication board connector (for CB55, CB25, CB22, CB5, and CB2)
• Communication Module (CM) Connector (only offered in MC/MN model, for CM55E, CM55, CM25E, CM25, and CM22connection).
• Memory Pack connector.
• Built-in communication port Connector (Port 0)
• Header of I/O output expansion for connecting with cables from expansion units/modules.
• 35mm-width DIN RAIL
• DIN RAIL tab
• Hole for screw fixation (ψ4.5×2)
• 24VDC power input and digital input terminals (Pitch 7.62mm)
• Main power input and digital output terminals (Pitch 7.62mm)
• Standard cover plate
• Built-in communication port cover plate (Port 0)
• Transmit (TX) and receive (RX) status indicators of built-in communication port (Port0)

The PLC Control Builder

Programmable Logic Controller (PLC) Control Builder is a tool of programming for building PLC based control solutions when the PLC hardware is using the AC 800M hardware. The PLC Control Builder presents with solutions type for loop control, alarm handling simple logic control, device control, etc. packaged as standard libraries. The Control Builder chains five programming languages, Instruction List (IL), Ladder Diagram (LD), Function Block Diagram (FBD), Sequential Function Chart (SFC), and Structured Text (ST) according to IEC 61131-3. The additional to this chains the language of Control Module. The other functionality of Control Builder is for online debugger and test mode.

The core user interface of Programmable Logic Controller (PLC) Control Builder is called Project Explorer and this is where you build and make your projects. A project consist the entire configuration required for a PLC based control solution, including hardware settings and control applications. Context menus are accommodating while linking parameters or configuring hardware units etc. click the right button of mouse on an object to open its matching context menu. Both the software and the hardware are modeled in a project.

It is transferred with a wide-ranging set of predefined type solutions saved in standard libraries. These include function blocks, data types, functions, and Control Modules that can be used in your projects. All standard libraries are incorporated during the PLC Control Builder setting up and are obtainable in your projects. PLC Control Builder gives the following libraries:
• The Basic library, consists blocks of basic building for control software of AC 800M like function block types, data types, and control module types with extensive functionality, that designed by ABB.
• The Communication Libraries contain function blocks for Foundation Fieldbus, SattBus, MMS, Siemens 3964R, and ModBusCOMLI protocols.
• The Control Libraries contain cascade PID control and single PID control function blocks, control modules, etc.
• The Alarm and Event Library, it includes function blocks for alarm printouts on a local printer, alarm and event detection.

Automation Technology of SIMATIC S7 controller

The individual controller of SIMATIC S7
As the PLC modular itself, this individual course system can be set together with the panel of modular training. The panel of modular training has an outline railing that accepts the modules and PLC. All controllers of S7-300 series are companionable with this outline railing. There are a variety of I/O modules existing that have 4 mm safety sockets to link peripheral equipments using connecting leads. These Input/Output modules are pre-wired to circuit boards of SIMATIC.

PLC programming in the COM3LAB
The COM3LAB Course presents basic concepts of PLC and shows their capabilities for being networked, including networking with actuators and sensors, on the PROFIBUS basis. Many samples, descriptions, and practical problems present PLC basics and behavior explicitly. The solid hardware complementary this training makes it possible for you to improve practice-oriented experience.

If the Profi-CASSY is joint with software of CBS 9 models, it will be resulting the universal device simulator. This combination of hardware and software is linked on one side, using PROFIBUS or using a flat cable directly, to the PLC and using USB to a PC. This provides the PC access to 2 analog and 16 digital inputs and outputs. Process simulations are obtainable for the most diverse device. These simulators are easy to assemble on the PC. Profi-CASSY makes the device‘s sensors and actuators accessible to a real controller.

There are 3 different simulations modes:
• In demo-mode, the process runs automatically on the display where it can be learned and observed without stress.
• In manual mode, the device can be experienced step-by-step. All actuators can be activated by click the mouse.
• In external mode, the control of the device is took over by a real PLC. Outputs of PLC are linked to inputs of Profi-CASSY, and thus the actuators of device. Inputs of PLC are linked to outputs of Profi-CASSY, which allows acquirement of all the device simulator‘s signals.

T 9.3 Automation Technology

LD DIDACTIC has engineered components of SIMATIC for practice-oriented vocational education and training. These components connection to peripheral device have built a panel of training that equipped with 4mm sockets of safety for the basic modules of mounting as good as the input/output modules. Additionally to the basic device units configured completely you can also choose the appropriate CPU for your special requirements and combine this with modules of input/output of your selection, or simply enlarge the already configured device units.

The multimedia of Automation Technology course and the vivid models as good as networking the components the programmable controller PLC is expanded into a whole system the ensuring objective-oriented training.
• Basic PLC programming with course of COM3LAB, automation and bus technology
• The PLC modular e.g SIMATIC S7-300
• The LD DIDACTIC training panel to accommodate components and up to 9 I/O modules
• Programming is conducted referring to IEC 1131-3 e.g. LAD, FBD, STL
• Simulation process of PC as good as models hardware
• The automation technology components networking sensor technology
• Logic modules and control relays for easy functions of open-loop control
• Visualization

T 9.3 Equipment Unit Configuration
• T 9.3.1 S7-300 PLC – It is configured completely in fundamental units with S7-300 controllers.
• T 9.3.2 Applications PLC - application models of PC simulation for movements and support of techniques programming.
• T 9.3.3 PROFIBUS DP - The Profibus is designed principally for the connecting of intelligent modules, e.g. the motor frequency converter.
• T 9.3.4 Sensor Technology – Device sets from the instrumentation and control technology fields planned for correlation to the automation technology.
• T 9.3.5 AS-Interface - The interface of actuator/sensor is an inexpensive option for connecting simple modules, such as actuators and sensors. Actuators and sensors can be linked to the controller via an unshielded or two-conductor line.

ELC Controllers and Modules

The Eaton Logic Controller (ELC) family offers four controller styles. These controllers provide combinations of the features as following:
• High speed pulse output and capture on all controllers
• Feature of interrupts
• Large module of AC/DC selection in, relay or transistor out
• Large analogue selection of combined, thermocouple, RTD Platinum, analogue in, out
• More than 200 instructions to select from: Communications, ASCII conversion, hex, decimal, floating point math, bit manipulations, logical, octal, BCD, block move, retentive data storage, block compare, time base from clock/calendar
• There are 2 serial ports of Modbus those are RTU or ASCII: 1 master/slave, 1 slave only
• Network communications on DeviceNet, Profibus, and Modbus TCP
• Controller of ELC can be wired for remote I/O communications.

ELC Expansion Modules
The modules of ELC expansion offer the amount correctly of I/O for application solutions. Select 4, 8, or 16 I/O. Any expansion number of modules can be added into the ELC processor to create 256 I/O.

ELC Specialty Modules
To add in the to expansion I/O, modules specialty like Temperature of Platinum, Thermocouple, Analogue In, Analogue Out, DeviceNet, Switch Module, and PROFIBUS DP etc. The module expansion could be added. To easily connect use the ELC-485APTR to ELC controllers, MVX drive on the RS485 port, and other devices.

ELC Accessories ELC-GPXFERMOD
The programs can be transferred to and from units of ELC-GPxx. These equipments can be written protected to ensure program integrity. ELC-HHP is friendly-to-use, when a PC is not available ELC controllers can be for hand-held programming tool. Applications can be directly programmed with the attached keypad with ELCHHP. Or downloaded from a PC and transferred to different ELCs. Or uploaded from an ELC, transferred and saved, to another ELC. If you are using the ELC-HHP no require for outlets since it draws its power from either the PC or the ELC through the attached cable.

Description of Eaton Logic Controller

One of the products Programmable Logic Controller (PLC) in marketplace is Eaton Logic Controller (ELC). This decreased sized ELC with its module abundant selection will offer a concept of “Just Right” that offering only what you want for the price you need.
• Size
It is a small package of PLC that offering the features or functions PLC largely. ELC is one third a D50 size, providing similar and a greater set than the D50. ELC is able to provide 46 I/O while a D50 is available for 14 I/O.
• Flexibility
To use the same controller, ELC controllers can handle I/O counts from 10 I/O to 256 I/O. ELC reduces the counting I/O process and deciding which controller to use, ELC is the only one required. ELC modules offer in many flavors of I/O from modules consisting 4 in / 4 out to modules consisting 8 in / 8 out. Add modules by simply snapping them into the closing the attached locks and mating connectors.
• PLC Features
ELC provides the greater PLCs feature set, from its timer resolution to 1 ms, high speed counter, PID, remote I/O ability, high speed pulse outputs, multiple communications ports, data storage interrupts, plus much more.
• Software
ELCSoft, the software, configures the entire line of ELC controllers. It programs in standard sequential function chart and ladder logic programming. It will help in understanding what registers are in use and what modules are enclosed to the Eaton Logic Controller. It controls that allow forcing, and runtime application. Wizards aid programming software of PIDs, remote I/O, and standard communications.
• Power One
Eaton Logic Controller easily communicates to drives of MVX, reducing the requirement to operate drives by input/output digital or voltage/current analogue. ELC is able to access the MVX parameters by serial communications, it is saving OEM money and also ELC communicates to IT.

Modicon PLC Status Display

The panel display on the front of the Micro PLCs is using LEDs to show the health and status of the unit’s CPU, communication ports, fixed I/O points, and battery.
PLC status base on the LEDs:
• power ok, when internal power is OK the green LED lighted ON
• ready, the amber LED lighted ON when the PLC has passed its power-up diagnostics, and remains lighted ON as long as the PLC is OK
• run, the green LED lighted ON when the PLC has started to run and is solving logic when the PLC has power but do not have a valid operating mode configuration
• battery low, the red LED lighted ON when the internal battery is no more power.
• exp link, This LED lighted ON if it detects the problem in the optional of battery capacitor or if the capacitor is not charged fully. A green LED lighted ON steadily when occur the valid communications on the I/O expansion connecting. Same indications happen in PLCs involved in the communication.
• comm 1 A green LED is flashes when communications happen on the first RS-232 port.
• comm 2 A green LED is flashes when communications happen on the second RS-232 port.
The LEDs array on the left side display shows the fixed discrete I/O points status on the PLC. The physical of I/O point to a number of LED is reference in the display, referring to the diagram of wiring.

The error is detected when the run LED on the right side is flashing in conjunction with any input of LEDs. The input LED pattern flashes shows the nature of the error. The people who program the PLC can base onto the Modicon Micro Ladder Logic Manual (890 USE 146 00) for a system crash codes description.

Technical Data PLC PU 104

The PU 104 gives a connecting between Ethernet TCP/IP networks and CAN-CAL together with its PLC functions. A 10BaseT and a 10Base2 interface is fitting in the PU 104 for linking into the Ethernet. PCs with Ethernet network modules and 32-bitWindows-based applications, have access directly to CAN fieldbus networks. An ANSI-C library is supporting the connecting function in the form of a 32-bitWindows DLL.

Programming with standard tools
The PU 104 Programming is programmed with a PC and a Windows-based software tool. The tool of universal programming is made for all of PMA’s P-open modules. According to your application, the software programming makes you select the most convenient method such as Ladder Diagram (LD), Function Block Diagram (FBD), Instruction List (IL), or the high-level language ’C’. The first from the 3 options are depending on the international standard IEC 1131-3. It provides full support during development of your own specific application programs, if necessary.

Below is the technical data of PLC PU 104:
• The configuration is Pre configured
• Both memory are 2 Mbytes SRAM and 2 Mbytes Flash EPROM
• Programming is using a PC and software Windows based with programming languages such as FBD, LD, IL of IEC 1131-3 and high level ‘C’ programming. The downloading will be via RS232 , CANbus or Ethernet
• 16 digital inputs for 24 VDC. 16 digital I/O
• The LEDs status are the 5 LEDs indicate the module’s operational status and the 32 red LEDs show the switching status of the digital IO.
• It is using 2 x CANbus interface. The protocol: CAN CAL/CANopen using interface 1 x RS 232, max. 0,15 A, 24 VDC. and for local I/O extensions with P-open modules.
• Module supply is 24 VDC with max 0.4A
• I/O energization 24 VDC grouped into six groups.

Module Intelligent PLC of PU 104

The PU 104 is apart of the series of P-open and gives compact PLC functions for automation applications that need distributed intelligence. It also modifies CAN with Ethernet, it is able Ethernet PCs directly to access CAN field busses, even no additional CAN interface. The unit features 16 digital I/O, and 16 on-board digital inputs which can be built individually as inputs or outputs as apart from real-time processing. CAN, CAN master or Slave implementation, plus a CANopen master is fitting in PU 104 of intelligent PLC module, which implement as a library for IEC 1131 and ’C’ for programming and communication functions. The dimension of PU 104 is 124 x 170 x 85.5 mm, ideally the PU 104 is suitable for mounting close to the process in de-centralized systems.

The extensions of system are implemented easily by contacting additional modules I/O to the PU 104. The connections are created with cables which plug into the extension bus module. The system of complete PLC result is connected via the CANbus.

Selective I/O energization
The inputs/outputs supply is supplied via 2 terminals at the signal level. The supply voltage is 24 VDC. The signal I/O’s can be grouped into six groups, each with its own supply.

Convenient field connections
The process or machine electrical wiring is directly connected to the terminal strips at the modules of top and bottom. The type of strips terminals are plug-in type, it is provide system pre-wiring as well as high speed module exchange. Below, the terminal strips alternatives are available as following for:
• Screw terminals
• Screwless spring-clamp terminals
• Crimp terminals.
The three wires principle is connecting the inputs/outputs. The LEDs of front panel is signing the status signal of every I/O, and the module’s operational status. The positions of LED are associated directly with an I/O corresponding.

DC 150 Intelligent DDC control and PLC module

The DC 150 gives good solutions for automation jobs with intelligence distribution. The module is particularly suited as a stand-alone controller as apart of standard PLC functions. Programming is created according to the international standard IEC 61131-3. The DC 150 is an ideal solution for fast control loops with its high precision calculation facilities and very fast scanning of I/O with 1 ms. For this objective, pre-configured controller function blocks are available.

The three serial interfaces and 2 ports of field-bus are provided for communication with a visualization system or a central PLC. Sam as the operating terminal connection, a PC or a supervisory computer for the engineering is possible. The DC 150 can be addressed remotely by means of a conventional modem, e.g. for down-loading and debugging. Aside real-time, 32-bit processing, the unit features 8 digital inputs/outputs, and 8 on-board digital inputs that can be individually configured as inputs or outputs, plus 8 analog inputs and 8 analog outputs. With its modem interface, real-time clock, and an expandable Flash memory (up to 9 Mbytes), the DC 150 meets all the requirements for de-centralized data logging.

Extensions are easily implemented by connecting additional I/O modules via the CANbus should more than the on-board I/O be needed. Same as a local operating terminal can be linked via CANbus. The module housing for clip on mounting is designed according to DIN rails standard. The housing dimension is 124 x 170 x 85.5 mm, ideally the DC 150 is suitable for mounting close to the process in de-centralized systems. For communication and programming, the DC 150 is fitted with a complete CANopen master/slave applicable as a library for IEC 61131-3.

Convenient field connections
The wiring electrical from the process or machine is directly taken to the terminal strips at the modules top and bottom. The following options are available for the terminal strips:
x Screw terminals
x Screwless spring-clamp terminals
x Crimp terminals.

RSLinx Communication Software

RSLinx is a communication software package of windows based developed by Rockwell Software to interface to all of the Rockwell and A-B industrial control and automation hardware. RSLinx comes in a variety of different flavors including RSLinx-Lite – PLC Programming software communication interface.
RSLinx-OEM – Provides DDE capability for Rockwell DDE capable software.
RSLinx Professional – Provides DDE capability to and DDE capable software.
RSLinx-Gateway – Communication network bridgeing, routing, and OPC server.
RSLinx SDK – Software Development Kit includes the OEM version.

In fact, all of the RSLinx software packages are the same. What differentiates the software packages from one other is the copy protection software key for RSLinx. If you run RSLinx without a key of software the software operates in the Lite mode. If you have a key the software works in the mode that the software key authorizes it to run in. This appendix will explore the capabilities of RSLinx-Lite. However, the driver configurations sections are applicable to all uses of RSLinx.

RSLinx is the intermediary communication between the hardware and the software package that needs data from the communication hardware. It must be configured to use the communication hardware interface of your choice for RSLinx to function. Select the correct communication hardware interface requires a thorough understanding of the device that is to be communicated with. It is important to understand the communication capability of the specific PLC that is being used, in the case of communicating with a PLC. Different types, revisions and models of PLCs have different communication capabilities.

For the objectives of this discussion and the following examples I am going to focus on the PLC hardware; specifically the PLC-5 and the SLC-500 processors. By focusing on the PLC hardware we can concentrate on the following communication hardware choices.
1. Serial – Using the serial port on a PC to the serial port on a PLC.
2. KT-Card – Use one of the many types of KT card to talk DH+, DH-485, or ControlNet.
3. Ethernet – Use Ethernet to communicate to an Ethernet capable processor.

Lock Unlock Door Using Mitsubishi PLC

PLC Type FX, Name Input / Output PLC :

INPUT PLC :
X000 ; Numeric 0 from KeyPad
X001 ; Numeric 1 from KeyPad
X002 ; Numeric 2 from KeyPad
X003 ; Numeric 3 from KeyPad
X004 ; Numeric 4 from KeyPad
X005 ; Numeric 5 from KeyPad
X006 ; Numeric 6 from KeyPad
X007 ; Numeric 7 from KeyPad
X010 ; Numeric 8 from KeyPad
X011 ; Numeric 9 from KeyPad
X012 ; ENTER Key from KeyPad
X013 ; Door closure Sensor
X014 ; Door Exit Button

OUTPUT PLC :
Y000 ; Output to Relay Coil (Used for Electromagetic Lock and Green LED)

PLC Programming for Lock Unlock Door using Mitsubishi PLC

Reading Ladder PLC Programming for Lock Unlock Door using Mitsubishi PLC :

Step 1 :
Password Data using D20
a.If M500 = OFF (Always ON) Then D20 = 5214 (can be modified and 4 Digits Decimal)

Step 2 :
Numeric 0 to 9 is pressed
Using D0 for temporary data storage
a.If X000 = ON (Numeric 0) Then PLS M0 = ON AND D0 = 0
b.If X001 = ON (Numeric 1) Then PLS M0 = ON AND D0 = 1
c.If X002 = ON (Numeric 2) Then PLS M0 = ON AND D0 = 2
d.If X003 = ON (Numeric 3) Then PLS M0 = ON AND D0 = 3
e.If X004 = ON (Numeric 4) Then PLS M0 = ON AND D0 = 4
f.If X005 = ON (Numeric 5) Then PLS M0 = ON AND D0 = 5
g.If X006 = ON (Numeric 6) Then PLS M0 = ON AND D0 = 6
h.If X007 = ON (Numeric 7) Then PLS M0 = ON AND D0 = 7
i.If X010 = ON (Numeric 8) Then PLS M0 = ON AND D0 = 8
j.If X011 = ON (Numeric 9) Then PLS M0 = ON AND D0 = 9
Note : PLS = Single-scan of target relay ON at rising edge of previous state

Step 3 :
Count the number keypad is pressed
Using D30 for Count data storage
a.If M0 = ON Then INC D30 (Increment target device value)

Step 4 :
Enter Released for Value D30 = 0 (Count data RESET)
a.If X012 = ON (ENTER key is pressed) Then PLF M1 = ON (Single-scan of target relay ON at falling edge of previous state)
b.If M1 = ON Then Value D30 = 0

Step 5 :
Password from the KeyPad
Using D12 for Password from the KeyPad
a.Keypad is pressed first, multiplied by 1000
(M0 = ON) -> (= K1 D30) -> (MUL K1000 D0 D1)
b.Keypad is pressed second, multiplied by 100
(M0 = ON) -> (= K2 D30) -> (MUL K100 D0 D2)
c.Keypad is pressed three, multiplied by 10
(M0 = ON) -> (= K3 D30) -> (MUL K10 D0 D3)
d.Keypad is pressed four, multiplied by 1
(M0 = ON) -> (= K4 D30) -> (MUL K1 D0 D4)
e.Sum all the data
(M0 = ON) -> (ADD D1 D2 D10)
(M0 = ON) -> (ADD D10 D3 D11)
(M0 = ON) -> (ADD D11 D4 D12)

Example :
Keypad is pressed :
first : Numeric 5 pressed -> 5 multiplied by 1000 = 5000
second : Numeric 2 pressed -> 2 multiplied by 100 = 200
three : Numeric 1 pressed -> 1 multiplied by 10 = 10
four : Numeric 4 pressed -> 4 multiplied by 1 = 4
Sum all the data : 5000 + 200 + 10 + 4 = 5214
So,Password from the keypad is 5214

Step 6 :
Check the number of digits
a.If D30 = 4 (4 times the keypad is pressed) Then M2 = ON

Step 7 :
Correct Password And UnLock Door
7.1. Correct Password
a.If X012 = ON (ENTER key is pressed) Then PLS M4 = ON (ENTER Down)
b.If M4 = ON (ENTER Down) AND M2 = ON AND Value(D12 = D20) Then SET M3 = ON
7.2. UnLock Door by Correct Password
c.If M3 = ON AND M7 = OFF AND T0 = OFF Then M6 = ON (Hold UnLock)
7.3. UnLock Door by Door Exit Button
d.If X014 = ON (Door Exit Button) AND M7 = OFF AND T0 = OFF Then M6 = ON (Hold UnLock)
7.3. UnLock Door
e.If M6 = ON Then Y000 = ON (UnLock Door)

Step 8 :
Lock Door by Door position
a.If X013 = ON (Door Closure Sensor) Then PLS M7 = ON
b.If M7 = ON Then M6 = OFF
c.If M6 = OFF Then Y000 = OFF (Lock Door)

Step 9 :
Lock Door by Timer
a.If Y000 = ON AND X013 = ON (Door Closure Sensor) Then Activate the Timer T0
b.If T0 = ON Then M6 = OFF
c.If M6 = OFF Then Y000 = OFF (Lock Door)

Step 10 :
a.If M0 = ON AND M3 = ON (Correct Password) Then RST M3 (M3 = OFF)
b.If M7 = ON AND M3 = ON (Correct Password) Then RST M3 (M3 = OFF)
c.If T0 = ON AND M3 = ON (Correct Password) Then RST M3 (M3 = OFF)

Please Download Programming for GX Developer :
Lock Unlock Door Using Mitsubishi PLC

See : Lock Unlock Door

Review of Available Portable PLC Training

There are two tools for training systems, commercially available ones and those proposed by education. A review of both is useful. Portable training systems commercially available fall generally into two categories:
• Hard wired “kits”;
• Simulators.

Hard wired “kits”
A kit generally contains of a PLC incorporating banks of switches to simulate input devices and lamps to simulate output devices [5]. They do not facilitate interfacing industrial electrical components to the PLC. They are useful for teaching programming only, for experienced programmers to explore new programming techniques and for black box software testing. They do not for students of entry level programming, provide the experience of selecting and connecting actual components to the PLC and generating the Input / Output (I/O) List to document those connections. The I/O List is a vital part of the documentation required for effective program design and maintenance.

Simulators
Simulators may be sub-divided further in to two categories: PC based using an actual PLC. Simulators generally have a range of industrial processes (“virtual machines”) such as “pick and place” and “tank level control systems”. The programmer chooses a “virtual machine” from a menu, writes the program to control it and downloads it to the PLC. The simulator PC communicates serially with the PLC simulating the “virtual machine”. The PLC and the machine or processes are both “virtual” in the second type that is no physical PLC exists. Same as with the system previously the programmer selects a “virtual machine” from a menu, writes the control program on the PC based “virtual PLC”. The “virtual machine” is then controlled by the “virtual” PLC.

Generally Simulators can be used effectively for engineering training. However, for PLC training, as with the hard wired kits the simulators are best exploited by students who have the applied skills required to interface the PLC to peripheral devices, have some programming skills and want to develop those programming skills. The simulators in common with the hardwired kits do not provide the practical experience of wiring up the PLC, interfacing it to peripheral devices and generating the electrical drawings and the I/O List to document the system.

Training System of Portable PLC

The Programmable Logic Controller is a robust industrial computer which accepts input data, both digital and analogue, from switches and sensors and controls outputs to drive devices such as motors, pneumatic devices and status indicators. At its most basic the PLC substitutes relay logic circuits, at its most advanced it can implement Proportional Integral and Derivative (PID) control algorithms over networks. While the Programmable Controller is by far the most common process control mechanism in the manufacturing spectrum of large to small business it has also found a niche in environment control, food processing, mining and in automated test equipment.

Programmable controllers were developed in the U.S. for the motor manufacturing industry in the 1960s. They appeared in the Irish industrial scene By the late 1970s. Today due to their increasing sophistication and falling costs they are to be found in the smallest production environment. The programming environment PLC may be dedicated terminal or a Personal Computer (PC). Latterly, with the event of the range of programming languages defined by IEC 6-1131 the PC is the favoured programming environment. Ladder Logic (LL) is currently the most popular language. There is however, anecdotal evidence that the other defined languages are slowly gaining acceptance.

As the PLC is part of a system automated there are several modules that should be included, or be a prerequisite, in any course. Those modules are design of electrical, software engineering, and in some cases, mechanical design. Software engineering together with applying a SLDC (Software Development Life Cycle) approach to the system being designed and the ability to write the control program. Electrical design encompasses design of electrical panel (and construction) to the relevant standard. The PLC is apart being run as a “stand alone” course is now an integral part of courses ranging from agricultural engineering to mechatronics and industrial automation. PLC courses, such as control engineering courses, must deliver “a balance of practical skills and theoretical knowledge” and as such are laboratory based.

Increasingly, in response to demands from industry PLC courses are being run in-house, in training rooms, away from the traditional venue of the automation laboratory using hardwired “kits” and PC based simulators.

PLC for Custom-design of a PID/PWM Program

The use of a DSP (Digital Signal Processor) to evaluate the actual value of an analogue process output and then compute a correction signal has many benefits. Digital Signal Processor does not suffer from the long-term drift effect that analogue circuits do. Changes to constants can be made easily without the actual physical change to the circuitry and simply modifying the loaded program or loading a new one can alter radically the mode of control. Realizing techniques of PWM and other advanced functions is some of the vast power points of digital controllers. In most cases DSPs are created to replace the ON-line analogue ones. This provides the continuous approaches to implement digitally the traditional analogue control modes such as PID actions.

Because of the advantages of the PLCs, a PLC type S7-200 was utilized as a DSP. Currently most modern sequential control systems are based on PLCs, which are in fact specialized industrial computers. Thus, the goal of this project is to design a PLC program for PID control algorithm and to develop it to get at the PLC output a PWM signal proportional to the value at the output of PID controller. In this case there is no require for a DAC IC nor for a specific power amplifier stage. Here the PWM signal that has the power static switch emulates the function of a D-type power amplifier. From another side, with the designed interface board, one can exclude the implementation of a high cost proprietary power interface module, this simplifies the circuit and reduces its cost.

PLC manufacturers are very often to provide the option of analogue I/O and support instant PID functions for extra cost. Such functions can be used immediately by entering the control parameters and constants. This feature is able to use if the analogue I/O module is installed. Therefore PID algorithm was created instead of using a ready one. This, also, offers more flexibility to use the program with those PLCs, which do not support ready PID loops. Designed I/O board satisfies our demands and costs one third of the I/O module's cost approximately.

InduSoft Import Wizard for RSLogix 5000

This article describes the interfaces provided in InduSoft Web Studio (IWS) to exchange data with ControlLogix PLCs from Allen-Bradley:
• InduSoft Import Wizard for RSLogix™ 5000 CSV Database: Using this tool, the user can import the tag names and the communication settings from the PLC program. IWS creates not only the tags in the Application Tags Database but also the communication driver worksheet automatically. This interface reduces the time invested dramatically to integrate the SCADA/HMI software with the ControlLogix PLC and reduces (or eliminates) the configuration error (e.g.: misaddressing).
• Driver of ABCIP Communication: This driver implements the CIP protocol over Ethernet/IP and exchanges data with the ControlLogix PLC during the runtime, using the tag names configured in the PLC project.

IWS allows you to create or add to a Tags database by importing tags from an external application database, including:
1. Other InduSoft Web Studio databases
2. OPC Server databases
3. CSV databases
4. ODBC databases
5. PanelBuilder Import Wizard
6. Database of RSLogix 5000 CSV, including Allen-Bradley RSLogix CSV files

To begin, you have to specify the type of database source you are going to use.
• Choose RSLogix 5000 CSV from the Source Type list, and then click the Next button.
• Click a radio button in the Options panel when the next Wizard screen displays

This interface enables the user to import the Tags Database and the communication interface configuration from the ControlLogix/FlexLogix PLC program files, including Allen-Bradley RSLogix CSV files. Before using this interface, you must export the project configuration using RSLogix 5000 programming software:
Tags Database: Open the project of PLC with RSLogix 5000 programming software. Right-click on the folder of Controller Tags, and choose the Export Tags option from the pop-up menu. Make sure to select the RSLogix 5000

Import/Export File (*.CSV), this option is in the Save as Type combo-box and the All Tags in Project in the Scope box. Select the Export button to create the CSV file with the Tags Database configuration. The Import Wizard makes the tags on the Tags Database and creates the communication driver worksheets automatically.

User-Defined Tags: Open the project of PLC with RSLogix 5000 programming software. Select File->Save As from the main menu. Make sure to select the RSLogix 5000 Import/Export File (*.L5K) option in the Save as Type box. Select the Save button to create the L5K file with the User-Defined Tags configuration.

Translation From FBD Into VeriLog

IEC 61131-3 FBD is a network of function blocks executed sequentially according to a (their) predefined order. In this section, we define the FBD programming language as a state transition system and propose FBDVerilog translation rules in a bottom-up manner. Explains function block translation, which is a unit of FBDs. Unlike “primitive” function blocks whose translation rules are straightforward, some FBD features cannot be mapped directly.

Function Block Translation
A function block is defined as a tuple composed of Name, input ports IP, output ports OP, and its behavior description BD as defined in Def. 1. IP and OP are the official terms used in IEC 61131-3. The behavior of a function block is defined as a set of predicates and assignments on input and output ports, respectively. A function block is a function from an input variables set, which are assigned to ports of input of the function block, to (usually) one output variable, which is assigned to one output port.

Definition Function Block
A function block is defined as a tuple FB = < Name, IP, OP, BD >, where Name: a name of function block IP: a set of input ports, {ip1, ip2, … , ipn} OP: a set of output ports, {op1} BD: behavioral description Σ(pFB, aFB), where - pFB : a predicate on IP - aFB : assignments on OP Let VFB-I = {v1, v2, ..., vn} be a set of function block input variables which has n input ports, and VFB-O = {vo} be a set of function block output variables. If we define Ii as a set of input domains of the input variable vi (1<=i<=n) and IFB = I1 I2 ... In, and also OFB = Oo in the same way, then a function block is defined as follows: fFB: IFB OFB.

PLC Programs Written In FBD

Software safety is an important issue for embedded real-time control systems such as those found in nuclear power plants. When verifying safety-critical software, formal methods play critical roles in demonstrating compliance to regulatory requirements. The Korea Nuclear Instrumentation & Control System R&D Center (KNICS) project1 used the NuSCR formal specification language and tool-set to formally specify and verify software requirements for reactor protection systems (RPS) for the Advance Power Reactor-1400 (APR-1400). During the design and implementation phases, programmable logical controllers (PLC) software were written in IEC 61131-3 Function Block Diagram (FBD), and software safety was verified thoroughly. Each release of FBDs becomes official only when authorities have verified the software; two types of formal verification, model checking and equivalence checking, were applied to our FBDs. While the former examined whether or not FBD meets required properties, the latter determined behavioral equivalence between two FBD revisions.

Units of equivalence checking can vary from a small module to a whole system, and verification tasks fulfill various needs of FBD programmers and safety engineers. Formal verification contributes to the demonstration of the software safety of PLC programs written in FBD. This paper proposes how the Verification Interacting with Synthesis (VIS) system can automatically verify FBDs. VIS is widely used in hardware analysis, and with its Verilog front-end, it is also suitable for software analysis. VIS supports computational tree logic (CTL) model checking, language emptiness checking, combinational and sequential equivalence checking, cycle-based simulation, and hierarchical synthesis.

Although we explored the possibility of using VIS's sequential equivalence checking and simulation to verify FBD programs for the Advance Power Reactor-1400 (APR-1400) RPS, we chose Cadence Symbolic Model Verifier (SMV) for model checking because VIS's CTL model checking has restrictions when specifying properties. To enable VIS's equivalence checking using VIS, we first defined the semantics of FBD as a state transition system and developed rules for translating FBDs into semantically equivalent Verilog. We also implemented the FBD Verifier 1.1 software tool to automate the translation and then used it on a subset of FBDs for APR-1400's RPS. We found VIS equivalence to be effective.

Technical IA 130 PLC Module

The IA 130 can be used to perform basic exercises on a PLC (programmable logic controller). A PLC is essentially a computer adapted to the needs of industry. Its inputs and outputs are not designed for humans, but for use in the control of machines. Machine and operator interact solely by way of limit switches, momentary-contact switches or photoelectric switches. The front panel is built as a laboratory patch board, where the input ports and output ports of the PLC can be connected to switches and displays via laboratory cables. In order to write programs the PLC must be connected to a PC (not supplied) via an RS232 interface.

The PLC programming software conforms to the international standard IEC 61131-3, and permits programming in the following languages: Statement List (STL), Ladder Diagram (LD), Structured Text (ST) and Function Block Diagram (FBD). Ladder Diagrams are based on graphical representations with contacts, coils and boxes, as per the circuit diagrams. Function Block Diagram language is based on graphical representation of the interlinking of logical function blocks, analogous to the logic diagrams. Statement List is an assembler-type language with a small, standardized non-hardware-dependent command set. Structured Text is a language similar to PASCAL, with mathematical expressions, assignments, function calls, iteration, condition selection, and PLCspecific add-ons. An example program is included in the module. IA 130 can be used as a control element in conjunction with electrical, pneumatic or hydraulic applications, such as with the handling device IA 210 or the mixing process RT 800.

The good-structured instructional material sets out the fundamentals and provides a step-by-step guide through the experiments.
• Familiarization with a PLC
• Familiarization with the essential fundamentals such as
a. Boolean algebra
b. compiling statement lists
c. interconnection diagrams and block diagrams
• Exercises in
a. programming
b. logical "AND" / "OR" gates
c. logic relays
d. output and input
• Configuration of program sequences by way of connectors, incorporating
a. timers
b. counters
c. cascade circuits
d. Higher-order monitoring relays etc.
• Fault finding

CLICK Programming Software PLC

CLICK Programming Software can be downloaded at no charge or a CD version may be purchased. The CLICK Programming Software is built to be a user-friendly application, and the tools, layout, and software interaction provide ease-of-use and quick learning. The simple operation of this software allows users to develop a ladder logic program quickly. The online help file gives information that will help you get acquainted with the software quickly.

PC requirements
CLICK PLC Windows-based programming software works with Windows® 2000 Service Pack 4, XP Home or Professional, or Vista (32 bit). These are the minimum system requirements:
• Personal Computer with a 333 MHz / higher processor (CPU) clock speed recommended; Intel Pentium/Celeron family or AMD K6/Athlon/Duron family, or compatible processor recommended.
• SVGA 800x600 pixels resolution. (1024x768 pixels resolution recommended)
• 150MB free hard-disk space
• 128MB free Ram (512MB recommended)
• CD-ROM or DVD drive for installing software from the CD
• USB port or 9-pin serial port for project transfer to PLC (USB port communications also requires USB-to-serial converter)

CLICK PLC Programming
Software
Includes software on CD-ROM and software installation manual. Free download available from the Web includes the manual in pdf format. Cable sold separately. Windows 2000/XP(Home/Pro)/Vista required.
Powerful features
CLICK Programming Software has amazingly powerful features for a free software product, such as
• Address picker
• Separate subroutine and interrupt routine features
• Rung comment feature

Address picker
The Address Picker is a high performance multi-function memory table which can be used to assign nicknames, create address comments, and establish initial values for specific memory locations. It can assign specific memory locations to be retentive during power outages. The Address Picker also has a high performance tools for sorting the memory table and making it easier to use.

Subroutine feature
Subroutines can be created to isolate a body of program code that is run selectively.

Rung comment feature
Create and edit rung comments easily with colors and three text styles.

Implementation of EPICS PLC

The vxWorks driver code contains the tags in scan lists depending on the requested update rate. One thread per PLC handles all read/write requests. EPICS device support allows binary, analog and multi-bit records to use the driver for input and output. Tags must refer to a value of scalar, a single array element or a structure element, not whole arrays or structures. The data types PLC BOOL, SINT, INT, DINT and REAL are handled.

One can change the configuration record at runtime, without rebooting the IOC, e.g. the tag name that a record refers to can be replaced. In case of a communication timeout or error, the driver disconnects from the PLC and attempts periodic reconnects. The driver combines requests as per default for array elements into one array transfer from the first to the highest requested element. This leads to a significant improvement in transfer times, but might have side effects: The IOC will always write the whole array whenever more than one element has been changed by output records. If the same PLC array has been modified by another source (PanelView display) since the last transfer, the IOC is unaware of these changes and will overwrite them. A transfer of array is also size-limited by the aforementioned PLC buffer limit.

The record configuration allows separate array element transfers as a workaround for these cases. The driver sends a CIP_Write_Data message for output records whenever the record is processed. Otherwise it will read the tag from the PLC and update the output record periodically if the value on the PLC differs from the one in the record. The driver keeps statistical information (error counts, last/minimum/maximum transfer time) for each scan list. Analog input records allow access to these values. One problem arose with BOOL arrays since they are transferred as DINT values. For an analog record, a tag of “test” is interpreted as addressing the 5th element of tag “test”. When this is applied to a BOOL array, the result would be the 5th DINT, containing bits 160-191. So for binary records, all array access is assumed to target BOOL arrays, and “test” would be transformed in a request to DINT[0], bit 5. This software has been tested on 68K, PPC and Pentium IOCs. The lower driver layer handles the different byte order.

ControlLogix PLC over Ethernet/IP

The Allen-Bradley ControlLogix line of Programmable Logic Controllers (PLCs) offers several interfaces:
Ethernet, ControlNet, DeviceNet, RS-232 and others. The interface of ControlLogix Ethernet module 1756-ENET uses EtherNet/IP, the ControlNet protocol, encapsulated in Ethernet packages, with specific service codes. The Experimental Physics and Industrial Control System (EPICS) driver has been developed that utilizes this EtherNet/IP protocol for controllers running the vxWorks RTOS as well as a Win32 and Unix/Linux test program. Features, limitations and performance of this interface are presented.

ControlNet is a deterministic serial communication system, its specification extends from the physical to the application layer of the seven layer ISO OSI model. ControlNet Release 2.0 introduced the TCP/IP encapsulation of data packages, replacing the Physical and Data Link layer with Ethernet respectively IP/UDP/TCP. The result was known as “ControlNet over Ethernet” and is now called EtherNet/IP.

Several subsystems of the Spallation Neutron Source project (SNS) employ Allen-Bradley ControlLogix PLCs. To integrate these into the EPICS-based accelerator control system, the EPICS input/output controllers (IOCs) need read and write access to the PLC data. Their Unix or Win32 boot hosts as well as almost every PC which is used to program the PLC is already equipped with an Ethernet interface, it is desirable to use the same technology for transferring the PLC data. Existing support and knowledge for cabling, network hardware, configuration and maintenance can thus be utilized.

Unconnected messaging is used since the advantages of connected messaging do not transfer from Control- Net to EtherNet/IP: Ethernet does not reserve bandwidth; guaranteed delivery is already handled by TCP. For CIP_Read_Data requests, comparison of connected to unconnected messaging resulted in slightly smaller messages and a 3% increase in throughput. As a drawback, the client application has to send requests at the established update interval of the connection or faster. Temporary Ethernet delays cause the PLC to close the connection. The ControlLogix Multi-Request Service (0x0A) is used to combine CIP_Read/Write_Data requests until either the total request or expected response size reaches the PLC buffer limit of approximately 500 bytes.

The INFORMA ISO-PLC Editor

Starting the package of INFORMA from the Matlab Command window is possible to activate the INFORMA ISO-PLC Editor that allows the user to quickly develop new specification using the FBD language. From the user viewpoint the main steps of an ISO PLC model design are:
• To open of an existing model or creation of a new one
• To add blocks to the scheme them from the available libraries
• Eventually definition of new blocks:
o Generic block: the PLC user can specify the block functionality using a high level language (i.e. C code), while the graphical aspect is standard;
o Customized block: the user can specify both the aspect and the functionality, acting on the Petri Net specification;
o Library block: a customized block can be added to the libraries and made available for future employment;
o Saving of the specification carried out.
In what follows the main element of editing are introduced together with their syntactic role.

Session
A SESSION is a operating window where it is possible to draw block diagram. The whole of sessions is structured dynamically.

Block
Blocks are the basic elements of the notations. There are three kinds of: normal, task, and session, all based on the same structure. Normal blocks are operational. They perform logical or mathematical operations (e.g., AND, +), or they control input/output (e.g. load, store). Task blocks describe the software architecture in terms of scheduling strategy. Session blocks represent new sessions. While sessions graphically describe the code to be executed, tasks are operative units. Predefined task types are: Daemon, Interrupt, Main, and Exception. The main task is executed periodically. At each cycle it calls the related sessions. A main task is always offer in a specification and can be interrupted only by tasks of higher priority, e.g., a daemon task.

A task of daemon has the highest priority level and is executed according to a predefined timing. It is impossible to assign the same priority to more than one daemon task. An exception task takes the CPU control on an exception. For individual task it is possible to specify several sessions, obtaining a tree structure. The information go through among the blocks is represented by lines displayed using the color of the related type of data.

Standardized Safety Function Blocks of PLCopen

Currently, the PLCopen workgroup has specified 19 safe function blocks regarding their inputs/outputs, state engine, error recognition and error handling. These blocks include important safety functions such as Emergency Stop, Safety Door, Mode Selector and Two-Hand Control. Based on the PLCopen specification, providers of safe automation systems can implement and certificate these blocks considerably easier. The exemplary mentioned blocks are already today part of the safe programming system SAFEPROG which has been successfully certified within the scope of the Phoenix Contact Interbus Safety Platform.

The correct use of safe function blocks according to the PLCopen is simplified for the PLC programmer by the manufacturer-embracing functionality. This also includes the low need for training and the easier transferring of programmed safety functions to different PLC system. A further advantage is the low effort arising for the commissioning staff when validating the PLC program, as parts of the safety logic are based on already certified software modules. KW-Software will be one of the first companies starting the implementation of the PLCopen safe function blocks. In 2005, 10 safe software blocks are expected to be provided by KWSoftware within a library in the programming system SAFEPROG.

Clear separation of safe and non-safe functions
To avoid a possible mistaking of safe and non-safe data types (variables), the data type SAFEBOOL was defined in the PLCopen specification. The data type SAFEBOOL can only be used in combination with safety-relevant software blocks. Corresponding plausibility checks – as they are implemented in SAFEPROG – should be performed by the programming system. To meet the programming guide lines described in the PLCopen specification, the graphic editor in the engineering software should support the safety-relevant programming by means of suitable measures. This can be done by displaying the different function block types with different colors, by marking non-safe data types (variables) - as shown in figure 3 - as well as by further plausibility checks in the graphic editor.

PLCopen safety specification

In the past, the embedded software (runtime system, operating system) and the hardware of safety relevant automation solutions were already intensely proofed by certification authorities. However, the functionality of a safety controller can only be completely used together with the related engineering software. But particularly in the field of safety-related application software, there are no integrated requirements. This results in the fact that a large part of today's engineering software tools have a non-uniform user interface and operation and different safety function characteristics. Another aggravating fact is that most of the existing engineering software does not fulfill current safety technology quality standards such as the IEC 61508. The reason for this dates back several years, because within the scope of the former standards DIN VDE 0801 and EN954-1, only little attention was paid to the application software. As a result, PLC programmers as well as certification authorities must deal again and again with the most different safety logic occurrences. In the user's view, the definition of a uniform standard for safety-relevant application software is a right and important step.

Within the context of the PLCopen, a specification for standardizing safety-focused application software was worked out by the PLCopen members – most of them are leading manufacturers of safety controllers or according programming tools – together with external organizations (BGIA, TÜV Rheinland). A preliminary version of this specification was presented at the Hanover Fair for the first time. The aim is to release this specification by the BGIA and TÜV Rheinland until the SPS/IPC Drives Fair in Nuremberg. Essentially, the specification describes the standardization of safe function blocks and the standardized use of these blocks in an engineering software tool. The following sections describe the most important contents in an exemplary way.
These include:
• Safe function blocks
• Safety data types
• Recommendations for programming guide lines
• Graded user levels

The Multiprog PLC Main Concepts

Multiprog is a system of standard programming for international Electro-Technical Commission (IEC) designed PLC and conventional PLC. According to the standard IEC61131-3, and includes the full range of IEC features. Multiprog makes all functions easily accessible via a menu, and can generate a project with a few dialogues. Having finished that, the students can immediately start developing a program. The IEC61131-3 standard is the modern approach for a wide range of programmable automation and control systems, not just PLC. Because the programming is now standardized, the teaching of programming becomes largely independent of the actual hardware being utilized. Moreover, the techniques learned and programs that are subsequently developed can be transferred between systems from different manufacturers.

Program Organization Units (POUs) are the crux of program development based on IEC61131-3. They can be categorized into three types, Functions (FUN), Function Blocks (FB) and Programs (PROG). A FUN is defined as a program organization unit that yields exactly one data element when executed. A FUN does not contain internal memory. The same arguments always yield the same output. An FB can process some outputs, and consist internal state information. Every function block instance has a structure with internal data, the inputs or default input values, and output, last output or default output values.

The use of blocks has two advantages. First, the interface has to be defined exactly, which means that the block operation and behavior also have precise definitions. The second is linked to the programmer’s skills. The code can be written with any of the five languages that the standard defines. The standard contains five different languages, which can be mixed within an application. It contains three graphical languages: 1) Sequential Function Chart (SFC); 2) Function Block Diagram (FDB); and 3) Ladder Diagram (LD); and two text-based languages: 1) Structured Text (ST) and 2) Instruction List (IL).

Special Operations (P-A/D) of GE Fanuc NSP

After pressing “F” (the function key) on the SOI-260 or “MODE” (the mode key) on the SOI-120, one of the menu items is labeled “Special”. This item provides access to the Point-Access/Display (P-A/D) feature. The P-A/D feature gives you access to all the unrestricted programmable controller addresses. With this access, addresses may be displayed and/or modified. This feature is extremely useful in start-up or debugging sessions of programs or regular programmable controller operations. After pressing “MODE” (SOI-120) or “F” (SOI-260), a Special Security Screen may be displayed (it has to be created with the SOI-SPS Programming Software). You must enter one of the three programmed security codes to continue to the Special Operations menu screen.

Point-Access/Display on the SOI-120

To display or modify programmable controller addresses from the SOI-120:
1. Press “MODE” (the mode key) on the SOI-120 keypad.
2. Select “Special” (item 3) from the menu that appears. If a Special Security Screen appears, enter any one of the programmed security codes.
3. Press “Bypass” (item 0), unless you want to Edit (item 1) the GE Fanuc network address.
4. Select “P-A/D” (item 1).
5. Select “NEXT” until the data type you want to display or modify appears (see Table 5.1), and then press “¿” (the enter key).
6. Select the address you want to display or modify, and then press “¿” (the enter key). Alternatively, you can press “F1” and “F2” to decrement and increment the address shown. For 16-bit registers with read/write access, you can press “PREV” or “NEXT” to move you between the address and the data fields so you can enter new data.
7. Press “¿” (the enter key) to load new data into the programmable controller. This new data is displayed immediately.

Note: Pressing “MENU” returns you to the main menu at any point.

Trouble shooting of GE Fanuc SNP

This chapter of the GE Fanuc SNP Communications Reference provides solutions to possible problems with the SOI-120 and SOI-260 and their use with the GE Fanuc SNP communications protocol. Typically, any problems that occur involve communications between the SOI-120 or SOI-260 and the PLC. The communications software used to communicate with the PLC has passed critical compliance tests, usually eliminating the software as a possible source of a problem. The only other possible sources are the cabling and the communication port parameters involved (baud rate, etc.). The communication parameters must be identical for both the SOI-120 or SOI-260 and the PLC. The cabling and the communications port parameters are always the first things to check. You can check the communications port parameters either from the SOI or from the SOI-SPS programming software. If the cabling and communications parameters are correct, put the SOI- 120 or SOI-260 in Self-Test mode to rule out any non-functioning features of the SOI.

The below screens appear on the SOI to indicate a problem:

Establishing Comm
Attempting to communicate to PLC. Action: None. Normal display when initiating communications with the PLC.

PLC ERR MJ/MN:0000
Communications not established with the PLC. This is displayed after attempting to establish communications with the PLC and fails after three (3) tries). (Refer to footnote for further details.) Action: Check cabling and communications parameters to verify that the PLC matches those of the SOI-200. Perform the Self-Test function if the Comm port is suspected.

COMM ERROR MJ/MN:0000
Press Any Key
Communication to the PLC was lost after three attempts. Action:
Check SOI-to-PLC cabling. Check PLC operating conditions.
The SOI reports the Major/Minor errors codes as received from the GE SNP PLC. If the major and minor error codes are nonzero the error code is defined by the GE SNP. Otherwise, if zero, the SOI did not detect a response from the PLC.

PROGRAMMING GE Fanuc SNP

The GE Fanuc SNP Communications Reference covers the following:
• supported GE Fanuc PLC registers
• supported SOI-120 and SOI-260 screen types and parameters
• GE Fanuc-specific configuration parameters

Supported Data Formats
The data format selected for a particular programmable controller memory location must reflect the correct format for the data actually stored in that location. This is the only way you can ensure that correct, consistent information is displayed on the SOI-120 or SOI-260. For instance, selecting a 16-Bit Hex format for one location will display data in one way. Selecting a 16-Bit Signed Integer format for the same location will display the data in another way. It is critical to understand each data format and its characteristics.

The programmable controller saves a binary (0 or 1) status for a bit location. The SOI will read a programmable controller bit location and determine whether the operational status of the bit is ON (1) or OFF (0). You can create the text to be displayed on the screen of the SOI-120 or SOI-260 for either state of a specified bit. This text can be up to twenty characters.

For instance, the OFF (0) state of a bit might display “Pump is OFF,” and the ON (1) state “Pump is ON.” SOI-SPS allocates enough screen characters for the longest of the two text strings. In this example, 12 characters would be allocated to display “Pump is OFF.” The fewer characters used, the less memory is required. In the example above, displaying "OFF" (given the appropriate context) conveys the same information in 3 characters as "Pump is OFF" does with 11 characters.

16-Bit Signed Integer
This data type displays a 16-bit register as a signed Integer (two’s complement) value. The register of the 16th bit is the sign bit and is set (1) for a negative and cleared (0) for a positive number. The 16-bit signed integer values have a range of -32768 to +32767.
This data format might be scaled within the SOI-120 or SOI-260 to different engineering units.

16-Bit Unsigned Integer
This format data displays a 16-bit register as an Unsigned Integer value. It shows a positive number by using the 16th bit as a data bit rather than a sign bit. The values of 16-bit Unsigned Integer have a range of 0 to +65,535.

Connecting to the GE Fanuc PLC

The SOI may be linked to the GE Fanuc PLC via the programming port or one of the SNP capable ports in an optional GE Fanuc Communications Coprocessor Module (Contact Spectrum Controls for information on interfacing to the CMM using Modbus protocol.)

Series 90-30 Resistor Termination:
The port of PLC communication Receive Data differential pair must be terminated as indicated if the PLC is either the first or last drop on the SNP bus. This is always the case in a point-to-point configuration. However, PLCs may be connected as multiple drops. Do not link the resistor termination if the PLC is not the first or last drop on the SNP bus.

Shield Ground:
The shield has to be grounded at the first drop on the SNP bus. Connect the SOI communication port pins 5 and 9, if the SOI is the first drop on the bus. Link pins 1 and 7 on the PLC port, if the PLC is the first drop on the bus. Do not link the shield to ground on more than one unit (SOI or PLC) on the SNP bus.

SOI Resistor Termination:
The port of SOI communication Receive Data differential pair must be terminated as indicated if the SOI is either the first or last drop on the SNP bus. This is always the case in a configuration of point-to-point n. However, multiple PLCs may be linked to the SNP bus. Do not link the resistor termination if the SOI is not the first or last drop on the SNP bus. The SOI will only link to and communicate with a PLC regardless of how many are attached to the SNP bus.

Outputting Printer Forms (SOI-260 only)
You can use the SOI-260’s optional printer port to output Printer Forms to a printer or other serial device, such as a large ASCII display unit. Printer forms are created in the SOI-SPS programming software and may include production reports, alarm messages, instructional text, etc.

GE Fanuc Series Six I/O CPU

In 1990, GE Fanuc introduced the Series 90–70 system, which incorporated a VME-based CPU and a complete line of I/O and specialty modules. The VME architecture allowed GE Fanuc to introduce third-party VME processing and specialty cards into the 90-70 backplane, greatly expanding the capabilities of the system for specific applications.

One specialty card for the 90–70 is an interface card that allows a 90–70 CPU to control Series Six I/O over the high-speed parallel I/O bus, a significant feature of the Series Six I/O structure. Use of the Series Six I/O interface card has significant impact on today’s Series Six users:
• The Series Six CPU can be removed and a 90–70 CPU, housing the I/O interface card, can directly interface to the local or remote Series Six I/O – there is no need to remove any of the I/O wiring, modules, racks or panels.
• The Series Six CPU program can be converted to 90–70 language with identical functionality.
• A majority program conversion can be completed and tested off-site, minimizing system downtime to change out the CPU rack itself.
• The 90–70 CPU can support Series Six I/O,90–70 I/O, and Genius I/O simultaneously. • Existing Series Six I/O can be replaced with 90–70 I/O or Genius I/O at any time in the future, minimizing machine downtime and spreading out the retrofit costs.

There have been some successful conversions using these techniques. Below are three case studies of the Series Six to 90–70 CPU conversion, each outlining a different client advantage.

A steel mill was operating a Series Six systems number in various applications. A plant-wide project required access to all PLCs via the Ethernet network on the factory floor for monitoring purposes. The first Series Six to be converted consisted of one CPU rack and seven I/O racks mounted in remote panels. Phase one of the project involved converting the Series Six program to 90–70 logic and testing the functionality to the system specifications. This first phase was completed off-site. In the second phase, the Series Six CPU rack was removed from the original panel and the 90–70 CPU rack with the Series Six interface card was installed in its place.

Extending the Life Of GE Fanuc Series Six PLC System

How much the cost is possible to totally replace a 20-year-old PLC system with hundreds or even thousands of I/O points in multiple racks in a critical process? Plenty. Besides buying all new hardware and enclosures and programming software, you would need to rebuild all the panels, ring out the I/O wiring, rewrite the PLC code, not to mention the cost of downtime required to changeover the field wiring and to troubleshoot the new system.

Not many PLC manufacturers will be excited about such a project. But what benefits could a new PLC provide over the 20-year-old version? Ethernet connectivity, faster processing speeds, more memory, more robust instruction set, and programming software that runs on today’s operating systems. But these are all CPU functions – why should you have to tear out your whole system when all you really need is better CPU.

Qualitrol International offers a conversion program whereby any Series Six CPU can be replaced with a current GE Fanuc Series 90–70 CPU.A special interface card residing in the 90–70 CPU rack interfaces directly to the Series Six parallel I/O structure. No field I/O requires to be rewired and the conversion can be done with minimal system downtime and with assurance that the new system will work as well, if not better, than the existing control system.

As the conversion result, the new system will have the following features:
• More set of robust instruction, including trigonometric functions, PID function blocks, and parameterized subroutines
• User defined C programming function blocks
• Programming via any standard laptop computer
• Programming software that runs on recent Operating Systems
• Ethernet communications fully supported
• Readily available spare parts
• Future expansion capabilities
• No require to remove existing Series Six I/O modules, racks, or power supplies
• No elimination of field wiring
• Use of existing CPU cabinets
• Specialty cards and third party processing can be added to the 90-70 CPU rack for increased system functionality

Panasonic PLC Programming Software of FPWIN Pro

FPWIN Pro is developed of the Panasonic programming software according to the international standard IEC 61131-3 (for Windows® 2000/XP/Vista). This is a new version resulting of experience gained over many years. It was one of the first manufacturers of PLC to offer an IEC 61131-3 programming software, and we are a leading member of the international organization PLCopen.
• One software for all FP-series PLCs
• 5 programming languages: LD (Ladder Diagram) , FBD (Function Block Diagram ), IL (Instruction List), SFC (Sequential Function Chart), ST (Structured Text)
• 6 languages are fully supported: English, French, Italian, German, Spanish and Japanese
• Good structured through program organization task, units and project management
• Service, remote programming, and diagnostics via Ethernet or modem
• Online documentation and extensive comments created hand in hand with the program
• Minimum program size through optimized compiler
• Powerful monitoring and debugging tools provide information on the current status of the PLC
• Support for function blocks and Comprehensive printed documentation and libraries help to get your hardware running in record time while maintaining rigorous quality standards
• Reuse of functions and function blocks saves time

Reuse of functions and function blocks saves programming and debugging time
In FPWIN Pro, Panasonic gives a unique concept for using function blocks and functions from libraries. The programmer can create his own or use a variety of ready-made libraries for standard routines and special applications. These libraries shorten the time needed drastically to develop applications, and consequently save valuable human resource costs. All Panasonic libraries include a complete online help file and programming examples.

Easy configuration dialogs
FPWIN Pro gives easy to use dialogs for easy configuration of the PLC, e.g. the screen display of the FP-e. You can check the configuration result directly with the display in the dialog.

Powerful compiler options
You can specify the FPWIN ProMemory areas by simply adjusting the sliders.

Features FP-07C Handheld Programming Panel and Training Box

Features of FP-07C handheld programming panel:
• Easy to use and portable, with copying, status monitoring, program editing and debugging functions, most suitable for field maintenance.
• Change mode working only by a single keystroke, without having tedious exit process from current working mode.
• Adopt super capacitor to keep data and program when power lose, convenient for loading data and register from multiple PLCs.

Training Box Features:
• It consists the basic items required by PLC digital I/O training, such as the FBs-24MCT highly functional main unit, the FBs-CM25E Ethernet module, digital input socket, simulated switches, and digital output socket. Including in the same kit are advanced application peripherals like encoder and stepping motor (coupled with belt for transmission), seven segment display, 10 large-diameter (10mm) LED indicators, thumbwheel switches, and keyboard. It reduces greatly the time and manpower used in wiring and resource management of teaching.
• The built-in RS485, RS232 and the Ethernet three ports (can be expanded to five with communication boards) not only enable the teacher’s computer to connect with the training kits of all students to conduct networking on-line teaching such as loading, monitoring, modifying, and storing, but also can be used in advanced course such as computer connection, intelligent ASCII peripherals as well.
• A special software “WinProladder teaching assistant” can let instructor download or upload ladder program to or from the PLC of the whole class or individual through computer. Instructor is able to perform monitoring, instruction and modification, and collect and save student's homework periodically with “WinProladder teaching assistant“, The teaching software is especially suitable for examination and contest and is the best choice for network teaching.
• The output of PLC is isolated by the relay with socket and fuse and then output to terminal. These isolations can prevent PLC from break down caused by incorrect wiring and easy for repair and replacement.

PLC Simulator Using FX Mitsubishi Trainer

Step 0
Download FX Mitsubishi Trainer
Goto 4shared.com or google.com and Search with keyword
FX Mitsubishi Trainer

Step 1
Main menu screen for PLC Simulator or MELSOFT FX TRAINER :

Step 2
Click Category tabs -> (A) Let's Learn the FX Series PLC!
Click Button Menu ->
A-3. Let's play a Little
Play a little and start writing a program

Step 3
3.1. See Ch1 (Let's Write a Program) in Guidance Window
3.2. Click button Edit Ladder in Remote Control
3.3. The PROGRAM indicator lamp should be lit in Remote Control
Remarks:
1. Remote Control
2. Guidance Window
3. Ladder Program Area
4. Ladder Tool Section
5. I/O Image Table for monitoring RUN status in the virtual PLC
6. Operation Panel
7. 3-D Graphic Simulation Virtual Manufacturing cell window

Step 4
Write a Program in Ladder Program Area
using Ladder Tool Section for Write a Program

Step 5
Convert this program with Press the F4 Key

Step 6
The program can be written to the PLC
Click Write to PLC in Remote Control

Step 7
Hide Guidance Window

Step 8
Ready in Simulated

For Download Video : click here

Program Testing and Documentation of FATEK FBs-PLC

Program Testing
• Provides multiple pages of status monitoring. User can monitor and modify the status of discrete contacts and registers on the status page. Each discrete input and output (include the internal relay) can be disabled and forced on or off. Each register can be selected individually to show with different format such as hexadecimal, decimal and binary. Best of all, all the layout of the status pages can be stored in the project and there is no need for user to re-define the page each time when he/she wants to monitor the status.
• Multiple high lighted ladder program display windows. The conducting condition of each contact element can be revealed by the color of the element drawing. The register value embedded with the function block also can be shown currently with ladder diagram. The discrete element can be easily disabled and forced on or off directly from the ladder diagram.

Program Documentation
• Provides discrete element, register, network, and program unit and project comment. Besides the project comment all other comments can be displayed with ladder diagram. With this feature the user can easily realize how the ladder program is working.
• Provides following report printout function:
The printed out of ladder diagram can select the scope and detail level of the ladder diagram for different kind of reporting requirements. Used ladder element cross-reference report can list the statistics of all ladder elements used in the project.
• The comment of the contact and register can be created by this software or by using text editor that were familiar with user. Comments can be imported from the text file and also can be exported to the application software such as Excel for further processing.
• The network of ladder program can be copied to other editing software such as Word by using copy and paste function. With this feature, can facilitate the documentation of program when use the editing software.