SIEMENS FILLING programming procedure step by step

Editor's Notes

• #1: Contents Page Use of Analog Modules ……............................................................................................................ 2 Measuring Range Modules .............................................................................................................. 3 Analog Module Addresses with S7-300 …....................................................................................... 4 Analog Module SM335 (Inputs) …................................................................................................... 5 Analog Module SM335 (Outputs) .................................................................................................... 6 Analog Input Module SM331 ........................................................................................................... 7 Analog Value Representation and Measured Value Resolution ....................................................... 8 Analog Value Representation of Different Measuring Ranges ....................................................... 9 Scaling Analog Input Values ......................................................................................................... 10 Unscaling a Real Number for Analog Output .................................................................................. 11 Analog Value Representation for the Analog Outputs ...................................................................... 12 Exercise: Assigning Parameters to the Analog Module SM335 ....................................................... 13 Exercise: Assigning Parameters to the Analog Module SM331 ....................................................... 14 Exercise: Controlling the Level in a Tank …………......................................................................... 15 Exercise: Diagnostic Interrupt from an Analog Module ..................................................................... 16
• #2: Principle In a production process, there are a variety of physical quantities (pressure, temperature, speed, rotational speed, pH value, viscosity, etc.) that need to be processed in the PLC for automation purposes. Sensor Measuring sensors respond to changes in the quantity to be measured by linear expansion, angular ductability, alteration of electrical conductivity, etc. Transducer Measuring transducers convert these above-mentioned changes into standard analog signals, such as: ± 500mV, ± 10V, ± 20mA, 4...20mA. These signals are supplied to the analog input modules. ADC Before these analog values can be processed in the CPU, they must be converted to digital form. This is done by the ADC (Analog-to-Digital Converter) on the analog input module. The analog-to-digital conversion is performed sequentially, that is, the signals are converted for each analog input channel in turn. Result Memory The result of the conversion is stored in the result memory and remains there until it is overwritten by a new value. The converted analog value can be read with the Load instruction “L PIW...”. Analog Output The Transfer instruction “T PQW...” is used to write the analog values calculated by the user program to an analog output module, where a DAC (Digital-to-Analog Converter) converts them to standard analog signals. Analog Actuators with standard analog input signals can be connected to the analog output modules direct.
• #3: Type of Measurement You set the type of measurement and the measuring range by setting coding keys on the measuring range module. Special modules without coding keys have different terminals for voltage and current measurement. Thus, the type of measurement can be set by wiring the appropriate terminal. Measuring Range The measuring range modules with their coding keys are located on the left- Module hand side of the module. You must set them correctly before installing the module. The possible settings are “A”, “B”, “C” and “D”. The settings for the various types of measurement and measuring ranges are printed on the module. Channel Groups On some modules, several channels are grouped together to form a channel group. In this case, the coding key setting applies to the whole channel group.
• #4: Address Area The S7-300 has a special address area for analog inputs and outputs, which is separate from the process image input and output tables for the digital modules (PII/PIQ). This address area extends from byte 256 to byte 767. Each analog channel occupies 2 bytes. Access You access the analog modules by means of Load and Transfer instructions. Example: The statement “L PIW256” reads the first channel of the first module in rack 0. S7-400 On the S7-400, the address area for the analog modules starts at byte 512.
• #5: Diagnostic Interrupt When the diagnostic interrupt is activated and a hardware fault occurs, such as a power supply failure, a diagnostic interrupt (OB 81) is triggered. As well, you must specify in the "Diagnostics" field which inputs are to be monitored. A wire break check is only possible with 4 to 20 mA power inputs. Scan Cycle Time The scan cycle time is the time it takes for the module to process ("convert") all the activated analog inputs once. The setting for the scan cycle time for A/D conversion can be between 0.5ms and 16ms. When it has processed all the analog inputs, the module can trigger a hardware interrupt (= End of Cycle interrupt) (only if a scan cycle time for conversion longer than 1ms has been selected). Note Unused inputs must be short-circuited on the hardware and "Deactivated" in the software. Deactivated analog inputs reduce the scan cycle time! Measuring Range When the type of measurement and the measuring range have been selected, Module the necessary coding key setting on the measuring range module is displayed. Example: For the measuring ranges selected in the slide above, the measuring range module must be inserted in position “C”. Resolution The analog inputs of the SM 335 have a resolution of 13 bits + sign, the analog outputs 11 bits + sign.
• #6: Note Unused output channels must remain open on the hardware (not be short-circuited like the analog inputs) and be “deactivated” in the software.
• #7: Parameters You can set two groups of parameters for analog input modules with the “HW Config” tool: Module as a Whole • Diagnostic Interrupt: If the “Group Diagnosis” checkbox has been activated and a diagnostic event occurs, the relevant information is entered in the diagnostics data area of the module and the diagnostic interrupt (OB82) is triggered. The analog module can detect the following diagnostic events: - Configuration/ parameter assignment errors - Wire break (if "With Wire Break Check" is activated) - Above measuring range - Below measuring range - No load voltage L+ • Hardware Interrupt when Limit Value Exceeded If the input value exceeds the range set by the entries for "Upper Limit Value" and "Lower Limit Value", the module triggers a hardware interrupt. Note: Only the first channel in a group can monitor the input value for violation of the selected limit values! Individual Inputs • Type of Measurement: When you click this box, the possible types of measurement (voltage, current...) are displayed. For unused channels or channel groups you select the "deactivated" option. You must connect these channels to chassis ground on the module • Measuring Range: When you click this box, the possible measuring ranges for the type of measurement selected are displayed. • Coding Key Setting: A very specific setting of the measuring range module becomes necessary when you select the type of measurement and the measuring range. This is displayed here. • The integration time and interference frequency suppression are interdependent (see next page).
• #8: Representation Analog values are represented as the two's complement. The value is positive if bit No. 15=0 and negative if bit No.15=1. Resolution If the resolution of an analog module is less than 15 bits, the analog value is written into the accumulator left-justified. The unused less significant bit positions are filled with “0”s. Integration Time The resolution is specified indirectly by selecting an integration time with the “HW Config” tool. The following table for the SM331 illustrates the relationship between integration time, resolution and interference frequency suppression: Integration time Resolution Interference frequency suppression (ms) (in bits) (Hz) 2.5 9 + sign bit 400 16.6 12 + sign bit 60 20 12 + sign bit 50 100 14 + sign bit. 10 Accuracy Resolutions of between 8 and 15 bits are possible, depending on the type of module. Conversion Time The conversion time depends on the conversion procedure used in the module (integrating procedure, successive approximation). The conversion times of the different modules are given in the S7-300 manual. Example: The SM344 has a conversion time of only 5 ms for all 4 input channels.
• #9: Voltage, Current Encoding the symmetrical voltage or current ranges (Symmetrical) • ± 80mV • ± 2.5 V • ± 3.2 mA • ± 250 mV • ± 5V • ± 10 mA • ± 500 mV • ± 10V • ± 20 mA • ± 1 V results in a rated range of -27648 to +27648. Voltage, Current Encoding the asymmetrical voltage or current ranges (Asymmetrical) • 0 to 2 V • 0 to 20 mA • 1 to 5 V • 4 to 20 mA results in a rated range of 0 to +27648. Resistance Encoding the resistance ranges • 0 to 150 Ohm • 0 to 300 Ohm • 0 to 600 Ohm results in a rated range of 0 to +27648. Temperature Temperatures are measured with resistance thermometers or thermocouples. Encoding results in a rated range of ten times the temperature range: Sensor: Temperature range: Rated range when encoded: • Pt 100 -200 to + 850 ºC -2000 to + 8500 • Ni 100 -60 to + 250 ºC -600 to + 2500 • Thermocouple type K -270 to + 1372 ºC -2700 to + 13720 • Thermocouple type N -270 to + 1300 ºC -2700 to + 13000 • Thermocouple type J -210 to + 1200 ºC -2100 to + 12000 • Thermocouple type E -270 to + 1000 ºC -2700 to + 10000.
• #10: Example The level in a tank is to be measured in liters. The measuring transformer was chosen in such a way that 500 liters have an analog value of 10 V. Scaling The analog module encodes the analog value 10 V as the integer value 27 648. This value now has to be converted to the physical quantity “liters”. This is known as “scaling” the analog value. Program Standard block FC 105 is used for scaling analog values. FC 105 is supplied with the STEP 7 software in the library "Standard Library" in the S7 Program "TI-S7 Converting Blocks". IN The analog value at input IN can be read in from the module direct or read from a data interface in INTEGER format. LO_LIM, HI_LIM Inputs LO_LIM (low limit) and HI_LIM (high limit) are used for specifying the limits for conversion to physical quantity. In the example the reading is scaled to the range 0 to 500 liters. OUT The scaled value (physical quantity) is stored as a real number at output OUT. BIPOLAR The input BIPOLAR determines whether negative values are also to be converted. In the above example, memory bit M0.0 has a signal "0" and thus indicates that the input value is unipolar. RET_VAL The output RET_VAL has the value 0 if execution is free of errors.
• #11: Example The user program calculates an anaolg value in the range 0 to 100.0%. This value is to be output via an analog output module. Unscaling Standard block FC106 is used for unscaling (conversion of a real number from 0 to 100.0% to a 16-bit integer between 0 and 27648). OUT The unscaled analog value at output OUT can be transferred in the form of a 16-bit integer to a data interface or to the module direct. Program FC 106 is supplied with the STEP 7 software in the library "Standard Library" in the S7 Program "TI-S7 Converting Blocks".
• #12: Voltage, Current For symmetrical voltage or current ranges a rated range of Symmetrical -27648 to +27648 is converted to: • ± 10V • ± 20mA. Voltage, Current For asymmetrical voltage or current ranges a rated range of Asymmetrical 0 to +27648 is converted to: • 0 to 10V • 1 to 5V • 0 to 20mA • 4 to 20mA. Overflow If the value to be converted reaches the overflow range, the analog output module is disabled (0V, 0mA).
• #13: Note Depending on which analog module is in your training unit, you are to do either this exercise or the one on the following page. Goal To get to know how to change the settings and parameters of analog modules. What to Do Change the settings of your analog module to correspond to those in the slide.
• #14: Note Depending on which analog module is in your training unit, you are to do either this exercise or the one on the previous page. Goal To get to know how to change the settings and parameters of analog modules. What to Do Change the settings of your analog module to correspond to those in the slide.
• #15: Task The tank has a maximum capacity of 600 liters. The level is measured using a measuring transducer. It has an analog value of 10 V when the maximum level is reached. This analog value is to be converted to a physical quantity (number of liters) using the FC 105 block. If the level goes below the minimum 50 liters, the output Q 9.2 (Q 5.2) is to flash until the level is once more 50 liters or more. The first potentiometer on the simulator specifies the level. What to Do 1. Create an FC 20 block in the S7 program "FILL" according to the task. 2. Call FC 20 in OB 1 as well. 3. Download the FC 20, FC 105 blocks and the OB1. 3. Test your program.
• #16: Task Solve the problem shown above using the diagnostic interrupt OB82 and the diagnostics capability of the analog input module. Note If you want to specifically evaluate which channel is in the overflow range, you have to use a system function here. What to Do 1. Write a program for OB82 in the S7 program "FILL" according to the task. 2. Supplement the program in OB 1 to control the output Q 9.1 or Q 5.1. 3. Test your program.