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IEC 61131-3 Hands on Training

IEC 61131-3 Hands on Training. Evolution of Control Technology. PLC. PC Based Ctrls. 1950 s 1960 s 1970 s 1980 s 1990 s 2000 20011. Relays. The Future of Automation. Current. Future. FALCON. Simpler, more cost effective Single source supplier

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IEC 61131-3 Hands on Training

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  1. IEC 61131-3 Hands on Training

  2. Evolution of Control Technology PLC PC Based Ctrls 1950s 1960s 1970s 1980s 1990s 2000 20011 Relays

  3. The Future of Automation Current Future FALCON • Simpler, more cost effective • Single source supplier • Single software package (4 vs. 1) • Decreased maintenance costs • Lower installation costs

  4. System Architecture Ethernet Production control

  5. Graphical User Interface Editor Configuration Utility Visual BASIC I/O Drivers Graphical User Interface Communication Drivers HMI I/O Driver Tool Kit Symbol Server Toolkit Software Architecture Program Editor Logic Engine D L L D L L Open XP Environment

  6. Program Editors • IEC 1131-3 Language Support • Ladder Diagram, Sequential Function Chart, Structured Text, Instruction List • Windows based Editing Tools • Familiar Tool Bars, Displays & Key Commands • On-line Help throughout • On-line and Off-line Editing • Simulate program without actual I/O Easy Program Editing

  7. FALCON Workshop • IEC-1131 Overview • International Standard of the International Electrotechnical • Commission (Global programming standard). • Specifies the syntax and semantics of a unified suite of • programming languages for programmable controllers • (IEC-61131-3). • Graphical Languages • Ladder Diagram (LD) • Function Block Diagram (FBD) • Sequential Function Chart (SFC) • Textual Languages • Instruction List (IL) • Structured Text (ST)

  8. Diagnostic Tools • On-line editing and debugging. • “Watch Window” allows display and forcing of variables and view of actual program status. • On-line Help Menu with contents and search capability. • Application specific message boxes driven by program. • System event logging. • I/O Status bits Increases Productivity

  9. I/O &Communication Drivers • I/O • Popular network • Cost effective IO solution • Supports up to six interfaces simultaneously • Motion Control • See brochure for complete list Ethernet Communication to 6 networks at the same time

  10. Profibus DP DeviceNet EtherNet I/P Interbus-S CAN-Open SERCOS Modbus RTU Modbus TCP/IP SIRPLEX AS-I AB RIO AB DH, DH+ I/O &Communication Drivers • GE 90/30 • GE Genius • Beckhoff TCP/IP • Yaskawa Remote I/O • Opto-22 Parallel • OptoMux • COM 1-4 Serial Channels • Wonderware • GE Cimplicity • Intellution FixDMAX • Visual Basic 6.0, .Net • CMC PCI I/O Interface Partial List of Device Drivers

  11. Real Time Motion Control • The FALCON provides motion connectivity to the popular motion experts -Standard Motion Control Algorithms -Flexible to meet the users needs -Cost effective IO solution -RTE providing Real Time Control Communication to 6 networks at the same time

  12. Complete Development Sys. Programming in SFC, Ladder Diagram and Structured Text Graphical User Interface Runtime Engine unlimited number of I/O

  13. Logic Engine • Runtime Logic Engine • unlimited I/O points (digital or analog) • with or without FALCON GUI. • Executes LD, SFC+ and ST programs • Monitoring and change of data values (but not editing) Logic Engine • Includes Drivers for: • Modbus TCP/IP

  14. User Interfaces / Toolkits • HMI (third party) • High-End User Interface/Distributed Structure /Historical capabilities • Full Featured HMI offering • FALCON Graphic User Interface • Embedded Graphical User Interface (GUI) • Easy to implement • Low cost HMI • Common database • High performance • Toolkits • Function Block Toolkit • Visual Basic Toolkit: License free applications

  15. Product Family • FALCON Software Only • FALCON Loaded on 15’’ Color Touch (3 PCI) • Pro Series (Enclosed Box with IO) • Service (PC Selection 10 or 15, Loading and Configuration, Telephone Support)

  16. Key Points • Real-time Control with Integrated HMI, I/O, OI, Motion and Diagnostics • One-Stop Shopping of Products and Services Open software environment on PC Platforms on XP • IEC 61131-3 Standard • Scaleable PC Environment • HMI Choices- Low-end HMI, HMI, Visual BASIC • Programmable Machine Diagnostics • Reduced hardware, engineering and total life cycle cost

  17. System Overview Hardware Structure FALCON is built upon a standard PC hardware platform. The main CPU provides both the application programming environment and application program execution (run time).

  18. Hardware Architecture • Mix different manufacturers process & motion control • FALCON runs under Windows XP as a protected user application • Drivers for each type of I/O are provided • Use standard PLC I/O • No PLC needed PLC

  19. System Overview Software Subsystem Program Editor/ Debugger Operator Interface Configuration Utility Program Manager Program Execution I/O Scanner

  20. Starting FALCON Starting the Program Editor • Access Levels: • Five Levels : 0-4 • “4567” default for level 4 • Level 0: Activate operator screens and controls in the GUI. • Selecting and running SFC programs. • Level 1: Running/Aborting RLL programs, viewing RLL/ • SFC programs. • Level 2: Editing SFC programs and executing project • management functions • Level 3: Editing RLL, modifying GUI, and modifying system • configuration files. • Level 4: Changing the passwords for access levels 1 - 4.

  21. Working with Projects About Projects: Project Management allows the user to organize the Work into logical divisions called projects: Program files Configuration files Operator Interface files

  22. Controlling I/O with FALCON Configuration Utility Overview The configuration files tell FALCON what interface cards are in the computer, and what I/O are attached to those cards. System Slot Board Profibus DeviceNet Connector Port I/O Point

  23. Create New System Configuration • Hands On Exercise • Page 10- 12

  24. Multitasking – I/O Scan Rate PLC Overhead I/O Scan Logic Outputs Limited capacity

  25. Multitasking – I/O Scan Rate I/O Scan Rate I/O Logic Other App’s FALCON Runtime HMI, Network or ? PC Allow enough time to solve logic and service the other applications. Expandable capacity

  26. Sequential Function Chart (SFC) SFC Overview Editor • Steps • Macro Steps • Actions • Transitions • Jump Labels • Jumps • Loops • Select Diverge • Simultaneous Diverge • Application Icon • Add Comments • Structured text in Steps • Step variables • Boolean or LD Transitions • Scaleable display • On-line changes

  27. SFC- Example

  28. SFC- Example Transition 1 Transition 3 Transition 2 Step 2 Step 3 Step 4 Transition 4 Transition 5 Transition 3 Transition 2 Step 3 Step 4 Selective Divergence Selective Convergence Transition 1 Step 2 Transition 3 Transition 2 Transition 3 Step 3 Step 4 Step 3 Step 4 Transition 4 Simultaneous Divergence Simultaneous Convergence Common Sequences

  29. Step System Variables Step_is_active(X) – STEP1.X - X = TRUE when active Step time(T) - STEP1.T - T = Elapsed time of step milliseconds T set to Zero at step start

  30. Creating an SFC • Hands On Exercise • Page 17

  31. Symbols/Data Types Symbol Mgr Overview The Symbol Manager allows the user to create and manage symbols for use in RLL or SFC programs.

  32. Symbols and Data Types Symbol Data Types • TIME • Timer (TMR) • User-Defined Data Type • PID Data Type • PID Inputs and Outputs • PRGCB Data Type • Pre-Defined System Symbols • REAL • Integer (INT) • Double WORD (DWORD) • WORD • BYTE • Boolean (BOOL) • DATE • Time of Day (TOD) • STRING

  33. Symbol Manager ? • Symbol Types: • Local – Used in program where defined only. • Global – Available to all programs in project. • Operator Interface and DDE • External – I/O Points

  34. Symbol Data Types MSB 0 LSB 7 • BOOL - Boolean (TRUE=1, FALSE=0) • BYTE – Unsigned integer 8 bit • Range 0 to 255 • DATE – D#YYYY-MM-DD • YYYY = 1970 to 9999 • MM = 1 to 12 • DD = 1 to 31 • TODAY = Current date

  35. Symbol Data Types • DWORD - Unsigned integer 32 bit • Range 0 to 4294967296 • INT – Integer • 32 bit word • Range –2146483648 to +2147483647 • REAL – Decimal • 64 bit word • Range +1.401298 E-48 to +3.402823 E38 LSB 31 MSB 0C

  36. Symbol Data Types • String – ASCII characters • ASCII characters within “This is a valid string” • Hex - $41 $42 $43 = A B C • TIME – T# • D or d – Days T#1D2h: 1 day and 2 hours • H or h – Hours t#26H: 26 hours • M or m – Minutes t#5m45s: 5 minutes and 45 seconds • S or s – Seconds t#26s200MS: 26 Seconds and 200 milliseconds • MS or ms – Milliseconds T#900ms: 900 milliseconds

  37. Symbol Data Types • TMR – Timer • Timer_name.PT = Real data value in seconds or T# format • Timer_name.EN = Boolean, will stop/start TMR • Timer_name.ET = elapsed time in seconds of TMR • Timer operations • Timer_name.EN = sets .ET to zero when TMR starts • Timer_name.ET = when equal to preset then Timer_name.EN is reset • Timer_name.EN = set to false then Timer_name.ET is frozen at the last value • Timer_name.ET = may be read any time

  38. Symbol Data Types • TOD – Time of Day • TOD#HH:MM:SS • HH = 0 to 23 • MM = 0 to 59 • SS = 0 to 59 • NOW – Current system time • MOVE to define NOW • ADD to add a duration to NOW

  39. Symbol Data Types LSB 15 MSB 0 • UINT/WORD • 16 bit unsigned integer • Range – 0 to 65535 • User-Defined Data Types • Groups of data types • Integers, Boolean, Strings…

  40. Symbol Data Types • System Created Symbols • TODAY, NOW, NULL, TMR • Counters - RLL counters status – CTU, CTD, CTUD (Local) • Timers – RLL timer status – TOF, TON, TP (Local) • “stepname”.X - SFC STEP Active/inactive status (Local) • “stepname”.T – SFC STEP elapsed execution time (Local) • Motion Control – Status of axis, axis variable group, Program control and spindle • File Control – Status of file operations • Program Control – Status of PRGCB data types

  41. Symbol Data Types • Run-Time Symbols • RT_ERROR – (INT) Math error • 0 = No error • 1 = divide by zero • 2 = negative square root • RT_ERROR must be cleared by the user • RT_FIRST_SCAN – (BOOL) • Set to true on first scan of first program to run • RT_SCAN_OVERRUN – (BOOL) • I/O scan + logic scan exceeds scan rate • RT_MAX_SCAN – (REAL) • Duration in ms of maximum scan duration

  42. Symbol Data Types • Run-Time Symbols • RT_LAST_SCAN – (REAL) • Duration in ms of last scan duration • RT_AVG_SCAN – (REAL) • Duration in ms of average scan duration • RT_LOGIC_MAX – (REAL) • Duration in ms of maximum logic scan duration • RT_LOGIC_LAST – (REAL) • Duration in ms of last logic scan duration • RT_LOGIC_AVG – (REAL) • Duration in ms of average logic scan duration

  43. Symbol Data Types • Run-Time Symbols • RT_IO_MAX – (REAL) • Duration in ms of maximum I/O scan duration • RT_IO_LAST – (REAL) • Duration in ms of last I/O scan duration • RT_IO_AVG – (REAL) • Duration in ms of average I/O scan duration • RT_MEM_PCT – (REAL) • Remaining system RAM allocated to the PC control software

  44. Symbol Data Types • Run-Time Symbols • RT_LOW_BATTERY – (BOOL) • Low battery signal from UPS • RT_POWER_FAIL – (BOOL) • Power fail signal from UPS • RT_SCAN_RATE – (REAL) • Active configuration scan rate setting in ms

  45. Create Symbols Hands On Exercise Page 32 & 33

  46. Adding Logic to Transitions Transitions Overview • A Transition represents the condition that allows program flow to pass from one or more Steps preceding the transition to one or more Steps following the Transition • A Boolean Transition is a Boolean • expression composed of Structured • Text • An RLL Transition consists of a • single RLL rung with an output • coil having the same name as the • Transition itself

  47. Adding Logic to Transitions • Transitions • Boolean Transitions • Structured Text • RLL Transition • Single rung of RLL • Output coil with same name as the transition

  48. Transition Evaluation • RLL rung power reaches coil and turns it on, Transition is true then the program flows to next step. • Boolean expression resolves to TRUE, Transition is true then the program flows to next step. More…

  49. Transition Evaluation • Step function must complete before the transition is evaluated • Transition holds FALSE the system will remain in the transition until it becomes TRUE.

  50. Transition Evaluation • Two I/O scans minimum per SFC step to complete • Execute the Step logic • If the Logic is completed move to step 2 • Evaluate the transition • If the transition is True the step is deactivated and released to the next step

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