Learning System for Automation and Communications Programmable logic Controllers Workbook Basic level 093314 Order No.SPS FPC GS Designation: D.S301-C-FPC-A-GB Edition: 12/1995 Layout: 7. Ebel © Copyright by Festo Didactic KG, D-73734 Esslingen, 1995 All rights reserved, including translation rights. No part of this publica- tion may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic. 3 Preface The Festo Didactic Learning System for Automation and Communica- tions is designed to meet a number of different training and vocational requirements, and the training packages are structured accordingly: Basic packages convey basic knowledge spanning a wide range of technologies Technology packages deal with important areas of open and closed-loop control technology Function packages explain the basic functions of automated systems Application packages provide basic and further training closely oriented to everyday industrial practice The modular design of the learning system permits applications beyond the limits of the individual packages.
PLC actuation, for example, is therefore possible of pneumatic, hydraulic and electrical actuators. All learning packages have an identical structure: Hardware Teachware Software Courses The hardware consists of industrial components and installations adapted for didactic purposes. The courseware is matched methodologically and didactically to the training hardware. The courseware comprises: Textbooks (with exercises and examples) Workbooks (with practical exercises, worksheets, supplementary notes, solutions and data sheets) Overhead transparencies and videos (as a visual means of teaching support) The teaching and learning media are available in several languages.
They have been designed for use in classroom teaching, but can also be used for self-study purposes. In the software field, computer-based training programs and programm- ing software for programmable logic controllers are available. Festo’s Didactic range of products for basic and further training is com- pleted by a comprehensive selection of courses matched to the con- tents of the technology packages. Festo Didactic • TP301 4 Layout of this workbook The workbook is structured as follows: Section A – Course Section B – Fundamentals Section C – Solutions Section D – Appendix Section A – Course teaches the programming of programmable logic controllers with the help of a series of progressive exercises.
Any necessary technical knowledge required for the implementation of an exercise is provided at the beginning. Functions are limited to the most elementary requirements. More detailed knowledge may be gained in section B. Section C – Solutions provides the solutions to the exercises with brief explanations.
Section B – Fundamentals contains generally applicable technical knowledge to supplement the training contents of the exercises in Sec- tion A. Theoretical links are established and the necessary technical terminology explained with the help of examples. An index provides an easy means of locating terminology. Section D – Appendix which contains data sheets and a glossary serves as a means of reference.
TP301 • Festo Didactic 5 Technology package TP301. 11 Table of contents Component/exercise table. 13 Notes on safety. 16 Section A – Course Components of a programmable logic controller Exercise 1: Design and commissioning of a programmable logic controller Components of a PLC.
A-3 Programming to IEC 1131 Exercise 2: From problem to solution – taking into consideration IEC 1131-3 Practical steps for PLC programming. A-9 Basic logic operations Exercise 3: Lamp circuit The assignment function. A-15 Exercise 4: Burglar alarm The NOT function. A-25 Exercise 5: Press with protective guard The AND function.
A-35 Exercise 6: Bell system The OR function. A-45 Logic control systems without latching properties Exercise 7: Stamping device Combination of AND/OR/NOT. A-55 Exercise 8: Silo control system for two bulk materials Combination circuit with branching. A-65 Logic control systems with latching properties Exercise 9: Fire alarm Setting an output.
A-73 Exercise 10: Drill breakage monitoring Setting and resetting an output. A-81 Festo Didactic • TP301 6 Exercise 11: Activating a cylinder Signal edges. A-89 Logic control systems with time response Exercise 12: Bonding of components Pulse. A-101 Exercise 13: Embossing device Switch-on signal delay.
A-111 Exercise 14: Clamping device Switch-off signal delay. A-121 Sequence control systems Exercise 15: Lifting device for packages Linear sequence. A-131 Exercise 16: Lifting and sorting device for packages Alternative branching. A-147 Exercise 17: Stamping device with counter Counting cycles.
A-159 Section B – Fundamentals Chapter 1 Automating with a PLC .2 Fields of application of a PLC .3 Basic design of a PLC .4 The new PLC standard IEC 1131 .1 The decimal number system .2 The binary number system .3 The BCD code .4 The hexadecimal number system .5 Signed binary numbers .7 Generation of binary and digital signals. B-16 TP301 • Festo Didactic 7 Chapter 3 Boolean operations .1 Basic logic functions .2 Further logic operations .3 Establishing switching functions .4 Simplification of logic functions .5 Karnaugh-Veitch diagram. B-30 Chapter 4 Design and mode of operation of a PLC .1 Structure of a PLC .2 Main processing unit of a PLC .3 Function mode of a PLC .4 Application program memory .7 Programming device / Personal computer. B-46 Chapter 5 Programming of a PLC .1 Systematic solution finding .2 IEC 1131-3 structuring resources.
B-56 Chapter 6 Common elements of programming languages.1 Resources of a PLC .2 Variables and data types .3 Program organisation units. B-76 Chapter 7 Function block diagram .1 Elements of function block diagram .2 Evaluation of networks. B-94 Festo Didactic • TP301 8 Chapter 8 Ladder diagram .1 Elements of ladder diagram.2 Functions and function blocks .3 Evaluation of current rungs. B-99 Chapter 9 Instruction list .3 Functions and function blocks.
B-104 Chapter 10 Structured text. B-115 Chapter 11 Sequential function chart .2 Elements of sequential function chart. B-143 Chapter 12 Logic control systems .1 What is a logic control system.2 Logic control systems without latching properties.3 Logic control systems with latching properties .3 Switch-on signal delay .4 Switch-off signal delay. B-167 TP301 • Festo Didactic 9 Chapter 14 Counter .4 Incremental/decremental counter.
B-178 Chapter 15 Sequence control systems.1 What is a sequence control system .2 Function chart to IEC 848 .3 Displacement-step diagram. B-186 Chapter 16 Commissioning and operational safety of a PLC .2 Operational safety of a PLC .1 The need for communication .4 Communication in the field area. B-198 Appendix Bibliography of illustrations. B-202 Bibliography of literature.
B-203 Guidelines and standards. B-209 Festo Didactic • TP301 10 Section C – Solutions Section D – Appendix Data sheets Signal input, electrical. 011088 Signalling device and distributor, electrical. 030311 Single-acting cylinder.
152887 Double-acting cylinder. 152888 On/off valve with filter regulator valve. 152896 Proximity sensor, inductive. 152902 Proximity sensor, capacitive.
152903 Proximity sensor, optical. 152904 Proximity sensor with cylinder mounting. 152905 5/2-way single solenoid valve. 152909 5/2-way double solenoid valve.
152910 Terminal unit for binary I/O. D-3 TP301 • Festo Didactic 11 Technology package TP301 "Programmable logic controllers" The technology package TP301 "Programmable logic controllers" is a component part of the Festo Didactic Learning System for Automation and Communications and forms the basic level of TP300. The training aims of TP301 are to learn how to program programmable logic controllers and to teach the fundamentals for creating programs in the programming languages ’ladder diagram’ (LD), ’function block diag- ram’ (FBD), ’instruction list’ (IL), ’structured text’ (ST) and ’sequential function chart’ (SFC). Programming is effected in accordance with IEC 1131-3.
You have the option of using this workbook in conjunction with alterna- tive programmable logic controllers by different manufacturers. Solution- s are available for Festo FPC100 programmable logic controllers, Siemens S5-95U, AEG A120 and Mitsubishi Melsec A1S. The exercises in this workbook may be carried out with either of two different equipment sets, i. a plug-in assembly board or a slotted assembly board version.
A basic knowledge of electro-pneumatics and sensor technology is recommended to work through technology pack- age TP301. The exercises in TP301 deal with the following main topics: Components of a programmable logic controller PLC programming to IEC 1131 Basic logic operations Logic control systems Sequence control systems The allocation of components and exercises can be seen from the fol- lowing component/exercise table. Festo Didactic • TP301 12 Allocation of component and exercise Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Signal input, electrical 1 1 1 1 1 1 1 1 1 1 1 1 1 Signalling device and 1 1 1 1 1 distributor, electrical Proximity sensor, optical 1 1 1 1 1 Proximity sensor, inductive 1 1 1 1 1 Proximity sensor, capacitive 1 1 1 1 1 Proximity sensor with 1 4 4 4 4 cylinder mounting 5/2-way single solenoid 1 1 2 1 1 1 1 2 2 2 valve 5/2-way double solenoid 1 1 1 valve Double-acting cylinder 1 1 2 1 2 2 2 Single-acting cylinder 1 1 1 1 1 1 On/off valve with filter 1 1 1 1 1 1 1 1 1 1 regulator valve Manifold 1 1 1 1 1 1 1 1 1 1 TP301 • Festo Didactic 13 Equipment set TP301, Slotted assembly board, Order No.: 080 261 Description Order No. Quantity Signal input, electrical 011 088 1 Signalling device and distributor, electrical 030 311 1 Proximity sensor, optical 152 904 1 Proximity sensor, inductive 152 902 1 Proximity sensor, capacitive 152 903 1 Proximity sensor with cylinder mounting 152 905 4 5/2-way single solenoid valve 152 909 2 5/2-way double solenoid valve 152 910 1 Double-acting cylinder 152 888 2 Single-acting cylinder 152 887 1 On/off valve with filter regulator valve 152 894 1 Manifold 152 896 1 Plastic tubing 151 496 Quick push-pull distributor 036 315 optional, not included in scope of delivery of equipment set Power supply unit 151 503 Set of cables 030 332 Plug-in adapter 035 651 Festo Didactic • TP301 14 Equipment set TP301, Plug-in assembly board, Order No.: 080 260 Description Order No.
Quantity Signal input, electrical 011 088 1 Signalling device and distributor, electrical 030 311 1 Proximity sensor, optical 150 758 1 Proximity sensor, inductive 150 757 1 Proximity sensor, capacitive 150 759 1 Proximity sensor with cylinder mounting 030 331 4 5/2-way single solenoid valve 030 315 2 5/2-way double solenoid valve 030 317 1 Double-acting cylinder 013 415 2 Single-acting cylinder 011 711 1 On/off valve with filter regulator valve 011 758 1 Manifold 011 713 1 Plastic tubing 006 204 Quick push-pull distributor 006 831 optional, not included in scope of delivery of equipment set Power supply unit 151 503 Set of cables 030 332 TP301 • Festo Didactic 15 Notes on safety The following notes should be followed in the interest of safety: Mount all components securely on the board. Do not switch on compressed air until all line connections have been established and secured. Proceed with care when switching on the compressed air. Cylinders may advance or retract as soon as the compressed air is switched on.
Switch off air supply immediately if air lines become detached. This prevents accidents. Do not disconnect air lines under pressure. Do not exceed the permitted working pressure of 8 bar.
Observe general safety regulations in accordance with DIN 58 126 and VDE 0100. Use only extra-low voltages of up to 24 V DC. Observe the data sheets referring to the individual components, in particular all notes regarding safety. Festo Didactic • TP301 16 Operating notes The following rules should be observed when constructing a circuit: Block output 2 of the valve, if a single-acting cylinder is actuated by a 5/2-way single solenoid valve in a circuit.
4(A) 2(B) 5(R) 3(S) 1(P) Plug for output 2 of a 5/2-way valve Input signals, which would result from an actual production process sequence, are reproduced in part by signals via push buttons or switches.