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IEC-61131-3-Programming-Industrial-Automation-Systems-Karl-Heinz.pdf

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    Cover
    IEC 61131-3: Programming Industrial Systems, Second Edition
    ISBN 3642120148
    Preface of the 2nd revised edition
    Contents
    1 Introduction
    1.1 Subject of the Book
    1.2 The IEC 61131 standard
    1.2.1 Goals and benefits of the standard
    1.2.2 History and components
    1.3 The Organisation PLCopen
    1.3.1 Aims of PLCopen
    1.3.2 Committees and fields of activity
    1.3.3 Results
    2 Building Blocks of IEC 61131-3
    2.1 Introduction to the New Standard
    2.1.1 Structure of the building blocks
    2.1.2 Introductory example written in IL
    2.1.3 PLC assignment
    2.2 The Program Organisation Unit (POU)
    2.3 Elements of a POU
    2.3.1 Example
    2.3.2 Declaration part
    2.3.3 Code part
    2.4 The Function Block
    2.4.1 Instances of function blocks
    2.4.2 Re-usable and object-oriented FBs
    2.4.3 Types of variables in FBs
    2.5 The Function
    2.5.1 Types of variables in functions and the function value
    2.6 The Program
    2.7 The Execution control with EN and ENO
    2.8 Calling Functions and Function Blocks
    2.8.1 Mutual calls of POUs
    2.8.2 Recursive calls are invalid
    2.8.3 Extendibility and overloading
    2.8.4 Calling with formal parameters
    2.8.5 Calls with input parameters omitted or in a different order
    2.8.6 FB instances as actual FB parameters
    2.9 Summary of POU Features
    3 Variables, Data Types and Common Elements
    3.1 Simple Language Elements
    3.1.1 Reserved keywords
    3.2 Literals and Identifiers
    3.2.1 Literals
    3.2.2 Identifiers
    3.2.3 Comments
    3.2.4 Pragmas
    3.3 Meanings of Data Types and Variables
    3.3.1 From direct PLC addresses via symbols to variables
    3.3.2 The data type determines the properties of variables
    3.3.3 Type-specific use of variables
    3.3.4 Automatic mapping of variables onto the PLC
    3.4 Data Types
    3.4.1 Elementary data types
    3.4.2 Derived data types (type definition)
    3.4.3 Generic data types
    3.5 Variables
    3.5.1 Inputs, outputs and flags as special variables
    3.5.2 Multi-element variables: arrays and structures
    3.5.3 Assignment of initial values at the start of a program
    3.5.4 Attributes of variable types
    3.5.5 Graphical representation of variable declarations
    4 The Programming Languages of IEC 61131-3
    4.1 Instruction List IL
    4.1.1 Instruction in IL
    4.1.2 The universal accumulator (Current Result)
    4.1.3 Operators
    4.1.4 Using functions and function blocks
    4.1.5 IL example: Mountain railway
    4.2 Structured Text ST
    4.2.1 ST statements
    4.2.2 Expression: Partial statement in ST
    4.2.3 Statement: Assignment
    4.2.4 Statement: Call of function blocks
    4.2.5 Statement: RETURN
    4.2.6 Statement: Selection and Multi- selection
    4.2.7 Statement: Iteration
    4.2.8 Example: Stereo cassette recorder
    4.3 Function Block Diagram FBD
    4.3.1 Networks, graphical elements and connections of LD and FBD
    4.3.2 Network architecture in FBD
    4.3.3 Graphical objects in FBD
    4.3.4 Programming methods in FBD
    4.3.5 Example: Stereo cassette recorder
    4.4 Ladder Diagram LD
    4.4.1 Networks, graphical elements and connections (LD)
    4.4.2 Network architecture in LD
    4.4.3 Graphical objects in LD
    4.4.4 Programming methods in LD
    4.4.5 Example in Ladder Diagram: Mountain railway
    4.5 The American way of Ladder programming
    4.5.1 Network Layout
    4.5.2 Module addresses and memory areas
    4.6 Sequential Function Chart SFC
    4.6.1 Step / Transition combination
    4.6.2 Step - transition sequence
    4.6.3 Detailed description of steps and transitions
    4.6.4 Step execution using action blocks and actions
    4.6.5 Detailed description of actions and action blocks
    4.6.6 Relationship between step, transition, action and action block
    4.6.7 Action qualifiers and execution control
    4.6.8 Example: “Dino Park”
    5 Standardised PLC Functionality
    5.1 Standard Functions
    5.1.1 Overloaded and extensible functions
    5.1.2 Examples
    5.2 Standard Function Blocks
    5.2.1 Examples
    6 State-of-the-Art PLC Configuration
    6.1 Structuring Projects with Configuration Elements
    6.2 Elements of a Real-World PLC Configuration
    6.3 Configuration Elements
    6.3.1 Definitions
    6.3.2 The CONFIGURATION
    6.3.3 The RESOURCE
    6.3.4 The TASK with run-time program
    6.3.5 ACCESS declarations
    6.4 Configuration Example
    6.5 Communication between Configurations and POUs
    7 Innovative PLC Programming Systems
    7.1 Requirements of Innovative Programming Tools
    7.2 Decompilation (Reverse Documentation)
    7.2.1 No decompilation
    7.2.2 Decompilation with symbols and comments
    7.2.3 Decompilation including graphics
    7.2.4 Sources stored in the PLC
    7.3 Language Compatibility
    7.3.1 Cross-compilation
    7.3.2 Language independence
    7.4 Documentation
    7.4.1 Cross-reference list
    7.4.2 Allocation list (wiring list)
    7.4.3 Comments
    7.5 Project Manager
    7.6 Test & Commissioning Functions
    7.6.1 Program transfer
    7.6.2 Online modification of a program
    7.6.3 Remote control: Starting and stopping the PLC
    7.6.4 Variable and program status
    7.6.5 Forcing
    7.6.6 Program test
    7.6.7 Testing Sequential Function Chart programs
    7.7 Data Blocks and Recipes
    7.8 FB Interconnection
    7.8.1 Data exchange and co-ordination of blocks in distributed systems
    7.8.2 Macro techniques in FB interconnection
    7.9 Diagnostics, Error Detection and Error Handling
    7.10 Hardware Dependence
    9 Programming by Configuring with IEC 61499
    8 Main Advantages of IEC 61131-3
    8.1 Convenience and Security with Variables and Data Types
    8.2 Blocks with Extended Capabilities
    8.3 PLC Configuration with Run-Time Behaviour
    8.4 Uniform Programming Languages
    8.5 Structured PLC Programs
    8.6 Trend towards Open PLC Programming Systems
    8.7 Conclusion
    9.1 Programming by FB Interconnection with IEC 61131-3
    9.2 IEC 61499 – The Programming Standard for DistributedPLC Systems
    9.2.1 System model
    9.2.2 Device model
    9.2.3 Resource model
    9.2.4 Application model
    9.2.5 Function block model
    9.2.6 Creating an application
    9.3 Overview of the Parts of IEC 61499
    10 Contents of CD-ROM and DVD
    10.1 IEC Programming Systems STEP 7 and OpenPCS
    10.2 Buyer's Guide for IEC 61131-3 PLC Programming Systems
    A Standard Functions
    A.1 Type Conversion Functions
    A.2 Numerical Functions
    A.3 Arithmetic Functions
    A.4 Bit-Shift Functions
    A.5 Bitwise Boolean Functions
    A.6 Selection Functions for Max., Min. and Limit
    A.7 Selection Functions for Binary Selection and Multiplexers
    A.8 Comparison Functions
    A.9 Character String Functions
    A.10 Functions for Time Data Types
    A.11 Functions for Enumerated Data Types
    B Standard Function Blocks
    B.1 Bistable Elements (Flip-Flops)
    B.2 Edge Detection
    B.3 Counters
    B.4 Timers
    C IL Examples
    C.1 Example of a FUNCTION
    C.2 Example of a FUNCTION_BLOCK
    C.3 Example of a PROGRAM
    D Standard Data Types
    E Causes of Error
    F Implementation-Dependent Parameters
    G IL Syntax Example
    G.1 Syntax Diagrams for IL
    G.2 IL Example from Syntax Diagrams
    H Reserved Keywords and Delimiters
    H.1 Reserved Keywords
    H.2 Delimiters
    I Glossary
    J Bibliography
    K Index
    Author Biographies
    IEC 61131-3: Programming Industrial Automation Systems
    Karl-Heinz John · Michael Tiegelkamp IEC 61131-3: Programming Industrial Automation Systems Concepts and Programming Languages, Requirements for Programming Systems, Decision-Making Aids Second Edition 123
    Karl-Heinz John Irrlrinnig 13 91301 Forchheim Germany karlheinz.john@gmx Michael Tiegelkamp Kurpfalzstr. 34 90602 Pyrbaum Germany Michael.Tiegelkamp@gmx.de This book contains one Trial DVD. “SIMATIC STEP 7 Professional, Edition 2006 SR5, Trial License” encompasses: SIMATIC STEP 7 V5.4 SP4, S7-GRAPH V5.3 SP6, S7-SCL V5.3 SP5, S7-PLCSIM V5.4 SP2 and can be used for trial purposes for 14 days. This Software can only be used with the Microsoft Windows XP Professional Edition SP3 or Microsoft Windows Vista 32 Bit Business SP1/SP2 or Microsoft Windows Vista 32 Bit Ultimate SP1/SP2 operating systems. Additional information can be found in the Internet at: http://www.siemens.com/sce/contact http://www.siemens.com/sce/modules http://www.siemens.com/sce/tp This book also contains one Trial CD-ROM: “Open PCS”, a system (full version) for programming with IEC 61131.3, running on any standard Windows PC, using the languages: IL, LD, FBD, SFC, ST and CFC; running under Windows Server 2003, Windows XP SP2 or Windows Vista 32bit. PLC simulation SmartPLC is available for simulating the programs on a PC. The dedicated OPC server SmartPLC/OPC is only required, if additional third-party hardware and/or external OPC clients are connected. Additional information can be found in the Internet at: http://www.infoteam.de ISBN 978-3-642-12014-5 DOI 10.1007/978-3-642-12015-2 Springer Heidelberg Dordrecht London New York e-ISBN 978-3-642-12015-2 Library of Congress Control Number: 2010925149 c Springer-Verlag Berlin Heidelberg 2001, 2 010 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover design: WMXDesign GmbH, Heidelberg Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com)
    Preface of the 2nd revised edition IEC 61131 (“IEC 1131” until 1998) has become widely established in recent years as the programming standard in automation industry. Today, a wide range of small to large PLC manufacturers offer programming systems that are based on this standard. Additional standards and recommendations (e.g. for Motion Control) complement IEC 61131 with functionality in response to growing market requirements. One of the most important advancements is IEC 61499 (formerly IEC 1499). The basic concepts and ideas of this standard are described in a separate chapter (Chapter 9). Its significance in connection with distributed PLC systems is discussed in Section 7.8. IEC 61131 is now available in a second edition. The numerous changes and supplements to this standard have been incorporated in the 2nd edition of this book. A comprehensive index at the end of the book facilitates the search for specific topics. The enclosed DVD and CD contain the complete demo versions of two program- ming systems (in the latest versions), enabling the reader to immediately implement and consolidate the knowledge gained from this book by practical application. We would like to thank SIEMENS AG and infoteam Software AG for providing the enclosed software. Our special thanks go again to Hans-Peter Otto, member of the IEC and DKE standardisation committees for his active support and mutual inspiration. With our sincere thanks also to all the people who helped to translate and finish this English version: Andrea Thieme, Kay Thomas-Sukrow, Robie O’Brien, Ormond O’Neill and Michael Sperber.
    VI Preface of the 2nd revised edition Above all, we want to thank our families, Susanne, Andreas, Tobias and Andrea, Vera, Olaf, Vanessa and Sebastian, for being so understanding and giving us the freedom to write this book. We are grateful about the great interest in this book and would like to thank our attentive readers for their numerous suggestions, comments and feedback on typographical errors. Karl-Heinz John Winter 2009/2010 Michael Tiegelkamp
    Contents 1 Introduction.........................................................................................................9 1.1 Subject of the Book..........................................................................................10 1.2 The IEC 61131 standard ..................................................................................12 1.2.1 Goals and benefits of the standard ................................................................12 Manufacturers (PLC hardware and software). ........................................................................13 Users.......................................................................................................................................13 1.2.2 History and components................................................................................13 1.3 The Organisation PLCopen ........................................................................16 1.3.1 Aims of PLCopen..........................................................................................16 1.3.2 Committees and fields of activity..................................................................17 1.3.3 Results...........................................................................................................18 .... . . 2 Building Blocks of IEC 61131-3.......................................................................21 2.1 Introduction to the New Standard ....................................................................21 2.1.1 Structure of the building blocks ....................................................................22 Declaration of variables ..........................................................................................................22 Code part of a POU.................................................................................................................23 2.1.2 Introductory example written in IL ...............................................................25 2.1.3 PLC assignment ............................................................................................27 2.2 The Program Organisation Unit (POU) ...........................................................30 2.3 Elements of a POU...........................................................................................32 2.3.1 Example ........................................................................................................33 2.3.2 Declaration part.............................................................................................34 Types of variables in POUs.....................................................................................................35 Characteristics of the POU interface.......................................................................................36 External and internal access to POU variables........................................................................37 2.3.3 Code part.......................................................................................................39 2.4 The Function Block..........................................................................................41 2.4.1 Instances of function blocks..........................................................................41 What is an “instance”?............................................................................................................41 Instance means “structure”.....................................................................................................43 Instance means “memory”. ....................................................................................................45 Relationship between FB instances and data blocks. ..............................................................46 2.4.2 Re-usable and object-oriented FBs ...............................................................46 2.4.3 Types of variables in FBs..............................................................................47 . . .
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