06 · Basics of PLCs

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Table of Contents

Introduction ..............................................................................2
PLCs .........................................................................................4
Number Systems ......................................................................8
Terminology ............................................................................ 14
Basic Requirements ................................................................23
S7-200 Micro PLCs .................................................................28
Connecting External Devices ..................................................39
Programming a PLC ................................................................41
Discrete Inputs/Outputs .........................................................49
Analog Inputs and Outputs .....................................................61
Timers .....................................................................................64
Counters ................................................................................. 71
High-Speed Instructions .........................................................75
Specialized Expansion Modules .............................................78
Review Answers .....................................................................84
Final Exam ..............................................................................85

1
 Introduction

Welcome to another course in the STEP series, Siemens

Technical Education Program, designed to prepare our
distributors to sell Siemens Energy & Automation products
more effectively. This course covers Basics of PLCs and related
products.

Upon completion of Basics of PLCs you should be able to:

• Identify the major components of a PLC and describe

their functions

• Convert numbers from decimal to binary, BCD, and

hexadecimal

• Identify typical discrete and analog inputs and outputs

• Read a basic ladder logic diagram and statement list

• Identify operational differences between different S7-200

models

• Identify the proper manual to refer to for programming or

installation of an S7-200 PLC

• Connect a simple discrete input and output to an S7-200

• Select the proper expansion module for analog inputs and

outputs

• Describe the operation of timers and counters

2
This knowledge will help you better understand customer
applications. In addition, you will be better able to describe
products to customers and determine important differences
between products. You should complete Basics of Electricity
before attempting Basics of PLCs. An understanding of many
of the concepts covered in Basics of Electricity is required
for Basics of PLCs. In addition you may wish to complete
Basics of Control Components. Devices covered in Basics
of Control Components are used with programmable logic
controllers.

If you are an employee of a Siemens Energy & Automation

authorized distributor, fill out the final exam tear-out card and
mail in the card. We will mail you a certificate of completion if
you score a passing grade. Good luck with your efforts.

SIMATIC, STEP 7, STEP 7-Micro, STEP 7-Micro/WIN, PG 702,

and PG 740 are registered trademarks of Siemens Energy &
Automation, Inc.

Other trademarks are the property of their respective owners.

3
 PLCs

Programmable Logic Controllers (PLCs), also referred to as

programmable controllers, are in the computer family. They are
used in commercial and industrial applications. A PLC monitors
inputs, makes decisions based on its program, and controls
outputs to automate a process or machine. This course is meant
to supply you with basic information on the functions and
configurations of PLCs.

Drive Motors

Lights Pumps

Photo Sensors Pushbutton

Switches

4
Basic PLC Operation PLCs consist of input modules or points, a Central Processing
Unit (CPU), and output modules or points. An input accepts a
variety of digital or analog signals from various field devices
(sensors) and converts them into a logic signal that can be used
by the CPU. The CPU makes decisions and executes control
instructions based on program instructions in memory. Output
modules convert control instructions from the CPU into a digital
or analog signal that can be used to control various field devices
(actuators). A programming device is used to input the desired
instructions. These instructions determine what the PLC will do
for a specific input. An operator interface device allows process
information to be displayed and new control parameters to be
entered.

Pushbuttons (sensors), in this simple example, connected to

PLC inputs, can be used to start and stop a motor connected to
a PLC through a motor starter (actuator).

Motor Starter
(Actuator)

Output
Motor

PLC

Input Start/Stop Pushbuttons

(Sensors)

5
Hard-Wired Control Prior to PLCs, many of these control tasks were solved with
contactor or relay controls. This is often referred to as hard-
wired control. Circuit diagrams had to be designed, electrical
components specified and installed, and wiring lists created.
Electricians would then wire the components necessary to
perform a specific task. If an error was made, the wires had
to be reconnected correctly. A change in function or system
expansion required extensive component changes and rewiring.

M OL T1
L1
M OL T2
460 VAC L2 Motor
M OL T3
L3

OL
1 M
CR

24 VAC
Start
Stop
2 CR

CR

Advantages of PLCs The same, as well as more complex tasks, can be done with
a PLC. Wiring between devices and relay contacts is done in
the PLC program. Hard-wiring, though still required to connect
field devices, is less intensive. Modifying the application and
correcting errors are easier to handle. It is easier to create
and change a program in a PLC than it is to wire and re-wire a
circuit.

Following are just a few of the advantages of PLCs:

• Smaller physical size than hard-wire solutions.

• Easier and faster to make changes.
• PLCs have integrated diagnostics and override functions.
• Diagnostics are centrally available.
• Applications can be immediately documented.
• Applications can be duplicated faster and less expensively.

6
Siemens PLCs Siemens makes several PLC product lines in the SIMATIC® S7
family. They are: S7-200, S7-300, and S7-400.

S7-200 The S7-200 is referred to as a micro PLC because of its small

size. The S7-200 has a brick design which means that the
power supply and I/O are on-board. The S7-200 can be used on
smaller, stand-alone applications such as elevators, car washes,
or mixing machines. It can also be used on more complex
industrial applications such as bottling and packaging machines.

S7-300 and S7-400 The S7-300 and S7-400 PLCs are used in more complex
applications that support a greater number of I/O points. Both
PLCs are modular and expandable. The power supply and I/O
consist of separate modules connected to the CPU. Choosing
either the S7-300 or S7-400 depends on the complexity of
the task and possible future expansion. Your Siemens sales
representative can provide you with additional information on
any of the Siemens PLCs.

7
 Number Systems

Since a PLC is a computer, it stores information in the form of

On or Off conditions (1 or 0), referred to as binary digits (bits).
Sometimes binary digits are used individually and sometimes
they are used to represent numerical values.

Decimal System Various number systems are used by PLCs. All number systems
have the same three characteristics: digits, base, weight. The
decimal system, which is commonly used in everyday life, has
the following characteristics:

Ten digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
Base 10
Weights 1, 10, 100, 1000, ...

Binary System The binary system is used by programmable controllers. The

binary system has the following characteristics:

Two digits 0, 1
Base 2
Weights Powers of base 2 (1, 2, 4, 8, 16, ...)

In the binary system 1s and 0s are arranged into columns. Each

column is weighted. The first column has a binary weight of
0
2 . This is equivalent to a decimal 1. This is referred to as the
least significant bit. The binary weight is doubled with each
succeeding column. The next column, for example, has a weight
1
of 2 , which is equivalent to a decimal 2. The decimal value is
doubled in each successive column. The number in the far left
hand column is referred to as the most significant bit. In this
7
example, the most significant bit has a binary weight of 2 . This
is equivalent to a decimal 128.

8
Converting Binary The following steps can be used to interpret a decimal
to Decimal number from a binary value.

1) Search from least to most significant bit for 1s.

2) Write down the decimal representation of each column
containing a 1.
3) Add the column values.

In the following example, the fourth and fifth columns from the
right contain a 1. The decimal value of the fourth column from
the right is 8, and the decimal value of the fifth column from
the right is 16. The decimal equivalent of this binary number is
24. The sum of all the weighted columns that contain a 1 is the
decimal number that the PLC has stored.

In the following example the fourth and sixth columns from the
right contain a 1. The decimal value of the fourth column from
the right is 8, and the decimal value of the sixth column from
the right is 32. The decimal equivalent of this binary number is
40.

Bits, Bytes, and Words Each binary piece of data is a bit. Eight bits make up one byte.
Two bytes, or 16 bits, make up one word.

9
Logic 0, Logic 1 Programmable controllers can only understand a signal that
is On or Off (present or not present). The binary system is a
system in which there are only two numbers, 1 and 0. Binary 1
indicates that a signal is present, or the switch is On. Binary 0
indicates that the signal is not present, or the switch is Off.

BCD Binary-Coded Decimal (BCD) are decimal numbers where

each digit is represented by a four-bit binary number. BCD is
commonly used with input and output devices. A thumbwheel
switch is one example of an input device that uses BCD. The
binary numbers are broken into groups of four bits, each group
representing a decimal equivalent. A four-digit thumbwheel
switch, like the one shown here, would control 16 (4 x 4) PLC
inputs.

10
Hexadecimal Hexadecimal is another system used in PLCs. The hexadecimal
system has the following characteristics:

16 digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F
Base 16
Weights Powers of base 16 (1, 16, 256, 4096 ...)

The ten digits of the decimal system are used for the first ten
digits of the hexadecimal system. The first six letters of the
alphabet are used for the remaining six digits.

A = 10 D = 13
B = 11 E = 14
C = 12 F = 15

The hexadecimal system is used in PLCs because it allows the

status of a large number of binary bits to be represented in a
small space such as on a computer screen or programming
device display. Each hexadecimal digit represents the exact
status of four binary bits. To convert a decimal number to a
hexadecimal number the decimal number is divided by the base
of 16. To convert decimal 28, for example, to hexadecimal:

Decimal 28 divided by 16 is 1 with a remainder of 12. Twelve is

equivalent to C in hexadecimal. The hexadecimal equivalent of
decimal 28 is 1C.

The decimal value of a hexadecimal number is obtained by

multiplying the individual hexadecimal digits by the base 16
weight and then adding the results. In the following example
the hexadecimal number 2B is converted to its decimal
equivalent of 43.
0
16 = 1
1
16 = 16
B = 11

11
Conversion of Numbers The following chart shows a few numeric values in decimal,
binary, BCD, and hexadecimal representation.

12
Review 1
1. Identify the following:

2. The binary number system has a base ____________ .

3. The hexadecimal number system has a base

____________ .

4. Convert a decimal 10 to the following:

Binary ____________

BCD ____________

Hexadecimal ____________

13
 Terminology

The language of PLCs consists of a commonly used set

of terms; many of which are unique to PLCs. In order to
understand the ideas and concepts of PLCs, an understanding
of these terms is necessary.

Sensor A sensor is a device that converts a physical condition into an

electrical signal for use by the PLC. Sensors are connected to
the input of a PLC. A pushbutton is one example of a sensor
that is connected to the PLC input. An electrical signal is sent
from the pushbutton to the PLC indicating the condition (open/
closed) of the pushbutton contacts.

Actuators Actuators convert an electrical signal from the PLC into a

physical condition. Actuators are connected to the PLC output.
A motor starter is one example of an actuator that is connected
to the PLC output. Depending on the output PLC signal the
motor starter will either start or stop the motor.

PLC
Output 1 Motor

Motor Starter
(Actuator)

14
Discrete Input A discrete input, also referred to as a digital input, is an input
that is either in an ON or OFF condition. Pushbuttons, toggle
switches, limit switches, proximity switches, and contact
closures are examples of discrete sensors which are connected
to the PLCs discrete or digital inputs. In the ON condition a
discrete input may be referred to as a logic 1 or a logic high. In
the OFF condition a discrete input may be referred to as a logic
0 or a logic low.

A Normally Open (NO) pushbutton is used in the following

example. One side of the pushbutton is connected to the first
PLC input. The other side of the pushbutton is connected to an
internal 24 VDC power supply. Many PLCs require a separate
power supply to power the inputs. In the open state, no voltage
is present at the PLC input. This is the OFF condition. When the
pushbutton is depressed, 24 VDC is applied to the PLC input.
This is the ON condition.

15
Analog Inputs An analog input is a continuous, variable signal. Typical analog
inputs may vary from 0 to 20 milliamps, 4 to 20 milliamps,
or 0 to 10 volts. In the following example, a level transmitter
monitors the level of liquid in a tank. Depending on the level
transmitter, the signal to the PLC can either increase or
decrease as the level increases or decreases.

Discrete Outputs A discrete output is an output that is either in an ON or OFF

condition. Solenoids, contactor coils, and lamps are examples
of actuator devices connected to discrete outputs. Discrete
outputs may also be referred to as digital outputs. In the
following example, a lamp can be turned on or off by the PLC
output it is connected to.

16
Analog Outputs An analog output is a continuous, variable signal. The output
may be as simple as a 0-10 VDC level that drives an analog
meter. Examples of analog meter outputs are speed, weight,
and temperature. The output signal may also be used on more
complex applications such as a current-to-pneumatic transducer
that controls an air-operated flow-control valve.

CPU The central processor unit (CPU) is a microprocessor system

that contains the system memory and is the PLC decision-
making unit. The CPU monitors the inputs and makes decisions
based on instructions held in the program memory. The
CPU performs relay, counting, timing, data comparison, and
sequential operations.

17
Programming A program consists of one or more instructions that accomplish
a task. Programming a PLC is simply constructing a set of
instructions. There are several ways to look at a program such
as ladder logic, statement lists, or function block diagrams.

Ladder Logic Ladder logic (LAD) is one programming language used with
PLCs. Ladder logic uses components that resemble elements
used in a line diagram format to describe hard-wired control.
Refer to the STEP course Basics of Control Components for
more information on line diagrams.

STEP 2000

Basics of
Control
Components

Ladder Logic Diagram The left vertical line of a ladder logic diagram represents the
power or energized conductor. The output element or instruction
represents the neutral or return path of the circuit. The right
vertical line, which represents the return path on a hard-wired
control line diagram, is omitted. Ladder logic diagrams are read
from left-to-right, top-to-bottom. Rungs are sometimes referred
to as networks. A network may have several control elements,
but only one output coil.

18
 In the example program shown example I0.0, I0.1 and Q0.0
represent the first instruction combination. If inputs I0.0 and
I0.1 are energized, output relay Q0.0 energizes. The inputs could
be switches, pushbuttons, or contact closures. I0.4, I0.5, and
Q1.1 represent the second instruction combination. If either
input I0.4 or I0.5 are energized, output relay Q0.1 energizes.

Statement list A statement list (STL) provides another view of a set of

instructions. The operation, what is to be done, is shown on the
left. The operand, the item to be operated on by the operation,
is shown on the right. A comparison between the statement
list shown below, and the ladder logic shown on the previous
page, reveals a similar structure. The set of instructions in this
statement list perform the same task as the ladder diagram.

Function Block Diagrams Function Block Diagrams (FBD) provide another view of a set of
instructions. Each function has a name to designate its specific
task. Functions are indicated by a rectangle. Inputs are shown
on the left-hand side of the rectangle and outputs are shown on
the right-hand side. The function block diagram shown below
performs the same function as shown by the ladder diagram
and statement list.

19
PLC Scan The PLC program is executed as part of a repetitive process
referred to as a scan. A PLC scan starts with the CPU reading
the status of inputs. The application program is executed using
the status of the inputs. Once the program is completed, the
CPU performs internal diagnostics and communication tasks.
The scan cycle ends by updating the outputs, then starts over.
The cycle time depends on the size of the program, the number
of I/Os, and the amount of communication required.

Software Software is any information in a form that a computer or PLC

can use. Software includes the instructions or programs that
direct hardware.

Hardware Hardware is the actual equipment. The PLC, the programming

device, and the connecting cable are examples of hardware.

20
Memory Size Kilo, abbreviated K, normally refers to 1000 units. When talking
about computer or PLC memory, however, 1K means 1024. This
10
is because of the binary number system (2 =1024). This can be
1024 bits, 1024 bytes, or 1024 words, depending on memory
type.

RAM Random Access Memory (RAM) is memory where data can be

directly accessed at any address. Data can be written to and
read from RAM. RAM is used as a temporary storage area.
RAM is volatile, meaning that the data stored in RAM will be
lost if power is lost. A battery backup is required to avoid losing
data in the event of a power loss.

ROM Read Only Memory (ROM) is a type of memory that data can
be read from but not written to. This type of memory is used
to protect data or programs from accidental erasure. ROM
memory is nonvolatile. This means a user program will not lose
data during a loss of electrical power. ROM is normally used to
store the programs that define the capabilities of the PLC.

EPROM Erasable Programmable Read Only Memory (EPROM) provides

some level of security against unauthorized or unwanted
changes in a program. EPROMs are designed so that data
stored in them can be read, but not easily altered. Changing
EPROM data requires a special effort. UVEPROMs (ultraviolet
erasable programmable read only memory) can only be erased
with an ultraviolet light. EEPROM (electronically erasable
programmable read only memory), can only be erased
electronically.

Firmware Firmware is user or application specific software burned into

EPROM and delivered as part of the hardware. Firmware gives
the PLC its basic functionality.

21
Putting it Together The memory of the S7-200 is divided into three areas: program
space, data space, and configurable parameter space.

• Program space stores the ladder logic (LAD) or statement

list (STL) program instructions. This area of memory controls
the way data space and I/O points are used. LAD or STL
instructions are written using a programming device such as
a PC, then loaded into program memory of the PLC.

• Data space is used as a working area, and includes memory

locations for calculations, temporary storage of intermediate
results and constants. Data space includes memory
locations for devices such as timers, counters, high-speed
counters, and analog inputs and outputs. Data space can be
accessed under program control.

• Configurable parameter space, or memory, stores either the

default or modified configuration parameters.

22
 Basic Requirements

In order to create or change a program, the following items are

needed:

• PLC
• Programming Device
• Programming Software
• Connector Cable

PLC Throughout this course we will be using the S7-200 because of

its ease of use.

23
Programming Devices The program is created in a programming device (PG) and then
transferred to the PLC. The program for the S7-200 can be
created using a dedicated Siemens SIMATIC S7 programming
device, such as a PG 720 (not shown) or PG 740, if STEP 7
Micro/WIN software is installed.

A personal computer (PC), with STEP 7 Micro/WIN installed,

can also be used as a programming device with the S7-200.

24
Software A software program is required in order to tell the PLC what
instructions it must follow. Programming software is typically
PLC specific. A software package for one PLC, or one family
of PLCs, such as the S7 family, would not be useful on other
PLCs. The S7-200 uses a Windows based software program
called STEP 7-Micro/WIN32. The PG 720 and PG 740 have STEP
7 software pre-installed. Micro/WIN32 is installed on a personal
computer in a similar manner to any other computer software.

Connector Cables PPI Connector cables are required to transfer data from the
(Point-to-Point Interface) programming device to the PLC. Communication can only
take place when the two devices speak the same language or
protocol. Communication between a Siemens programming
device and the S7-200 is referred to as PPI protocol (point-
to- point interface). An appropriate cable is required for a
programming device such as a PG 720 or PG 740. The S7-200
uses a 9-pin, D-connector. This is a straight-through serial device
that is compatible with Siemens programming devices (MPI
port) and is a standard connector for other serial interfaces.

SF/DIAG

Programming Device Cable

25
 A special cable is needed when a personal computer is used as
a programming device. Two versions of this cable are available.
One version, called an RS-232/PPI Multi-Master Cable, connects
a personal computer’s RS-232 interface to the PLC’s RS-485
connector. The other version, called a USB/PPI Multi-Master
Cable, connects a personal computer’s USB interface to the
PLC’s RS-485 connector.

26
Review 2
1. A switch or a pushbutton is a ____________ input.

2. A lamp or a solenoid is an example of a ___________

output.

3. The ____________ makes decisions and executes

control instructions based on the input signals.

4. ____________ ____________ is a PLC programming

language that uses components resembling elements
used in a line diagram.

5. A ____________ consists of one or more instructions

that accomplish a task.

6. Memory is divided into three areas: ____________ ,

____________ , and ____________ ____________ space.

7. When talking about computer or PLC memory, 1K

refers to ____________ bits, bytes, or words.

8. Software that is placed in hardware is called

____________ .

9. Which of the following is not required when creating or

changing a PLC program?

a. PLC
b. Programming Device
c. Programming Software
d. Connector Cable
e. Printer

10. An RS-232/PPI Multi-Master cable or a USB/PPI-Multi-

Master cable may be used to connect a personal
computer to the PLC’s ____________ connector.

27
 S7-200 Micro PLCs

The S7-200 Micro PLC is the smallest member of the SIMATIC

S7 family of programmable controllers. The central processing
unit (CPU) is internal to the PLC. Inputs and outputs (I/O) are
the system control points. Inputs monitor field devices, such as
switches and sensors. Outputs control other devices, such as
motors and pumps. The programming port is the connection to
the programming device.

S7-200 Models There are five S7-200 CPU types: CPU 221, CPU 222, CPU 224,
CPU 224XP, and CPU 226 and two power supply configurations
for each type.

Model Description Power Supply Input Types Output Types

221 DC/DC/DC 20.4-28.8 VDC 6 DC 4 DC
221 AC/DC/Relay 85-264 VAC, 47-63 Hz 6 DC 4 Relay
222 DC/DC/DC 20.4-28.8 VDC 8 DC 6 DC
222 AC/DC/Relay 85-264 VAC, 47-63 Hz 8 DC 6 Relay
224 DC/DC/DC 20.4-28.8 VDC 14 DC 10 DC
224 AC/DC/Relay 85-264 VAC, 47-63 Hz 14 DC 10 Relay
224XP DC/DC/DC 20.4-28.8 VDC 14 DC, 2 Analog 10 DC, 1 Analog
224XP AC/DC/Relay 85-264 VAC, 47-63 Hz 14 DC, 2 Analog 10 Relay, 1 Analog
226 DC/DC/DC 20.4-28.8 VDC 24 DC 16 DC
226 AC/DC/Relay 85-264 VAC, 47-63 Hz 24 DC 16 Relay

The model description indicates the type of CPU, the power

supply, the type of input, and the type of output.

28
S7-200 Features The S7-200 family includes a wide variety of CPUs and features.
This variety provides a range of features to aid in designing a
cost-effective automation solution. The following table provides
a summary of the major features, many of which will be
covered in this course.

Feature CPU 221 CPU 222 CPU 224 CPU 224XP CPU 226
Memory

Program (with run mode edit) 4096 Bytes 4096 Bytes 8192 Bytes 12288 Bytes 16384 Bytes

Program (w/o run mode edit) 4096 Bytes 4096 Bytes 12288 Bytes 16384 Bytes 24576 Bytes
User Data 2048 Bytes 2048 Bytes 8192 Bytes 10240 Bytes 10240 Bytes
Memory Type EEPROM EEPROM EEPROM EEPROM EEPROM
Memory Cartridge EEPROM EEPROM EEPROM EEPROM EEPROM
Data Backup (super cap) 50 Hours 50 Hours 100 Hours 100 Hours 100 Hours
Data Backup (opt. battery) 200 Days 200 Days 200 Days 200 Days 200 Days
I/O
Local Digital I/O 6 In/4 Out 8 In/6 Out 14 In/10 Out 14 In/10 Out 24 In/16 Out
Local Analog I/O None None None 2 In/1 Out None
Max Expansion Modules None 2 7 7 7
Instructions
Boolean Execution Speed 0.22 µs/Inst. 0.22 µs/Inst. 0.22 µs/Inst. 0.22 µs/Inst. 0.22 µs/Inst.
Internal Relays 256 256 256 256 256
Counters 256 256 256 256 256
TImers 256 256 256 256 256
Sequential Control Relays 256 256 256 256 256
For/Next Loops Yes Yes Yes Yes Yes
Integer Math (+-*/) Yes Yes Yes Yes Yes
Floating-Point Math (+-*/) Yes Yes Yes Yes Yes
Enhanced Features
4 (30 KHz),
High-Speed Counters 4 (30 KHz) 4 (30 KHz) 6 (30 KHz) 6 (30 KHz)
2 (200 KHz)
Analog Adjustments 1 1 2 2 2
Pulse Outputs (DC) 2 (20 KHz) 2 (20 KHz) 2 (20 KHz) 2 (100 KHz) 2 (20 KHz)
Timed Interrupts 2 (1 - 255ms) 2 (1 - 255ms) 2 (1 - 255ms) 2 (1 - 255ms) 2 (1 - 255ms)
Edge Interrupts 4 4 4 4 4
Real-Time Clock Optional Optional Built-In Built-In Built-In
Password Protection Yes Yes Yes Yes Yes
Communications
Number of Ports 1 (RS-485) 1 (RS-485) 1 (RS-485) 2 (RS-485) 2 (RS-485)
PPI, MPI, PPI, MPI, PPI, MPI, PPI, MPI, PPI, MPI,
Protocols Supported
Freeport Freeport Freeport Freeport Freeport
Peer-to-Peer PPI Master Mode (NETR/NETW) (NETR/NETW) (NETR/NETW) (NETR/NETW) (NETR/NETW)

29
Mode Switch and When the mode switch is in the RUN position the CPU is in the
Analog Adjustment run mode and executing the program. When the mode switch
is in the STOP position the CPU is stopped. When the mode
switch is in the TERM position the programming device can
select the operating mode.

The analog adjustment is used to increase or decrease values

stored in special memory. These values can be used to update
the value of a timer or counter, or can be used to set limits.

Optional Cartridge The S7-200 supports an optional memory cartridge that

provides a portable EEPROM storage for your program. The
cartridge can be used to copy a program from one S7-200 PLC
to a like S7-200 PLC.

In addition, two other cartridges are available. A real-time clock

with battery is available for use on the CPU 221 and CPU 222.
The battery provides up to 200 days of data retention time
in the event of a power loss. The CPU 224, CPU 224XP and
CPU 226 have a real-time clock built in. Another cartridge is
available with a battery only.

SF/DIAG

30
Expansion Modules The S7-200 PLCs are expandable. Expansion modules contain
additional inputs and outputs. These are connected to the base
unit using a ribbon connector.

The ribbon connector is protected by a cover on the base unit.

Side-by-side mounting completely encloses and protects the
ribbon connector.

31
Available Expansion The CPU 221 comes with 6 digital inputs and 4 digital outputs.
These are not expandable. The CPU 222 comes with 8 digital
inputs and 6 digital outputs and will accept up to 2 expansion
modules. The CPU 224 and CPU 224XP come with 14 digital
inputs and 10 digital outputs and will accept up to 7 expansion
modules. The S7-226 comes with 24 digital inputs and 16
digital outputs and will accept up to 7 expansion modules.

6 Inputs, 4 Outputs
CPU221 No Expansion Modules (EM)

8 Inputs, 6 Outputs
CPU222 EM EM Up to 2 Expansion Modules

14 Inputs, 10 Outputs
CPU224 EM EM EM EM EM EM EM Up to 7 Expansion Modules

14 Inputs, 10 Outputs
CPU224XP EM EM EM EM EM EM EM 2 Analog In, 1 Analog Out
Up to 7 Expansion Modules

24 Inputs, 16 Outputs
CPU226 EM EM EM EM EM EM EM Up to 7 Expansion Modules

Status Indicators The CPU status indicators reflect the current mode of CPU
operation. When the CPU is in the RUN mode, the green RUN
indicator is lit. When the CPU is in the STOP mode, the yellow
STOP indicator is lit. The System Fault/Diagnostic (SF/DIAG)
indicator turns red for a system fault and yellow to indicate
certain diagnostic conditions.

The I/O status indicators represent the On or Off status of

corresponding inputs and outputs. For example, when the CPU
senses an input is on, the corresponding green indicator is lit.

32
Installing The S7-200 can be installed in one of two ways. A DIN clip
allows installation on a standard DIN rail. The DIN clip snaps
open to allow installation and snaps closed to secure the
unit on the rail. The S7-200 can also be panel mounted using
installation holes located behind the access covers.

External Power Supply An S7-200 can be connected to either a 24 VDC or a 120/230

Sources VAC power supply depending on the CPU. An S7-200 DC/DC/
DC would be connected to a 24 VDC power supply.

24 VDC
Power Supply

An S7-200 AC/DC/Relay would be connected to a 120 or 230

VAC power supply.

Neutral
Ground Line

33
I/O Numbering S7-200 inputs and outputs are labeled at the wiring terminations
and next to the status indicators. These alphanumeric symbols
identify the I/O address to which a device is connected. This
address is used by the CPU to determine which input is present
and which output needs to be turned on or off. I designates
a discrete input and Q designates a discrete output. The first
number identifies the byte, the second number identifies the
bit. Input I0.0, for example, is byte 0, bit 0.

I0.0 = Byte 0, Bit 0

I0.1 = Byte 0, Bit 1
I1.0 = Byte 1, Bit 0
I1.1 = Byte 1, Bit 1

The following table identifies the input and output designations.

Inputs Input devices, such as switches, pushbuttons, and other sensor

devices are connected to the terminal strip under the bottom
cover of the PLC.

Input Devices
Connected Here

Pushbutton Switch

34
Input Simulator A convenient method of testing a program is to wire toggle
switches to the inputs. Input simulators with prewired toggle
switches are available for the S7-200s. Switches are wired
between the 24 VDC power supply (L+) and the inputs. For
example, the switch on the far left is wired between the first
input (0.0) and L+. When the switch is closed, 24 VDC is applied
to the input. This is referred to as a logic 1. When the switch
is open, 0 VDC is applied to the input. This is referred to as a
logic 0.

Outputs Output devices, such as relays, are connected to the terminal

strip under the top cover of the PLC. When testing a program,
it is not necessary to connect output devices. The LED status
indicators signal if an output is active.

Light Relay

From Input Power Supply

Output Devices
Wired Here

35
Optional Connector An optional fan-out connector allows for field wiring connections
to remain fixed when removing or replacing a CPU 221 or
CPU 222. The appropriate connector slides into either the input,
output, or expansion module terminals.

Removable Terminal Strip The CPU 224, CPU 224XP, and CPU 226 do not have an optional
fan-out connector. Instead, the terminal strips are removable.
This allows the field wiring connections to remain fixed when
removing or replacing the PLC.

36
Super Capacitor A super capacitor, so named because of its ability to maintain a
charge for a long period of time, protects data stored in RAM in
the event of a power loss. The RAM memory is typically backed
up on the CPU 221 and CPU 222 for 50 hours, and on the
CPU 224, CPU 224 XP, and CPU 226 for 100 hours.

Reference Manual The SIMATIC S7-200 Programmable Controller System

Manual provides complete information on installing and
programming the S7-200 PLCs.

37
Review 3
1. The five models of S7-200 are ____________ ,
____________ , ____________ , ____________, and
____________ .

2. Which of the following is not available on an CPU 221?

a. Mode Switch
b. Expansion Port
c. Programming Port
d. Status Indicators

3. A CPU 222 can have a maximum of ____________

expansion modules and a CPU 224 can have a
maximum of ____________ expansion modules.

4. A CPU 222 has ____________ DC inputs and

____________ DC outputs without expansion modules.

5. A CPU 224 has ____________ DC inputs and

____________ DC outputs without expansion modules.

6. The fourth output of an S7-200 would be labeled

____________ .

7. S7-200 can be panel mounted or installed on a

____________ rail.

38
 Connecting External Devices

TD200 The S7-200 programming port can be used to communicate

with a variety of external devices. One such device is the TD200
text display unit. The TD200 displays messages read from the
S7-200, allows adjustment of designated program variables,
provides the ability to force, and permits setting of the time and
date. The TD200 can be connected to an external power supply
or receive its power from the S7-200.

SF/DIAG

Programming PPI Protocol

Device Cable

Freeport Mode The programming port has a mode called freeport mode.
Freeport mode allows connectivity to various intelligent sensing
devices such as a bar code reader.

Bar-Code Decoder

Bar-Code Reader

Programming Port Freeport Mode

RS-485 to RS-232
Interface

39
Printer Freeport mode can also be used to connect to a non-SIMATIC
printer.

Freeport Mode

Programming Port

Connecting Cable
Serial to Parallel
Converter

Interconnection It is possible to use one programming device to address

multiple S7-200 devices on the same communication cable. A
total of 31 units can be interconnected without a repeater.

IBM or
IBM Compatible PC

S7-200 S7-200 S7-200

PPI Interconnection

40
 Programming a PLC

STEP 7-Micro/WIN32 is the program software used with the

S7-200 PLC to create the PLC operating program. STEP 7
consists of a number of instructions that must be arranged
in a logical order to obtain the desired PLC operation. These
instructions are divided into three groups: standard instructions,
special instructions, and high-speed instructions.

Standard Instructions Standard instructions consists of instructions that are found in

most programs. Standard instructions include: timer, counter,
math, logical, increment/decrement/invert, move, and block
instructions.

Special Instructions Special instructions are used to manipulate data. Special

instructions include: shift, table, find, conversion, for/next, and
real-time instructions.

High-Speed Instructions High-speed instructions allow for events and interrupts to occur
independent of the PLC scan time. These include high-speed
counters, interrupts, output, and transmit instructions.

It is not the purpose of this text to explain all of the instructions

and capabilities. A few of the more common instructions
necessary for a basic understanding of PLC operation will
be discussed. PLC operation is limited only by the hardware
capabilities and the ingenuity of the person programming it.
Refer to the SIMATIC S7-200 Programmable Controller
System Manual for detailed information concerning these
instructions.

41
Micro/WIN32 The programming software can be run Off-line or On-line. Off-
line programming allows the user to edit the ladder diagram
and perform a number of maintenance tasks. The PLC does
not need to be connected to the programming device in this
mode. On-line programming requires the PLC to be connected
to the programming device. In this mode program changes are
downloaded to the PLC. In addition, status of the input/output
elements can be monitored. The CPU can be started, stopped,
or reset.

Symbols In order to understand the instructions a PLC is to carry out, an

understanding of the language is necessary. The language of
PLC ladder logic consists of a commonly used set of symbols
that represent control components and instructions.

Contacts One of the most confusing aspects of PLC programming for

first-time users is the relationship between the device that
controls a status bit and the programming function that uses
a status bit. Two of the most common programming functions
are the normally open (NO) contact and the normally closed
(NC) contact. Symbolically, power flows through these contacts
when they are closed. The normally open contact (NO) is closed
when the input or output status bit controlling the contact is 1.
The normally closed contact (NC) is closed when the input or
output status bit controlling the contact is 0.

42
Coils Coils represent relays that are energized when power flows
to them. When a coil is energized, it causes a corresponding
output to turn on by changing the state of the status bit
controlling that output to 1. That same output status bit may be
used to control normally open and normally closed contacts
elsewhere in the program.

Boxes Boxes represent various instructions or functions that are

executed when power flows to the box. Typical box functions
are timers, counters, and math operations.

Entering Elements Control elements are entered in the ladder diagram by

positioning the cursor and selecting the element from a lists.
In the following example the cursor has been placed in the
position to the right of I0.2. A coil was selected from a pull-
down list and inserted in this position.

Network 1

I0.0 I0.1 Q0.0

Network 2

Cursor
I0.2

43
An AND Operation Each rung or network on a ladder represents a logic operation.
The following programming example demonstrates an AND
operation. Two contact closures and one output coil are placed
on network 1. They were assigned addresses I0.0, I0.1, and
Q0.0. Note that in the statement list a new logic operation
always begins with a load instruction (LD). In this example I0.0
(input 1) and (A in the statement list) I0.1 (input 2) must be
true in order for output Q0.0 (output 1) to be true. It can also
be seen that I0.0 and I0.1 must be true for Q0.0 to be true by
looking at the function block diagram representation.

Another way to see how an AND function works is with

a Boolean logic diagram. In Boolean logic an AND gate is
represented by a number of inputs on the left side. In this case
there are two inputs. The output is represented on the right
side. It can be seen from the table that both inputs must be a
logic 1 in order for the output to be a logic 1.

And (A) Function And (A) Function

Input 1 I0.0
Output 1 Q0.0
Input 2 I0.1

Input 1 Input 2 Output 1 I0.0 I0.1 Q0.0

0 0 0 0 0 0
0 1 0 0 1 0
1 0 0 1 0 0
1 1 1 1 1 1

44
An OR Operation In this example an OR operation is used in network 1. It can be
seen that if either input I0.2 (input 3) or (O in the statement list)
input I0.3 (input 4), or both are true, then output Q0.1 (output 2)
will be true.

Another way to see how an OR function works is with a

Boolean logic diagram. The symbol differs slightly from an AND
function. The OR function is represented by a number of inputs
on the left side. In this case there are two inputs. The output is
represented on the right side. It can be seen from the table that
any input can be a logic 1 in order for the output to be a logic 1.

Or (O) Function Or (O) Function

Input 3 I0.4
Output 2 Q0.1
Input 4 I0.5

Input 3 Input 4 Output 2 I0.4 I0.5 Q0.1

0 0 0 0 0 0
0 1 1 0 1 1
1 0 1 1 0 1
1 1 1 1 1 1

45
Testing a Program Once a program has been written it needs to be tested and
debugged. One way this can be done is to simulate the field
inputs with an input simulator, such as the one made for the
S7-200. The program is first downloaded from the programming
device to the CPU. The selector switch is placed in the RUN
position. The simulator switches are operated and the resulting
indication is observed on the output status indicator lamps.

Status Functions After a program has been loaded and is running in the PLC, the
actual status of ladder elements can be monitored using STEP
7 Micro/WIN32 software. The standard method of showing a
ladder element is by indicating the circuit condition it produces
when the device is in the deenergized or non operated state.
In the following illustration input 1 (I0.0) is programmed as a
normally open (NO) contact. In this condition, power will not
flow through the contacts to the output (Q0.0).

46
 When viewing the ladder diagram in the status mode, control
elements that are active, or true (logic 1), are highlighted. In the
example shown the toggle switch connected to input 1 has
been closed. Power can now flow through the control element
associated with input 1 (I0.0) and activate the output (Q0.0). The
lamp will illuminate.

Forcing Forcing is another useful tool in the commissioning of an

application. It can be used to temporarily override the input
or output status of the application in order to test and debug
the program. The force function can also be used to override
discrete output points. The force function can be used to skip
portions of a program by enabling a jump instruction with a
forced memory bit. Under normal circumstances the toggle
switch, shown in the illustration below, would have to be closed
to enable input 1 (I0.0) and turn on the output light. Forcing
enables input 1 even though the input toggle switch is open.
With input 1 forced high the output light will illuminate. When
a function is forced the control bit identifier is highlighted. The
element is also highlighted because it is on.

47
 The following table shows the appearance of ladder elements in
the Off, forced, and On condition.

48
 Discrete Inputs/Outputs

To understand discrete control of a programmable controller the

same simple lamp circuit illustrated with forcing will be used.
This is only for instructional purposes as a circuit this simple
would not require a programmable controller. In this example
the lamp is off when the switch is open and on when the
switch is closed.

Wiring To accomplish this task, a switch is wired to the input of the

PLC and an indicator light is wired to output terminal.

Light

Switch

49
 The following drawing illustrates the sequence of events. A
switch is wired to the input module of the PLC. A lamp is wired
to the output module. The program is in the CPU. The CPU
scans the inputs. When it finds the switch open I0.0 receives
a binary 0. This instructs Q0.0 to send a binary 0 to the output
module. The lamp is off. When it finds the switch closed I0.0
receives a binary 1. This instructs Q0.0 to send a binary 1 to the
output module, turning on the lamp.

Program Instruction When the switch is open the CPU receives a logic 0 from input
I0.0. The CPU sends a logic 0 to output Q0.0 and the light is off.

When the switch is closed the CPU receives a logic 1 from

input I0.0. The CPU sends a logic 1 to output Q0.0, thus
activating Q0.0. The light turns on.

50
Motor Starter Example The following example involves a motor start and stop circuit.
The line diagram illustrates how a normally open and a
normally closed pushbutton might be used in a control circuit.
In this example a motor started (M) is wired in series with
a normally open momentary pushbutton (Start), a normally
closed momentary pushbutton (Stop), and the normally closed
contacts of an overload relay (OL).

Momentarily depressing the Start pushbutton completes the

path of current flow and energizes the motor starter (M).

51
 This closes the associated M and Ma (auxiliary contact located
in the motor starter) contacts. When the Start button is released
a holding circuit exists to the M contactor through the auxiliary
contacts Ma. The motor will run until the normally closed
Stop button is depressed, or the overload relay opens the OL
contacts, breaking the path of current flow to the motor starter
and opening the associated M and Ma contacts.

This control task can also be accomplished with a PLC.

Motor Starter
(Actuator)

Output
Motor

PLC

Input Start/Stop Pushbuttons

(Sensors)

52
Program Instruction A normally open Start pushbutton is wired to the first input
(I0.0), a normally closed Stop pushbutton is wired to the second
input (I0.1), and normally closed overload relay contacts (part
of the motor starter) are connected to the third input (I0.2).
The first input (I0.0), second input (I0.1), and third input (I0.2)
form an AND circuit and are used to control normally open
programming function contacts on Network 1. I0.1 status bit is
a logic 1 because the normally closed (NC) Stop Pushbutton is
closed. I0.2 status bit is a logic 1 because the normally closed
(NC) overload relay (OL) contacts are closed. Output Q0.0 is
also programmed on Network 1. In addition, a normally open set
of contacts associated with Q0.0 is programmed on Network
1 to form an OR circuit. A motor starter is connected to output
Q0.0.

When the Start pushbutton is depressed the CPU receives a

logic 1 from input I0.0. This causes the I0.0 contact to close.
All three inputs are now a logic 1. The CPU sends a logic 1
to output Q0.0. The motor starter is energized and the motor
starts.

53
 When the Start pushbutton is pressed, output Q0.0 is now
true and on the next scan, when normally open contact Q0.0 is
solved, the contact will close and output Q0.0 will stay on even
if the Start pushbutton has been released.

The motor will continue to run until the Stop pushbutton is

depressed. Input I0.1 will now be a logic 0 (false). The CPU will
send a binary 0 to output Q0.0. The motor will turn off.

54
 When the Stop pushbutton is released I0.1 logic function will
again be true and the program ready for the next time the Start
pushbutton is pressed.

Expanding the Application The application can be easily expanded to include indicator
lights for RUN and STOP conditions. In this example a RUN
indicator light is connected to output Q0.1 and a STOP indicator
light is connected to output Q0.2.

Motor Starter
(Actuator)

Motor
Output Indicator Lights

PLC

Input Start/Stop Pushbuttons

(Sensors)

55
 It can be seen from the ladder logic that a normally open output
Q0.0 is connected on Network 2 to output Q0.1 and a normally
closed Q0.0 contact is connected to output Q0.2 on network
3. In a stopped condition output Q0.0 is off. The normally open
Q0.0 contacts on Network 2 are open and the RUN indicator,
connected to output Q0.1 light is off. The normally closed Q0.1
on Network 3 lights are closed and the STOP indicator light,
connected to output Q0.2 is on.

56
 When the PLC starts the motor output Q0.0 is now a logic
high (On). The normally open Q0.0 contacts on Network 2 now
switch to a logic 1 (closed) and output Q0.1 turns the RUN
indicator on. The normally closed Q0.0 contacts on Network
3 switch to a logic 0 (open) and the STOP indicator light
connected to output Q0.2 is now off.

Adding a Limit Switch The application can be further expanded by adding a limit
switch with normally open contacts to input I0.3.

Motor Starter
(Actuator)

Motor
Output Indicator Lights

PLC

Input Start/Stop Pushbuttons

(Sensors)
Limit Switch

57
 A limit switch could be used to stop the motor or prevent the
motor from being started. An access door to the motor, or its
associated equipment, is one example of a limit switch’s use.
If the access door is open, the normally open contacts of LS1
connected to input I0.3 are open and the motor will not start.

When the access door is closed, the normally open contacts on

the limit switch (LS1) are closed. Input I0.3 is now on (logic 1),
and the motor will start when the Start pushbutton is pressed.

58
Expansion The PLC program can be expanded to accommodate many
commercial and industrial applications. Additional Start/Stop
pushbuttons and indicator lights can be added for remote
operation, or control of a second motor starter and motor.
Overtravel limit switches can be added along with proximity
switches for sensing object position. In addition, expansion
modules can be added to further increase the I/O capability. The
applications are only limited by the number of I/Os and amount
of memory available on the PLC.

Motor Starters
(Digital Outputs)

Indicator Lights
(Digital Outputs)

I/O Expansion Module

Pushbuttons
(Digital Inputs) Sensors
(Digital Inputs)

59
Review 4
1. Identify the following symbols:

a. ____________

b. ____________

c. ____________

2. Complete the following tables:

3. In the following instruction Q0.0 will be true (logic 1)

when ____________ or ____________ is true, and when
____________ is true.

60
Analog Inputs and Outputs

PLCs must also work with continuous or analog signals. Typical

analog signals are 0 - 10 VDC or 4 - 20 mA. Analog signals are
used to represent changing values such as speed, temperature,
weight, and level. A PLC cannot process these signals in
an analog form. The PLC must convert the analog signal
into a digital representation. An expansion module, capable
of converting the analog signal, must be used. The S7-200
analog modules convert standard voltage and current analog
values into a 12-bit digital representation. The digital values are
transferred to the PLC for use in register or word locations.

In addition, analog modules are available for use with

thermocouple and RTD type sensors used in to achieve a high
level of accuracy in temperature measurement.

SF/DIAG

Analog Expansion Module

61
Application Example A field device that measures a varying value is typically
connected to a transducer. In the following example a scale
is connected to a load cell. A load cell is a device that takes a
varying value and converts it to a variable voltage or current
output. In this example the load cell is converting a value of
weight into a 0 - 10 VDC output. The output value depends
entirely on the manufactured specifications for the device. This
load cell outputs 0 - 10 VDC for a 0 - 500 Lbs input. The 0 - 10
VDC load cell output is connected to the input of an analog
expansion module.

The example application can be expanded to include a conveyor

system with a gate to direct packages of varying weight.
As packages move along the conveyor they are weighed. A
package that weighs at or greater than a specified value is
routed along one conveyor path. A package that weighs less
than a specified value is routed along another conveyor path,
where it will later be inspected for missing contents.

62
Analog Outputs Analog outputs are used in applications requiring control
capability of field devices which respond to continuous voltage
or current levels. Analog outputs may be used as a variable
reference for control valves, chart recorders, electric motor
drives, analog meters, and pressure transducers. Like analog
inputs, analog outputs are generally connected to a controlling
device through a transducer. The transducer takes the voltage
signal and, depending on the requirement, amplifies, reduces,
or changes it into another signal which controls the device. In
the following example a 0 - 10 VDC signal controls a 0 - 500 Lbs.
scale analog meter.

63
 Timers

Timers are devices that count increments of time. Traffic lights

are one example where timers are used. In this example timers
are used to control the length of time between signal changes.

Timers are represented by boxes in ladder logic. When a timer

receives an enable, the timer starts to time. The timer compares
its current time with the preset time. The output of the timer
is a logic 0 as long as the current time is less than the preset
time. When the current time is greater than the preset time the
timer output is a logic 1. S7-200 uses three types of timers: On-
Delay (TON), Retentive On-Delay (TONR), and Off-Delay (TOF).

64
S7-200 Timers S7-200 timers are provided with resolutions of 1 millisecond,
10 milliseconds, and 100 milliseconds. The maximum value of
these timers is 32.767 seconds, 327.67 seconds, and 3276.7
seconds, respectively. By adding program elements, logic can
be programmed for much greater time intervals.

Hard-Wired Timing Circuit Timers used with PLCs can be compared to timing circuits used
in hard-wired control line diagrams. In the following example, a
normally open (NO) switch (S1) is used with a timer (TR1). For
this example the timer has been set for 5 seconds. When S1
is closed, TR1 begins timing. When 5 seconds have elapsed,
TR1 will close its associated normally open TR1 contacts,
illuminating pilot light PL1. When S1 is open, deenergizing TR1,
the TR1 contacts open, immediately extinguishing PL1. This type
of timer is referred to as ON delay. ON delay indicates that once
a timer receives an enable signal, a predetermined amount of
time (set by the timer) must pass before the timer’s contacts
change state.

On-Delay (TON) When the On-Delay timer (TON) receives an enable (logic 1) at
its input (IN), a predetermined amount of time (preset time - PT)
passes before the timer bit (T-bit) turns on. The T-bit is a logic
function internal to the timer and is not shown on the symbol.
The timer resets to the starting time when the enabling input
goes to a logic 0.

65
 In the following simple timer example, a switch is connected to
input I0.3, and a light is connected to output Q0.1.

When the switch is closed input 4 becomes a logic 1, which

is loaded into timer T37. T37 has a time base of 100 ms (.100
seconds). The preset time (PT) value has been set to 150. This
is equivalent to 15 seconds (.100 x 150 ). The light will turn on
15 seconds after the input switch is closed. If the switch were
opened before 15 seconds had passed, then reclosed, the timer
would again begin timing at 0.

I0.3 T37

IN TON

150 PT

T37 Q0.1

66
 A small sample of the flexibility of PLCs is shown in the
following program logic. By reprogramming the T37 contact as
a normally closed contact, the function of the circuit is changed
to cause the indicator light to turn off only when the timer times
out. This function change was accomplished without changing
or rewiring I/O devices.

I0.3 T37

IN TON

150 PT

T37 Q0.1

Retentive On-Delay (TONR) The Retentive On-Delay timer (TONR) functions in a similar
manner to the On-Delay timer (TON). There is one difference.
The Retentive On-Delay timer times as long as the enabling
input is on, but does not reset when the input goes off. The
timer must be reset with a RESET (R) instruction.

67
 The same example used with the On-Delay timer will be
used with the Retentive On-Delay timer. When the switch is
closed at input I0.3, timer T5 (Retentive timer) begins timing.
If, for example, after 10 seconds input I0.3 is opened the timer
stops. When input I0.3 is closed the timer will begin timing at
10 seconds. The light will turn on 5 seconds after input I0.3
has been closed the second time. A RESET (R) instruction
can be added. Here a pushbutton is connected to input I0.2.
If after 10 seconds input I0.3 were opened, T5 can be reset by
momentarily closing input I0.2. T5 will be reset to 0 and begin
timing from 0 when input I0.3 is closed again.

I0.2 T5

I0.3
T5

IN TONR

150 PT

T5 Q0.1

Off-Delay (TOF) The Off-Delay timer is used to delay an output off for a fixed
period of time after the input turns off. When the enabling bit
turns on the timer bit turns on immediately and the value is set
to 0. When the input turns off, the timer counts until the preset
time has elapsed before the timer bit turns off.

TXXX

IN TOF

PT

68
S7-200 Timers The S7-200s have 256 timers. The specific T number chosen
for the timer determines its time base and whether it is TON,
TONR, or TOF.

Timer Example In the following example a tank will be filled with two
chemicals, mixed, and then drained. When the Start Button is
pressed at input I0.0, the program starts pump 1 controlled by
output Q0.0. Pump 1 runs for 5 seconds, filling the tank with
the first chemical, then shuts off. The program then starts pump
2, controlled by output Q0.1. Pump 2 runs for 3 seconds filling
the tank with the second chemical. After 3 seconds pump 2
shuts off. The program starts the mixer motor, connected to
output Q0.2 and mixes the two chemicals for 60 seconds. The
program then opens the drain valve controlled by output Q0.3,
and starts pump 3 controlled by output Q0.4. Pump 3 shuts off
after 8 seconds and the process stops. A manual Stop switch is
also provided at input I0.1.

69
Review 5
1. Analog signals are converted into a ____________
format by the PLC.

2. Three types of timers available in the S7-200 are On-

Delay, ____________ On-Delay, and ____________-
Delay.

3. The maximum time available on a 100 millisecond time

base timer is ____________ seconds.

4. A count of 25 on a 10 millisecond time base timer

represents a time of __________ milliseconds.

5. There are ____________ timers in the S7-200.

70
Counters

Counters used in PLCs serve the same function as mechanical

counters. Counters compare an accumulated value to a preset
value to control circuit functions. Control applications that
commonly use counters include the following:

• Count to a preset value and cause an event to occur

• Cause an event to occur until the count reaches a preset

value

A bottling machine, for example, may use a counter to count

bottles into groups of six for packaging.

71
 Counters are represented by boxes in ladder logic. Counters
increment/decrement one count each time the input transitions
from off (logic 0) to on (logic 1). The counters are reset when
a RESET instruction is executed. S7-200 uses three types of
counters: up counter (CTU), down counter (CTD), and up/down
counter (CTUD).

XXX XXX XXX

CTU CTD CTUD
CU CD
CD
CU
R LD R
PV
PV PV

Count Up Count Down Count Up/Down

S7-200 Counters There are 256 counters in the S7-200, numbered C0 through
C255. The same number cannot be assigned to more than
one counter. For example, if an up counter is assigned number
45, a down counter cannot also be assigned number 45. The
maximum count value of a counter is ±32,767.

Up Counter The up counter counts up from a current value to a preset value

(PV). Input CU is the count input. Each time CU transitions from
a logic 0 to a logic 1 the counter increments by a count of 1.
Input R is the reset. A preset count value is stored in PV input.
If the current count is equal to or greater than the preset value
stored in PV, the output bit (Q) turns on (not shown).

XXX
CTU
CU

PV

72
Down Counter The down counter counts down from the preset value (PV) each
time CD transitions from a logic 0 to a logic 1. When the current
value is equal to zero the counter output bit (Q) turns on (not
shown). The counter resets and loads the current value with the
preset value (PV) when the load input (LD) is enabled.

XXX
CTD
CD

LD

PV

Up/Down Counter The up/down counter counts up or down from the preset value
each time either CD or CU transitions from a logic 0 to a logic 1.
When the current value is equal to the preset value, the output
QU turns on. When the current value (CV) is equal to zero, the
output QD turns on. The counter loads the current value (CV)
with the preset value (PV) when the load input (LD) is enabled.
Similarly, the counter resets and loads the current value (CV)
with zero when the reset (R) is enabled. The counter stops
counting when it reaches preset or zero.

XXX
CTUD
CD
CU
R
LD
PV

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Counter Example A counter might be used to keep track of the number of
vehicles in a parking lot. As vehicles enter the lot through an
entrance gate, the counter counts up. As vehicles exit the lot
through an exit gate, the counter counts down. When the lot is
full a sign at the entrance gate turns on indicating the lot is full.

Up/down counter C48 is used in this example. A switch,

connected to the entrance gate, has been wired to input I0.0.
A switch, connected to the exit gate, has been wired to input
I0.1. A reset switch, located at the collection booth, has been
wired to input I0.2. The parking lot has 150 parking spaces. This
value has been stored in the preset value (PV). The counter
output has been directed to output Q0.1. Output 2 is connected
to a “Parking Lot Full” sign. As cars enter the lot the entrance
gate opens. Input I0.0 transitions from a logic 0 to a logic 1,
incrementing the count by one. As cars leave the lot the exit
gate opens. Input I0.1 transitions from a logic 0 to a logic 1,
decrementing the count by 1. When the count has reached 150
output Q0.1 transitions from a logic 0 to a logic 1. The “Parking
Lot Full” sign illuminates. When a car exits, decrementing the
count to 149, the sign turns off.

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 High-Speed Instructions

As discussed earlier, PLCs have a scan time. The scan time

depends on the size of the program, the number of I/Os, and
the amount of communication required. Events may occur in
an application that require a response from the PLC before
the scan cycle is complete. For these applications high-speed
instructions can be used.

High-Speed Counters High-speed counters are represented by boxes in ladder logic.

CPU 221 and CPU 222 support four high-speed counters
(HSC0, HSC3, HSC4, HSC5). CPU 224, CPU 224XP, and
CPU 226 support six high-speed counters (HSC0, HSC1, HSC2,
HSC3, HSC4, HSC5).

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Definition Boxes and The high-speed counter definition boxes are used to assign
High-Speed Counters a mode to the counter. High-speed counters can be defined
by the definition box to operate in any of the twelve available
modes. It should be noted that not all counters can operate
in all of the available modes. Refer to the S7-Programmable
Controller System Manual for definitions available for each
counter. Each counter has dedicated inputs for clocks, direction
control, reset, and start where these functions are supported.

Positioning Positioning is one example of an application that can use

high-speed counters. In the following illustration a motor is
connected through a starter to a PLC output. The motor shaft
is connected to an encoder and a positioning actuator. The
encoder emits a series of pulses as the motor turns. In this
example the program will move an object from position 1 to
position 6. Assume the encoder generates 600 pulses per
revolution, and it takes 1000 motor revolutions to move the
object from one position to another. To move the object from
position 1 to position 6 (5 positions) would take 5000 motor
revolutions. The counter would count up 30,000 counts (5000
revolutions x 600 pulses per revolution) and stop the motor.

0 1 2 3 4 5 6 7 8 9 10

Encoder Motor

Starter

Interrupts Interrupts are another example of an instruction that must

be executed before the PLC has completed the scan cycle.
Interrupts in the S7-200 are prioritized in the following order:

1. Communications
2. I/O Interrupts
3. Time-Based Interrupts

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PTO Pulse Train Output (PTO) is used to provide a series of pulses
to an output device, such as a stepper motor driver. The PTO
provides a square wave output for a specified number of pulses
and a specified cycle time. The number of pulses can be from
1 to 4,294,967,295 pulses. PTOs have a 50% duty cycle. This
means the pulse is off for the same amount of time it is on. The
number of pulses and the cycle time can be changed with an
interrupt. In the following example each pulse is on for 500 ms,
and off for 500 ms. After four pulses an interrupt occurs which
changes the cycle time to 1000 ms.

Q0.0

4 Pulses 4 Pulses
500 milliseconds Each 1000 milliseconds Each

Interrupt
Occurs

PWM The Pulse Width Modulation (PWM) function provides a fixed

cycle time with a variable duty cycle time. When the pulse
width is equal to the cycle time, the duty cycle is 100% and
the output is turned on continuously. In the following example
the output has a 10% duty cycle (on 10% off 90%). After an
interrupt the cycle switches to a 50% duty cycle (on 50%, off
50%).

On Off On Off

Q0.0

10% 50%
Duty Cycle Duty Cycle

The PWM function can be used to provide a programmable

or adjustable control of machine timing. This allows machine
operation to be varied to compensate for product variations or
mechanical wear.

Transmit Transmit allows communication with external devices, such as

modems, printers, computers, via the serial interface. See the
section titled “Connecting External Devices” for examples.

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 Specialized Expansion Modules

In addition to I/O modules, expansion modules are available

for the S7-200 that measure temperature, control positioning
applications, and provide various communication functions.

EM 241 In any complex system communication is essential. Modems

are electronic devices used for sending and receiving data
over long distances. The EM 241 is an expansion module that
supports communication between an S7-200 PLC and STEP 7
Micro/WIN via a modem.

The EM 241 provides an international telephone line interface,

supports sending numeric and text paging messages, as well
as SMS (Short Message Service) messages to cellular phones.
This is useful for remote diagnostics and maintenance, machine
control, alarm systems, and general communication functions.

In addition to CPU-to-CPU communication via a telephone line,

the EM 241 also supports the ModBus RTU protocol. Protocols
are rules that identify how devices should communicate with
each other. ModBus RTU is a protocol originally developed
by MODICON, which is now part of Schneider Automation.
ModBus RTU has been widely used by other companies.

CP 243-1, CP 243-1 IT Industrial Ethernet provides a proven means of networking

computers and a variety of intelligent devices. CP 243-1 and
CP 243-1 IT are communication processors used to connect the
S7-200 system to Industrial Ethernet.

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 Ethernet Communications

CP 243-1 Ethernet
CP 243-1 IT Internet

The S7-200 can be remotely configured, programmed, and

diagnosed via Industrial Ethernet using STEP 7 Micro/WIN.
The S7-200 can also communicate with other S7-200, S7-300,
and S7-400 PLCs and a variety of other devices using Industrial
Ethernet.

The IT functions of the CP 243-1 IT Internet module simplify the

process of setting up a control system that can email diagnostic
information or transfer files using Internet protocols.

EM 277 Information flow between intelligent devices such as PLCs,

computers, variable speed drives, actuators, and sensors is
often accomplished through a local area network (LAN). LANs
are used in office, manufacturing, and industrial areas.

In the past, these networks were often proprietary systems

designed to a specific vendor’s standards. Siemens has
been a leader in pushing the trend to open systems based
upon international standards developed through industry
associations. PROFIBUS-DP and Actuator Sensor Interface (AS-
i) are examples of these open networks.

The PROFIBUS-DP EM 277 module allows connection of

the S7-200 CPU to a PROFIBUS-DP network as a slave. The
CP 243-2 Communication Processor allows communication
between AS-i devices and an S7-200.

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PROFIBUS DP PROFIBUS DP is an open bus standard for a wide range
of applications in various manufacturing and automation
processes. PROFIBUS DP works at the field device level such
as power meters, motor protectors, circuit breakers, and lighting
controls. Through PROFIBUS DP the features of S7-200 PLCs
can be used to their full extent within a distributed system.
An advantage to PROFIBUS DP is the ability to communicate
between PROFIBUS DP devices of different vendors. This
provides uniform communication between all SIMATIC devices
on the PROFIBUS DP network as well as devices from other
manufacturers.

AS-i Actuator Sensor Interface (AS-i or AS-Interface) is a system

for networking binary devices such as sensors. Until recently,
extensive parallel control wiring was needed to connect sensors
to the controlling device. AS-i replaces complex wiring with a
simple 2-core cable. The cable is designed so that devices can
only be connected correctly. Several devices can be connected
to the cable.

80
 PLCs, for example, use I/O modules to receive inputs from
binary devices such as sensors. Binary outputs are used to turn
on or off a process as the result of an input.

EM 253 Position control describes a range of applications that involve

movement with varying degrees of precision. Rotary tables and
traversing cars are examples where objects are moved from
one position during a product’s manufacturing process.

The EM 253 is a positioning module that enables the user to

control the speed and position for either stepper motors or
servo motors. The EM 253 interfaces between an S7-200 PLC
and the stepper/servo motor’s power control module.

Control
Actual Value

Stepper Motor
Power Module
Servo/Stepper
Servo Motor

S7-200 with EM 253

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EM 253 Features The EM 253 provides functionality for single-axis, open-loop
position control. Features of the module include:

• High-speed control with a range of 12 - 200,000 pulse per

second

• Jerk (S curve) or linear acceleration/deceleration

• Configurable measuring system to enter data as

engineering units (such as inches or centimeters) or
number of pulses

• Configurable backlash compensation

• Supports absolute, relative, and manual methods of

position control

• Continuous operation

• Provides up to 25 motion profiles with up to 4 speed

changes per profile

• Four different reference-point seek modes, with a choice

of the starting seek direction and final approach direction
for each sequence

Web Site For more information and sales support on the S7-200 visit our
web site at:

http://www.automation.siemens.com/s7-200/index_76.htm.

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Review 6
1. The S7-200 supports ____________ counters.

2. Three types of counters used in S7-200 are

____________ , ____________ , and ____________ .

3. Counters can count to a maximum of ____________ .

4. Events that require an action from the PLC before the

scan cycle is complete are controlled by ____________
____________ instructions.

5. Depending on the counter, there are up to

____________ modes available on high-speed counters.

6. The ____________ allows communication between AS-i

devices and an S7-200.

7. The ____________ is a position control module.

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 Review Answers

Review 1 1) a: input module, b: CPU, c: output module, d: programming

device, e: operator interface; 2) 2; 3) 16; 4) 1010, 0001 0000, A.

Review 2 1) discrete; 2) discrete; 3) CPU; 4) Ladder logic; 5) program;

6) program, data, configuarable parameter; 7) 1024; 8) firmware;
9) e; 10) RS-485.

Review 3 1) 221, 222, 224, 224XP, 226; 2) b; 3) 2, 7; 4) 8, 6; 5) 14, 10;

6) Q0.3; 7) DIN.

Review 4 1) a: box, b: contact, c: coil; 2) AND Function - a: 0, b: 0, c: 0, d: 1,

Or Function - e: 0, f: 1, g: 1, h: 1; 3) I0.0 or Q0.0, and I0.1.

Review 5 1) digital; 2) retentive, off; 3) 3276.7 seconds; 4) 250; 5) 256.

Review 6 1) 256; 2) CTU, CTD, CTUD; 3) ±32,767; 4) high-speed; 5) 12;

6) CP 243-2 Communication Processor; 7) EM 253.

84
Final Exam

The final exam is intended to be a learning tool. The book

may be used during the exam. A tear-out answer sheet is
provided. After completing the test, mail the answer sheet in for
grading. A grade of 70% or better is passing. Upon successful
completion of the test a certificate will be issued.

1. The component of a PLC that makes decisions and

executes control instructions based on the input signals is
the ____________ .

a. CPU b. Input module

c. Programming device d. Operator interface

2. One byte is made up of ____________ .

a. 2 bits b. 8 bits
c. 16 bits d. 32 bits

3. The binary equivalent of a decimal 5 is ____________ .

a. 11 b. 100
c. 101 d. 111

4. An input that is either On or Off is a/an ____________ input.

a. analog b. discrete
c. high-speed d. normally open

5. A programming language that uses symbols resembling

elements used in hard-wired control line diagrams is
referred to as a ____________ .

a. ladder logic diagram b. statement list

c. network d. PLC scan

6. A type of memory that can be read from but not written to

is ____________ .

a. RAM b. ROM
c. firmware d. K memory

85
 7. A USB/PPI Multi-Master cable connects a personal
computer’s USB interface to a/an ____________ connector
on an S7-200 CPU.

a. RS-485 b. RS-232
c. Ethernet d. PROFIBUS-DP

8. The CPU 224 AC/DC/RELAY has ____________ .

a. 8 DC inputs and 10 relay outputs

b. 8 AC inputs and 6 relay outputs
c. 14 DC inputs and 14 relay outputs
d. 14 DC inputs and 10 relay outputs

9. CPU 224 will accept up to ____________ expansion

modules.

a. none b. 7
c. 10 d. 30

10. The S7-222 has the ability to store ____________ kbytes in

user data.

a. 4 b. 8
c. 2 d. 5

11. Which of the following is not part of a PLC scan?

a. Read Inputs b. Execute Program

c. Force Interrupts d. Update Outputs

12. The address designation for output four of an S7-200 is

____________ .

a. I0.4 b. I0.3
c. Q0.3 d. Q0.4

13. CPU 221 and CPU 222 provide ____________ high-speed

counters .

a. two b. three
c. four d. five

14. The maximum value of an S7-200 timer with a resolution

of 1 millisecond is ____________ seconds.

a. 3.2767 b. 32.767
c. 327.67 d. 3276.7

86
15. An S7-200 timer with a time base of 100 ms can count to
a maximum value of ____________ seconds.

a. 3.2767 b. 32.767
c. 327.67 d. 3276.7

16. The time base of TON 32 of is ____________ ms.

a. .1 b. 10
c. 1 d. 100

17. The maximum count of an S7-200 up counter is

____________ .

a. 32,767 b. 65,534
c. 98,301 d. 1,000,000

18. A/An ____________ is used to assign a mode to a high-

speed counter.

a. toggle switch b. interrupt

c. PLC scan d. definition box

19. ____________ instructions allows communication

with external devices, such as modems, printers, and
computers.

a. Transmit b. Interrupt
c. High-speed counters d. High-speed outputs

20. ____________ is used to temporarily override the input or

output status in order to test and debug the program.

a. Transmit b. Forcing
c. Interrupt d. PLC scan

87
 quickSTEP Online Courses

quickSTEP online courses are available at

http://www.sea.siemens.com/step.

The quickSTEP training site is divided into three sections:

Courses, Downloads, and a Glossary. Online courses
include reviews, a final exam, the ability to print a certificate
of completion, and the opportunity to register in the Sales
& Distributor training database to maintain a record of your
accomplishments.

From this site the complete text of all STEP courses can be
downloaded in PDF format. These files contain the most recent
changes and updates to the STEP courses.

A unique feature of the quickSTEP site is our pictorial glossary.

The pictorial glossary can be accessed from anywhere within
a quickSTEP course. This enables the student to look up an
unfamiliar word without leaving the current work area.

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