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MAS Programming Table of contents

18.03.2013, 43930126 System Manual

MAS Software, page 3.1

MAS Programming

3. 18.03.2013

Table of contents

1. IEC 61131 ................................................................................................................ 10

1.1 Why a standard? ............................................................................................................. 10

1.1.1 Existing problems .............................................................................................. 10

1.1.2 Objectives of IEC 61131-3 ................................................................................. 10

1.2 Introduction to IEC 61131................................................................................................ 11

–............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 11

1.3 Programming languages ................................................................................................. 12

1.3.1 Textual languages.............................................................................................. 12

1.3.1.1 IL - Instruction List ................................................................................ 12

1.3.1.2 ST - Structured Text ............................................................................. 13

1.3.1.3 ANSI-C ................................................................................................. 13

1.3.2 Graphical languages .......................................................................................... 14

1.3.2.1 FBD – Function Block Diagram ............................................................ 14

1.3.2.2 LD – Ladder Diagram ........................................................................... 15

1.3.2.3 SFC – Sequential Function Chart ......................................................... 16

1.4 Software model acc. to IEC 61131-3 ............................................................................... 18

1.4.1 Configuration elements ...................................................................................... 19

1.4.1.1 Configuration ........................................................................................ 19

1.4.1.2 Resources ............................................................................................ 20

1.4.1.3 Task ..................................................................................................... 20

1.4.1.4 Global variables ................................................................................... 20

1.4.1.5 Access path ......................................................................................... 20

1.4.2 POUs – Program Organization Units ................................................................. 21

1.4.2.1 PRG: Program ...................................................................................... 21

1.4.2.2 FB: Function Block ............................................................................... 21

1.4.2.3 FUN: Function ...................................................................................... 22

1.4.3 Data types.......................................................................................................... 22

1.4.3.1 Variables .............................................................................................. 23

1.4.3.2 Absolute (directly represented) variables ............................................. 23

1.4.3.3 Symbolic programming......................................................................... 24

1.4.3.4 Variable classes ................................................................................... 24

1.4.3.5 Global and local variables .................................................................... 25

1.5 Literature and references concerning IEC 61131 ............................................................ 25

2. Theory of programming ............................................................................................. 26

2.1 Working method of the CPU ............................................................................................ 26

2.1.1 Scanner task ...................................................................................................... 26

2.1.2 Cyclical program processing .............................................................................. 27

2.1.3 Time-controlled program processing .................................................................. 28

2.1.4 Internal synchronization (I/O phase) .................................................................. 29

2.1.4.1 Process image ..................................................................................... 29

MAS Programming Table of contents

18.03.2013, 43930126 System Manual

MAS Software, page 3.2

2.2 System behaviour ........................................................................................................... 30

2.2.1 Operating states and start-up behaviour ............................................................ 30

2.2.1.1 Initializing the system ........................................................................... 30

2.2.1.2 Start-up behaviour................................................................................ 30

2.2.2 FTP access ........................................................................................................ 31

- ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 31

2.3 Variable types and address ranges ................................................................................. 32

2.3.1 Simple standard data types ............................................................................... 32

2.3.1.1 Absolute (direct) and symbolic representation ..................................... 32

2.3.1.2 ANY_BIT data types ............................................................................. 32

2.3.1.3 ANY_INT data types ............................................................................ 33

2.3.1.4 ANY_REAL data types ......................................................................... 33

2.3.1.5 TIME data type ..................................................................................... 33

2.3.1.6 DATE_AND_TIME data type ................................................................ 33

2.3.1.7 STRING data type ................................................................................ 34

2.3.2 Multi element variables ...................................................................................... 34

2.3.2.1 Array .................................................................................................... 35

2.3.2.2 Structure (Struct) .................................................................................. 35

2.3.3 Using variables .................................................................................................. 35

2.3.4 Initial values of variables .................................................................................... 36

2.3.4.1 When does which initial value apply? ................................................... 36

2.4 Address ranges of variables and flags ............................................................................ 36

2.4.1.1 Inputs and output variables .................................................................. 37

2.4.1.2 System and user flags .......................................................................... 39

2.4.1.3 System flag area .................................................................................. 40

2.5 Variable types ................................................................................................................. 41

2.5.1 RETAIN variables .............................................................................................. 42

2.5.1.1 Retain concept ..................................................................................... 42

2.5.2 Global and local variables .................................................................................. 42

2.5.3 Validity of variables ............................................................................................ 43

2.5.4 Declaring and inserting variables in IEC headers .............................................. 43

2.5.4.1 Local variables ..................................................................................... 43

2.5.4.2 Hardware I/O ........................................................................................ 44

2.5.4.3 Global Variable List (GVL) ................................................................... 46

2.5.4.4 Data Unit Type (DUT) .......................................................................... 48

2.5.4.5 Function Blocks (FB) ............................................................................ 48

2.6 Programming recommendations ..................................................................................... 49

2.6.1 Naming .............................................................................................................. 49

2.6.2 Variable names .................................................................................................. 49

2.6.3 Program Organization Units (POU) .................................................................... 50

2.6.3.1 Program (PRG) .................................................................................... 50

2.6.3.2 Function Block (FB) .............................................................................. 50

2.6.3.3 Function (FUN)..................................................................................... 51

2.6.4 SFC ................................................................................................................... 51

2.6.4.1 Steps .................................................................................................... 51

2.6.4.2 Transitions ........................................................................................... 51

2.6.4.3 Actions ................................................................................................. 51

2.6.4.4 Jumps .................................................................................................. 52

MAS Programming Table of contents

18.03.2013, 43930126 System Manual

MAS Software, page 3.3

2.6.5 Program structure .............................................................................................. 52

2.6.5.1 General principles ................................................................................ 52

2.6.5.2 Example of a possible program structure ............................................. 53

2.6.6 Remarks ............................................................................................................ 54

2.7 Compiling, downloading and monitoring programs .......................................................... 54

2.7.1 Compiling ........................................................................................................... 55

2.7.1.1 Compiling the entire project ................................................................. 55

2.7.1.2 Partial compilation ................................................................................ 55

2.7.1.3 Compiler messages ............................................................................. 56

2.7.2 Download ........................................................................................................... 57

2.7.2.1 Access to the CPU ............................................................................... 59

2.7.2.2 Remote operation ................................................................................. 60

2.7.3 Online change .................................................................................................... 61

2.7.3.1 What does "online change" mean? ...................................................... 61

2.7.4 Online monitoring ............................................................................................... 62

2.7.4.1 Monitoring a body................................................................................. 63

2.7.4.2 Monitoring a header ............................................................................. 66

2.7.4.3 Entry Data Monitor ............................................................................... 66

2.7.4.4 Select data format ................................................................................ 67

2.7.4.5 Trend display ....................................................................................... 68

2.7.5 Backup/restore ................................................................................................... 70

3. Hardware-specific ..................................................................................................... 71

3.1 Introduction ..................................................................................................................... 71

3.2 Program processing ........................................................................................................ 71

3.2.1 Scanner task ...................................................................................................... 72

3.2.2 Cyclical program processing .............................................................................. 73

3.2.3 Time-controlled program processing .................................................................. 74

3.3 Internal synchronization (I/O phase)................................................................................ 75

3.3.1 Process image ................................................................................................... 75

3.3.2 Synch and event mode ...................................................................................... 76

3.3.2.1 Event mode (default) ............................................................................ 77

3.3.2.2 Synch mode ......................................................................................... 77

3.4 Operating statuses and startup behaviour ....................................................................... 78

3.4.1 Status diagram ................................................................................................... 78

3.4.1.1 Initializing the system ........................................................................... 79

3.4.2 Startup behaviour and service functions ............................................................ 80

3.4.2.1 CPU 83x-Tx ......................................................................................... 81

3.4.2.2 CPU 73x-Tx and CPU 854-T ................................................................ 81

3.4.2.3 CPU 72x-Tx ......................................................................................... 81

3.4.2.4 Flash cassette FMC 701-T ................................................................... 81

3.4.3 Memory map ...................................................................................................... 83

3.4.4 Retain variables CPU 854-T .............................................................................. 83

3.4.5 Address ranges .................................................................................................. 83

3.4.5.1 Variables and markers ......................................................................... 83

3.4.5.2 Absolute addressing ............................................................................. 84

3.4.5.3 User marker range ............................................................................... 84

3.4.5.4 System marker range ........................................................................... 85

3.5 Initialization and file system of the CPU 854-T ................................................................ 85

3.5.1 Initializing the system ......................................................................................... 85

3.5.2 Image of the compact flash (C:\) ........................................................................ 86

MAS Programming Table of contents

18.03.2013, 43930126 System Manual

MAS Software, page 3.4

4. Programming ............................................................................................................ 87

4.1 Introduction ..................................................................................................................... 87

4.1.1 The accumulator ................................................................................................ 87

4.1.1.1 Loading and saving .............................................................................. 87

4.2 Standard operators & logic operations ............................................................................ 88

4.2.1 Programming example for logic operations ........................................................ 89

4.2.1.1 Teaching objectives ............................................................................. 89

4.2.1.2 Task ..................................................................................................... 89

4.2.1.3 Solutions .............................................................................................. 89

4.2.2 Arithmetic operators ........................................................................................... 91

4.2.2.1 Arithmetic programming example ......................................................... 92

4.2.3 Comparisons ...................................................................................................... 93

4.3 Function calls .................................................................................................................. 94

4.3.1 Call in Instruction List [IL] ................................................................................... 95

4.3.2 Call in Function Block Diagram [FBD] and Ladder Diagram [LD] ....................... 95

4.3.3 Call in Structured Text [ST] ................................................................................ 95

4.4 Standard functions .......................................................................................................... 96

4.4.1 Functions for type conversion ............................................................................ 96

4.4.2 Numerical functions ........................................................................................... 97

4.4.2.1 Functions for numerical operations ...................................................... 97

4.4.2.2 Trigonometric functions ........................................................................ 97

4.4.3 Bit manipulation functions .................................................................................. 98

4.4.4 Selection functions ............................................................................................. 98

4.4.5 String functions .................................................................................................. 99

4.4.6 Sample program: Type conversion and selection ............................................ 100

4.4.6.1 Task ................................................................................................... 100

4.4.6.2 Solutions ............................................................................................ 100

4.5 Creating a function ........................................................................................................ 102

4.5.1 Sample program: Temperature conversion ...................................................... 102

4.6 Function block calls ....................................................................................................... 106

4.6.1 Call in Instruction List [IL] ................................................................................. 107

4.6.2 Call in Function Block Diagram [FBD] and Ladder Diagram [LD] ..................... 108

4.6.3 Call in Structured Text [ST] .............................................................................. 108

4.7 Standard Function Blocks ............................................................................................. 109

4.7.1 Function Blocks for bi-stable elements (flip-flops) ............................................ 109

4.7.1.1 Examples: Setting and resetting Boolean variables ........................... 109

4.7.2 Sample program: Bi-stable elements ............................................................... 111

4.7.2.1 Teaching objectives ........................................................................... 111

4.7.2.2 Task ................................................................................................... 111

4.7.2.3 Solutions ............................................................................................ 111

4.7.3 Function blocks for edge detection .................................................................. 112

4.7.3.1 SELE–Trigger..................................................................................... 112

4.7.3.2 Edge detection according to IEC 61131-3 .......................................... 113

4.7.4 Function blocks for counters ............................................................................ 114

4.7.4.1 Counter with arithmetical functions .................................................... 114

4.7.4.2 Counters with function blocks ............................................................. 114

4.7.5 Function blocks for timers ................................................................................ 115

MAS Programming Table of contents

18.03.2013, 43930126 System Manual

MAS Software, page 3.5

4.8 Type conversion ............................................................................................................ 118

4.8.1 Function blocks for type conversion ................................................................. 118

4.8.2 Sample program: Type conversion and RTC ................................................... 120

4.8.2.1 Teaching objective ............................................................................. 120

4.8.2.2 Task ................................................................................................... 120

4.8.2.3 Solutions ............................................................................................ 121

4.8.3 Applying the arithmetical operators to time types ............................................. 122

4.9 Creating a function block ............................................................................................... 123

4.9.1 Sample program: Analog value processing ...................................................... 123

4.10 Jumps and jump flags ................................................................................................... 127

4.10.1 Returns ............................................................................................................ 128

4.10.2 Sample program: Jumps, timers and trigonometric instructions ....................... 128

4.10.2.1 Teaching objective ............................................................................. 128

4.10.2.2 Task ................................................................................................... 128

4.10.2.3 Solutions ............................................................................................ 128

4.10.3 Sample program: Car park ............................................................................... 130

4.10.3.1 Teaching objectives ........................................................................... 130

4.10.3.2 Task ................................................................................................... 130

4.10.4 Solutions with SELE-Trigger ............................................................................ 131

4.10.5 Solution with trigger according to IEC 61131-3 ................................................ 132

4.11 Selection in Structured Text [ST] ................................................................................... 134

4.11.1 Selection with 'IF' ............................................................................................. 134

4.11.1.1 Statements ......................................................................................... 134

4.11.2 Selection with 'CASE OF' ................................................................................. 135

4.11.3 Loops ............................................................................................................... 136

4.11.3.1 Loop with 'WHILE DO' ........................................................................ 136

4.11.3.2 Statements ......................................................................................... 136

4.11.3.3 Loop with 'REPEAT' ........................................................................... 137

4.11.3.4 Statements ......................................................................................... 137

4.11.3.5 FOR-loop ........................................................................................... 138

4.11.3.6 Cancel with 'EXIT' .............................................................................. 138

4.11.3.7 Statements ......................................................................................... 138

4.12 Creating a user library ................................................................................................... 139

4.13 Real time clock RTC ..................................................................................................... 143

4.14 Serial port RS-232 ......................................................................................................... 144

4.14.1 Configuration ................................................................................................... 144

4.15 Programming in SFC ..................................................................................................... 147

4.15.1 Elements of Sequential Function Chart ............................................................ 148

4.15.1.1 Step ................................................................................................... 148

4.15.1.2 Transition ........................................................................................... 149

4.15.1.3 Alternative branching ......................................................................... 150

4.15.1.4 Parallel branching .............................................................................. 150

4.15.1.5 Jumps ................................................................................................ 151

4.15.1.6 Action ................................................................................................. 151

4.15.1.7 Action assignment .............................................................................. 152

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