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Manual Cos i Mir Plc
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Transcript of Manual Cos i Mir Plc
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682526 EN
06/04
COSIMIR PLC
Manual
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Order No.: 682526
Description: MANUAL
Designation: D:HB-COSI-PLC-EDU-EN
Edition: 06/2004
Authors: Christine Lffler
Graphics: Doris Schwarzenberger
Layout: 09.06.2004, Beatrice Huber
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2004
Internet: www.festo.com/didactic
E-Mail: [email protected]
The copying, distribution and utilization of this document as well as the
communication of its contents to others without express authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility
model or ornamental design registration.
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Festo Didactic GmbH & Co. KG COSIMIR PLC 3
1. What will you learn from the manual?___________________ 7
2. This is how you install COSIMIR PLC _________________ 10
2.1 System requirements ________________________________ 10
2.2 Installation of COSIMIR PLC
via on-line activation ________________________________ 12
2.3 Network installation of COSIMIR PLC __________________ 26
2.4 Installation of the communication program EzOPC ________ 28
3. These functions support you in the preparation
of PC workstations for students _______________________ 29
3.1 Description of files for a process model _________________ 29
3.2 Creating a user-specific working environment ____________ 30
3.3 Creating files with fault settings
for a process model _________________________________ 33
4. The COSIMIR PLC system ___________________________ 37
4.1 Overview of COSIMIR PLC ___________________________ 37
4.2 The process models of COSIMIR PLC __________________ 39
4.3 Controlling the process models via internal PLC __________ 44
4.4 Controlling the process models via external PLC __________ 45
4.5 Functions for fault setting
in the process model ________________________________ 47
4.6 Functions for the analysis of process models_____________ 48
Contents
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Contents
4 Festo Didactic GmbH & Co. KG COSIMIR PLC
5. Important control functions of COSIMIR PLC ___________ 50
5.1 Loading the process model ___________________________ 50
5.2 Simulating the process model ________________________ 59
5.3 Displaying and operating a process model ______________ 62
5.4 Changing the view of the process model ________________ 65
5.5 The Inputs and Outputs windows ______________________ 69
5.6 The Manual Operation window ________________________ 70
5.7 Controlling a process model via the internal S7 PLC _______ 84
5.8 Controlling a process model via the external
Soft PLC S7-PLCSIM _________________________________ 94
5.9 Controlling a process model via an external PLC _________ 108
5.10 Setting faults in the process model____________________ 121
5.11 Eliminating faults in the process model ________________ 129
5.12 Logging of fault elimination __________________________ 134
6. The following training contents can be taught with
COSIMIR PLC ____________________________________ 136
6.1 Training contents __________________________________ 136
6.2 Target group ______________________________________ 137
6.3 Previous knowledge ________________________________ 138
6.4 Example: Assigning of training aims to training syllabi ____ 138
6.5 The training concept of COSIMIR PLC _________________ 143
7. This is how you establish the mode of operation and
structure of a system in COSIMIR PLC _______________ 145
7.1 Training aims _____________________________________ 145
7.2 Methods _________________________________________ 146
7.3 Support via COSIMIR PLC __________________________ 150
7.4 Example _________________________________________ 150
7.5 Example _________________________________________ 156
7.6 Example _________________________________________ 161
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Contents
Festo Didactic GmbH & Co. KG COSIMIR PLC 5
8. This is how you establish the mode of operation of the
components forming part of a system in COSIMIR PLC __ 166
8.1 Training aims _____________________________________ 166
8.2 Methods _________________________________________ 167
8.3 Support via COSIMIR PLC __________________________ 167
8.4 Example _________________________________________ 168
9. This is how you use COSIMIR PLC in PLC programming _ 175
9.1 Training aims _____________________________________ 175
9.2 Methods _________________________________________ 176
9.3 Support via COSIMIR PLC __________________________ 178
9.4 Example _________________________________________ 178
9.5 Example _________________________________________ 185
10. This is how you carry out systematic fault finding
on a simulated system _____________________________ 193
10.1 Training aims _____________________________________ 193
10.2 Methods _________________________________________ 194
10.3 This is how COSIMIR PLC supports you________________ 201
10.4 Example _________________________________________ 201
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6 Festo Didactic GmbH & Co. KG COSIMIR PLC
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Festo Didactic GmbH & Co. KG COSIMIR PLC 7
COSIMIR PLC is a PC-based graphic 3D simulation system consisting of
preassembled process models. These process models represent
automated systems of varying complexity.
COSIMIR PLC is a tool, which enables you
to familiarise yourself with the mode of operation and structure of a
system,
to practise PLC programming and testing of the PLC programs und
to carry out systematic fault finding on systems.
These process models, also called work cells, are also available in the
form of actual systems.
This manual is intended for
Instructors
The manual provides ideas and suggestions on how COSIMIR PLC
can be used for tuition in vocational and further training.
Teachers
The information and instructions on how to operate COSMIR PLC are
of particular interest to the above.
The manual is subdivided into the following subject areas:
Chapter 2 contains information and notes regarding the installation
of COSIMIR PLC .
Chapter 3 contains information on how to set up COSIMIR PLC on
students PC workstations.
Chapters 4 and 5 describe the system and the main user functions of
COSIMIR PLC .
Chapter 6 deals with didactic aspects and lists the training contents
taught with COSIMIR PLC . It also describes the training concept
and the resulting possibilites for use in tuition.
1. What will you learn from the manual?
What is COSIMIR PLC ?
Target group
Composition of the manual
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1. What will you learn from the manual?
8 Festo Didactic GmbH & Co. KG COSIMIR PLC
Chapters 7 to 10 describe actual problem definitions regarding the
training contents, the methodical approach to solutions and their
realisation in COSIMIR PLC . The exercises are for example carried
out on the distribution station.
Certain print formats have been used for text as well as key
combinations and sequences to enable you to find information more
easily.
Print format Meaning
Bold This format is used for command names,
menu names, dialog window names, directory
names and command options.
Key1 + key2 A plus sign (+) between the key names means
that you must press the keys mentioned
simultaneously.
Key1 key2 A minus sign () between the key names
means that you need to press the keys
mentioned in succession.
Additional descriptions and support are available via the on-line Help.
The on-line Help comprises
COSIMIR Help with operation and
COSIMIR PLC Assistant.
The on-line Help consists of detailed information regarding the
functions and operation of COSIMIR PLC .
Conventions
Additional support
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1. What will you learn from the manual?
Festo Didactic GmbH & Co. KG COSIMIR PLC 9
This Help function is also a component part of the software package
COSIMIR Rob. COSIMIR Rob has a wider function scope than
COSIMIR PLC and the combined on-line Help therefore describes more
functions than those required for COSIMIR PLC .
The menu bar of the on-line Help provides functions that you are
already familiar with from using a standard Internet browser. These
include: Next and back, select start page, print selected topics, show
and hide the navigation bar or Internet connection options.
The additional indexes such as Contents, Index, Search or Favourites,
furthermore give you the option of conveniently navigating through the
information provided in the Help menu of COSIMIR PLC .
COSIMIR PLC Assistant provides detailed function descriptions and
technical documentation for the individual process models. It also
comprises a sample PLC program for the more complex process models.
The PLC program is created in STEP 7.
All process models can be directly accessed via the graphic navigator.
Adobe Acrobat Reader will need to be installed on your PC to view PDF
documents. The Adobe Acrobat Reader program is available free of
charge and can be downloaded via the Internet address
www.adobe.com.
Our telephone Hotline is available 24 hours, should you have any
queries when installing or commissioning COSIMIR PLC .
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10 Festo Didactic GmbH & Co. KG COSIMIR PLC
With COSIMIR PLC you have also acquired a CD-ROM and these
instructions. We offer two methods for the software installation:
Network installation with dongle for parallel interface or USB
interface
Installation with on-line activation.
The system requirements for COSIMIR PLC are specified.
The system requirements for a PLC programming system are not taken
into consideration. A PLC programming system is required, if you create
your own PLC programs for the process models.
Minimum configuration for COSIMIR PLC
Processor Pentium II 300 MHz processor or higher
Main memory 128 MB
Hard disk space 800 MB available
Operating system Windows 98; Windows NT/2000/XP;
Microsoft Internet Explorer
Version 5.0 or later
Graphics card Card with 3D acceleration and OpenGL
support, 32 MB RAM
Monitor 17 with screen resolution 1024 x 768 Pixel
Interfaces Parallel or USB interface for dongle with
network licence
optional: serial interface for connection to
PLC
Additional Adobe Acrobat Reader Version 6.0 or later
2. This is how you install COSIMIR PLC
2.1
System requirements
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 11
Recommended configuration for COSIMIR PLC
Processor Pentium IV 1 GHz processor
Main memory 256 MB
Hard disk space 800 MB available
Operating system Windows 98; Windows NT/2000/XP;
Microsoft Internet Explorer
Version 5.0 or later
Graphics card Card with 3D acceleration and OpenGL
support, 64 MB RAM
Monitor 19 with screen resolution 1024 x 768 Pixel
Interfaces Parallel or USB interface for dongle with
network licence
optional: serial interface for connection to
PLC
Additional Adobe Acrobat Reader Version 6.0 or later
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2. This is how you install COSIMIR PLC
12 Festo Didactic GmbH & Co. KG COSIMIR PLC
The initial steps for installation:
Switch on the PC and start up Microsoft Windows.
Insert the COSIMIR PLC CD-ROM.
Click onto Execute in the Start menu.
Enter d:setup.exe in the input field of the open dialog window.
Confirm this entry with OK.
The start screen of the installation program is now displayed:
Follow the instructions of the installation program. If you are unsure
when answering some of the questions, click onto either Back or
Cancel.
First, you will be familiarised with the licence agreements of Festo
Didactic. You must accept these licence agreements in all instances,
2.2
Installation of COSIMIR
PLC via on-line activation
Preparing the installation
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 13
otherwise it is not possible to continue with the installation. Select
Accept and then click onto the Next button.
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2. This is how you install COSIMIR PLC
14 Festo Didactic GmbH & Co. KG COSIMIR PLC
You are then offered the option of installing the software for only one
registered user.
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 15
In the following dialog window, you are requested to enter the product
ID. The product ID is a 12-digit number, which you will find on the
reverse side of the CD-ROM sleeve.
If you enter an incorrect product ID, you will receive a message from the
program, requesting you to enter a valid product ID.
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2. This is how you install COSIMIR PLC
16 Festo Didactic GmbH & Co. KG COSIMIR PLC
In the window Select Target Folder , define the subdirectory, in which
COSIMIR PLC is to be installed. We have selected the subdirectory
C:\Programme\didactic\COSIMIR PLC as a default setting for you.
To install the program in a different directory, click onto the Search
button.
You should always select an installation directory, which does not
contain any other versions of COSIMIR.
You also have the option of specifying a particular program group where
the COSIMIR PLC symbols are stored. We have specified Festo Didactic
for the program group as a default setting. You can of course rename
this.
Note
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 17
COSIMIR PLC is now ready for installation. Click onto Next to start the
installation.
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2. This is how you install COSIMIR PLC
18 Festo Didactic GmbH & Co. KG COSIMIR PLC
The Start window of COSIMIR PLC:
Carrying out the
installation
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 19
You can install COSIMIR PLC using two different options. These are:
COSIMIR extensions as well as robot and PLC languages.
We strongly recommend that you accept the preset option.
The following window is displayed if you click onto the Options button
to select the COSIMIR main program:
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2. This is how you install COSIMIR PLC
20 Festo Didactic GmbH & Co. KG COSIMIR PLC
You are now advised of the successful completion of the COSIMIR PLC
installation. Now click onto Finish.
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 21
The installation of COSIMIR PLC is complete. You now still need to
decide whether you wish to carry out the licence activation immediately
or at a later stage.
Various options are available to you for the activation of your licence:
On-line activation
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2. This is how you install COSIMIR PLC
22 Festo Didactic GmbH & Co. KG COSIMIR PLC
We recommend that you use the direct on-line activation as a default
setting.
You can however also carry out the activation from another PC. If you do
not have an Internet connection, you can also request the activation
code via telephone.
This telephone service is available
Monday to Friday from 8:00 h to 22:00 h CET.
You have decided to use direct on-line activation:
You are requested to establish an Internet connection. Having done so,
click onto Next and your licence will then been activated automatically.
The following message will be displayed if direct communication is not
possible due to Internet access protected by a firewall:
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 23
The activation code is available on the relevant Internet page.
Highlight the activation code and copy it via the clipboard to the input
field provided for the activation code using Ctrl+C and Ctrl+V.
Activation is complete as soon as you click onto Finish.
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2. This is how you install COSIMIR PLC
24 Festo Didactic GmbH & Co. KG COSIMIR PLC
You have selected the option of carrying out the on-line activation from
another PC. The following request is therefore displayed:
Now establish Internet access to the specified Internet address on
another PC. The following window is then displayed:
Indirect activation
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 25
Copy the licence code to the relevant input field. Now click onto the
Generate activation code button.
The activation code is now displayed. Copy this code and insert it in the
specified field of your installation computer.
You have decided to request the activation code via telephone:
Contact Festo Didactic via one of the telephone numbers listed. Quote
your licence code and you will then be given the activation code for your
COSIMIR PLC software.
Enter the activation code in the input field designated for this. The
licence will be activated as soon as you click onto Finish.
Telephone request
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2. This is how you install COSIMIR PLC
26 Festo Didactic GmbH & Co. KG COSIMIR PLC
You can save the licence code and the activation code prior to
completing the licence activation via Finish. To do so, click onto the
Print/Copy button.
You are offered various options of saving the licence code and
activation code.
If you have purchased a multiple licence, you will need to activate each
individual installation. You will be given the relevant information during
each activation as to how many licences can still be activated with the
product ID quoted.
The term network installation refers primarily to the software licence
allocation. With network installations, the software is made available
via a network and a central licence server.
You will need a green dongle for the network installation. The licences
are allocated dynamically and can be requested from any workstation in
the network up to the maximum number ordered. The licence server is a
computer on the network, which performs the licence allocation. The
dongle needs to be permanently inserted in the parallel or USB port
during the operation of COSIMIR PLC so that users on the network are
able to permanently access the information of the dongle.
Multiple licence
2.3
Network installation
of COSIMIR PLC
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2. This is how you install COSIMIR PLC
Festo Didactic GmbH & Co. KG COSIMIR PLC 27
You also have the option of setting up a local single station licence.
Start the installation as described above. The following start screen is
then displayed:
To set up a single station version, select the second option. The
installation process is effected in the same as described above.
If you have already completed an installation, you can subsequently
make additions to the COSIMIR PLC installation using the option
Change Components.
Single station
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2. This is how you install COSIMIR PLC
28 Festo Didactic GmbH & Co. KG COSIMIR PLC
The software program EzOPC is required if you control the process
models of COSIMIR PLC via an external PLC. EzOPC effects the
communication between the process model and the external PLC.
This is how you install EzOPC
1. Insert the COSIMIR PLC CD-ROM.
2. Click onto Execute in the Start menu.
3. Enter d:\EzOPC\ezopc_setup.exe in the input field of the open dialog
window and confirm it with OK.
The start screen of the installation program is now displayed:
4. Follow the instructions of the installation program.
2.4
Installation of the com-
munication program
EzOPC
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Festo Didactic GmbH & Co. KG COSIMIR PLC 29
COSIMIR PLC consists of functions to support you in the use of the
software program during training.
These include:
An individual working environment that can be set up on each
students PC. This working environment stores user specific data for
COSIMIR PLC .
Files with fault settings for a process model can be centrally set up
by instructors and easily copied to the PC workstation of the
students.
The example of the distribution station process model is used to
demonstrate which files belong to a process model and what
information is stored in these files.
The name of the directory for the distribution process model is
DistributingStation.
3. These functions support you with the preparation
of PC workstations for students
3.1
Description of files for a
process model
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3. These functions support you with the preparation of PC workstations for students
30 Festo Didactic GmbH & Co. KG COSIMIR PLC
File Description
DistributingStation.mod Process model for simulation via the internal S7-PLC.
DistributingStation.ini Initialisations for the process model: This file contains all user
specific settings for the process model such as window
configuration, fault settings, etc.
DistributingStation.prot Protocol of fault localisation: This file is read in the teacher mode
and displayed in the fault log window.
DistributingStation.htm
DistributingStation.xls
DistributingStation.txt
Export of fault log: Changes in the fault localisation and in the fault
log are automatically exported to these files. These files can then for
instance be viewed via Microsoft Internet Explorer or Microsoft
Excel.
DistributingStation.mcf Settings regarding fault setting: This file contains all settings
regarding the activation, start, duration and localisation of a fault. If
this file exists in the process model directory, then it overwrites the
settings in the INI file. If not, then the fault settings stored in the INI
file are used.
User-specific working environments consist in the main of the process
models and files with the user specific data.
User specific data are:
Window configurations,
Settings for the process model,
Settings regarding fault setting,
Protocol of fault localisation.
In order to create a user-specific working environment, the process
models are saved to a separate directory on the PC. Any user specific
data is then also stored in this directory.
3.2
Creating a user-specific
work environment
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3. These functions support you with the preparation of PC workstations for students
Festo Didactic GmbH & Co. KG COSIMIR PLC 31
For example, to set up the working environment for three different users
on one PC, you will need to copy the process models into three different
directories. Each user will then be working with his/her own directory,
which corresponds to the users working environment. The user loads
the process models with which he/she is working in COSIMIR PLC from
his/her directory.
COSIMIR PLC supports you with the setting up of user specific working
environments. Use the setup program SetupSamples.exe for this.
The SetupSamples.exe program
The SetupSamples.exe program enables you to create the user specific
working environments for COSIMIR PLC on a PC.
The setup program SetupSamles.exe installs the process models
assistant-aided on a computer or a network path.
The choice of installation directory is arbitrary.
No administrator rights on the computer are required.
This is how you create a user specific working environment for
COSIMIR PLC
1. Insert the COSIMIR PLC CD-ROM.
2. Click onto Execute in the Start menu.
3. Enter d: SetupSamles.exe in the input field of the open dialog
window and confirm this with OK.
The start screen of the installation program is now displayed.
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3. These functions support you with the preparation of PC workstations for students
32 Festo Didactic GmbH & Co. KG COSIMIR PLC
4. Follow the instructions of the installation program. Select the
desired working directory as the installation directory.
5. If users want to work in their working environment, then they are to
start COSIMIR PLC . The process models that users are to work with
must always be loaded from the users working directory.
You can load a process model from any working directory by
selecting Open in the File menu and navigating through your
working directory and selecting the desired process model.
Please note that file names of process models to be controlled via
an external PLC always end with the identifier OPC. File names of
process models controlled via the internal PLC do not end with the
identifier OPC.
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3. These functions support you with the preparation of PC workstations for students
Festo Didactic GmbH & Co. KG COSIMIR PLC 33
You can also start the setup program SetupSamples.exe from the
Windows command line (cmd.exe). To install several working
environments from COSIMIR PLC on one PC, you have the option of
carrying out the installation by means of a batch file. The batch file is
called up via the Windows command line.
Excerpt from a batch file:
SetupSamples.exe /S XD:C:\CosimirPLC\Student1
SetupSamples.exe /S XD:C:\CosimirPLC\Student2
SetupSamples.exe /S XD:C:\CosimirPLC\Student3
Files with fault settings for a process model can be created centrally by
teaching staff and copied to the PC workstations of students in a simple
manner.
Note
3.3
Creating files with fault
settings for a process
model
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3. These functions support you with the preparation of PC workstations for students
34 Festo Didactic GmbH & Co. KG COSIMIR PLC
This is how you create a file centrally with fault settings for a process
model:
1. Start COSIMIR PLC .
2. Load the desired process model, e.g. the process model Distribution
Station. The process model is to be controlled via the internal PLC
and the file name therefore does not include the identifier OPC.
3. Open the Fault Setting window by clicking onto Fault Setting in the
Execute menu.
4. The Fault Setting window opens once you have entered the
password.
5. Now set a fault for example for the PLC input 1B1.
6. Activate the context sensitive menu via the right mouse button and
select the option Export.
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3. These functions support you with the preparation of PC workstations for students
Festo Didactic GmbH & Co. KG COSIMIR PLC 35
7. The faults set for the process model DistributingStation.mod have
been exported to the file DistributingStation.mcf. You will find this
file in the same directory, in which the process model loaded at the
time is also stored.
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3. These functions support you with the preparation of PC workstations for students
36 Festo Didactic GmbH & Co. KG COSIMIR PLC
8. Now copy the file with the fault settings to the user specific working
environments. The user specific working environments are those
directories, where only the process models have been installed.
Select the directory in which the relevant process model is stored as
directory, in this case the Distribution Station process model.
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Festo Didactic GmbH & Co. KG COSIMIR PLC 37
COSIMIR PLC comprises the following:
The simulation software COSIMIR PLC
The communication software EzOPC
The on-line COSIMIR Help
The on-line COSIMIR PLC Assistant
A PDF file with information regarding EzOPC
A manual
COSIMIR PLC is a PC-based 3D simulation system with preassembled
process models.
Internal S7 PLC
OPC client
EzOPC (OPC server)
EasyPort
ExternalPLC
S7-PLCSIM
Operatingfunctions
COSIMIRassistant
COSIMIRhelp
Process models
MC7-Code
Component parts of COSIMIR PLC
4. The COSIMIR PLC system
4.1
Overview of
COSIMIR PLC
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4. The COSIMIR PLC system
38 Festo Didactic GmbH & Co. KG COSIMIR PLC
The following are required to simulate the operation of a process:
A PLC and PLC program to control the process,
The simulation to simulate the behaviour of the process. This
simulation ensures for example, that cylinders move and sensors
are activated.
Sample PLC programs are available for complex process models. These
PLC programs define a possible process control system. You can of
course create new PLC programs that generate a different process
execution.
When loading a process model, the sample PLC program is
automatically downloaded at the same time, provided that it exists. The
PLC program is executed via a SIMATIC S7 simulator. This S7 simulator
is a component part of COSIMIR PLC . The integrated
S7 simulator is also referred to as the internal PLC.
Once the process model has been loaded, the process can be simulated
immediately.
The advantage with this is that you can familiarise yourself with,
activate and monitor the process. Plus there is no need for you to have
created a PLC program beforehand.
One particular additional function offered by COSIMIR PLC is the
possibility of simulating faults, whereby you can set typical faults in a
process model. The following can for example be causes of malfunction:
A mechanically displaced sensor, a cable break or failure of an entire
module. The cause of the fault must be found by means of systematic
fault finding and eliminated.
One of the main focal points of COSIMIR PLC is the monitoring and
analysis of processes and elimination of faults.
Another focal point is the creation of your own PLC programs for the
process models. These PLC programs are loaded to an external PLC and
COSIMIR PLC exchanges the input/output signals with the external PLC
via the OPC interface.
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4. The COSIMIR PLC system
Festo Didactic GmbH & Co. KG COSIMIR PLC 39
The following can be used as external PLCs
Any actual PLC
The Soft PLC SIMATIC S7-PLCSIM
COSIMIR PLC requires the software program EzOPC for connection to
an external PLC. The OPC server EzOPC communicates with any PLC via
the EasyPort interface.
.
Please note: EzOPC is not installed automatically with the software
program COSIMIR PLC . If required, this program is to be installed from
the DC-ROM provided.
The process models are realistic replicas of actual working stations and
modules.
Each process model comprises two work cells. The work cell whose file
name does not have the ending OPC is controlled via an internal PLC. If
you wish to control the process model via an external PLC, you need to
select the process model with the file name ending in OPC.
Process model Description File name
Processing Station
The process model represents a
simulation of the MPS Processing
Station of Festo Didactic. In this
work cell, workpieces are to be
tested, processed and transferred
to the adjacent station. A sample
PLC program is available for this
process model.
ProcessingStation.mod
ProcessingStation(OPC).mod
4.2
The process models
of COSIMIR PLC
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4. The COSIMIR PLC system
40 Festo Didactic GmbH & Co. KG COSIMIR PLC
Process model Description File name
Handling Station
The process model represents a
simulation of the Festo Didactic
MPS Handling Station. In this
work cell, workpieces are to be
removed from a retainer and,
depending on the results of
material testing, deposited on a
slide. A sample PLC program is
available for this process model.
HandlingStation.mod
HandlingStation(OPC).mod
Stacker Store Station
The process model represents a
simulation of the Festo Didactic
Stacker Store. In this work cell,
workpieces are to be put into and
removed from storage. A sample
PLC program is available for this
process model.
StoreWorkCell.mod
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4. The COSIMIR PLC system
Festo Didactic GmbH & Co. KG COSIMIR PLC 41
Process model Description File name
Testing Station
The process model represents a
simulation of the Festo Didactic
MPS Testing Station. In this work
cell, the material characteristics
of the workpieces is to be
determined and the workpiece
height checked. Depending on
the test result, the workpiece is
either ejected or transferred to
the adjacent station. A sample
PLC program is available for this
process model.
TestingStation.mod
TestingStation(OPC).mod
Buffer Station
The process model represents a
simulation of the Festo Didactic
MPS Buffer Station. In this work
cell, workpieces are to be
transported, buffered and
separated out. A sample PLC
program is available for this
process model.
BufferStation.mod
BufferStation(OPC).mod
Sorting Station
The process model represents a
simulation of the Festo Didactic
MPS Sorting Station. In this
workcell, workpieces are to be
sorted according to material and
colour. A sample PLC program is
available for this process model.
SortingStation.mod
SortingStation(OPC).mod
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42 Festo Didactic GmbH & Co. KG COSIMIR PLC
Process model Description File name
Distribution Station
The process model represents a
simultation of the Festo Didactic
MPS Distribution Station. In this
work cell, workpieces are to be
separated out and transferred to
the adjacent station. A sample
PLC program is available for this
process model.
DistributingStation.mod
DistributingStation(OPC).mod
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Process model Description File name
Rotary Indexing Table Module
The process model represents a
simulation of the Festo Didactic
MPS Rotary Indexing Table
module. In this work cell,
workpieces are to be tested and
polished in two parallel
sequences.
RotaryTable.mod
RotaryTable(OPC).mod
Stacking Magazine Module
The process model represents a
simulation of the Festo Didactic
MPS Stacking Magazine module.
In this work cell, workpieces are
to be separated out from the
magazine.
StackMagazine.mod
StackMagazine(OPC).mod
Changer Module
The process model represents a
simulation of the Festo Didactic
MPS Changer module. In this
work cell, workpieces are to be
picked up by a vacuum suction
cup and transferred by means of a
semi-rotary actuator.
ChangerModule.mod
ChangerModule(OPC).mod
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The PLC integrated into COSIMIR PLC is a SIMATIC S7 simulator. The S7
simulator can execute LDR, FCH and STL programs created in STEP 7.
The internal PLC executes the sample PLC programs provided for the
process models and enables you to immediately simulate the
processes.
Detailed information regarding the function scope of the internal PLC is
available via the COSIMIR on-line Help.
4.3
Controlling the process
models via internal PLC
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If you are creating and testing your own PLC programs, we recommend
that you download the programs to an external PLC and execute them
from there. The advantage of this is that you can choose the PLC and
programming system of your choice. Also, the testing and diagnostic
functions designated by the program for this purpose are available to
you for fault finding in the PLC program. This includes the status display
of PLC input/outputs and variables, the on-line display of the PLC
program and also the read-out of machine statuses.
If you are using the Soft PLC7-PLCSIM as external PLC, you do not
require any additional hardware components.
Information exchange with configuration via external Soft PLC S7-PLCSIM
4.4
Controlling the process
models via external PLC
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If you are using a hardware PLC as external PLC, you will require
EasyPort and the data cable for the exchange of input/output signals.
EasyPort transmits the input/output signals of the PLC to the OPC
server ExOPC via the serial interface of the PC and the OPC server
passes on the data to the process model simulation. Conversely, the
statuses of sensors and actuators are communicated from the process
model to the external PLC.
Information exchange with configuration via external hardware PLC
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The dialog window for fault setting is password protected. Only
instructors have access to this dialog.
A list of typical faults is available for each process model, from which
you can select one or several faults.
The exercise for students is to identify and describe the fault within the
process and to then determine the cause of it. The students then enter
the suspected fault in the dialog window for fault elimination. If the fault
has been correctly identified, the process will then function correctly.
The entries in the dialog window for fault elimination are logged and can
be seen by instructors and trainers.
4.5
Functions for fault setting
in the process model
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COSIMIR PLC offers you various options of monitoring and analysing
the execution of a process.
As soon as the simulation of a process model is active and a PLC is
controlling the process, you can activate and visually monitor progress.
The process is controlled by means of the keys and switches on the
control console.
4.6
Functions for the analysis
of process models
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The electrical status of the process components is displayed by LEDs
on the sensors and valves.
If pressure is applied to a cylinder connection, the connection is
highlighed in blue. The pneumatic tubing itself is not simulated.
The statuses of the PLC inputs/outputs are shown in separate
windows.
An overview of all process statuses and process operations is
provided in the Manual Operation window.
If you want to run the process step-by-step, you need to use the Manual
Operation as a tool to control the process. You can stop the process at
defined points by setting breakpoints.
In the absence of an active PLC program during process model
simulation, you can use the Manual Operation window to activate
individual process activities. This will enable you to, for instance,
control the movement of a cylinder or switch on or off an electrical
motor.
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This chapter describes the main control functions of COSIMIR PLC . MS
Windows programs provides various options for activating commands.
In this account, commands are initiated via the options in the menu bar.
You can of course also use the symbols bar, appropriate key
combinations or the context sensitive menu via the right mouse button.
Detailed information regarding the use of all options in COSIMIR PLC is
available via the on-line Help for this software package.
Prior to loading a process model, you will need to decide whether the
process model is to be controlled via the internal or via an external PLC.
The file names of process models to be activated via an external PLC
end with the identifier OPC.
You can load the process model with the help of COSIMIR PLC
Assistant or a command in the menu bar.
5. Important control functions of COSIMIR PLC
5.1
Loading a process model
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This is how you load a process model via COSIMIR PLC Assistant
1. Start COSIMIR PLC .
Once COSIMIR PLC is started, both the View window and the Help
window are displayed.
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2. Select the desired process model, for example the process model
Distribution, controlled via the internal PLC.
The process model is opened by clicking onto Open Distribution (for
internal PLC).
Please note:
A click onto the picture or the title of the process model will take you to
COSIMIR PLC Assistant, where a function description and technical
documentation regarding the process model are at your disposal.
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3. The process model for the Distribution station is loaded and is
displayed in the View window. In addition, you will also find the
status of the PLC input/outputs in the Inputs and Outputs windows.
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A dialog window is displayed via File download, if you open a process
model the first time via the on-line Help.
Note
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If you select the option Open File from your Current Position, you need
to deactivate Always Confirm Open Files of this Type and click OK.
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This is how you load a process model by activating a menu command
1. Click onto Open in the File menu.
The process models are filed under the default setting
c:\Programme\didactic\COSIMIR PLC \samples.
Each process model is in its own subdirectory.
2. Select the desired process model, for example the process model
Distribution, controlled via the internal PLC. To do so, open the
subdirectdory DistributingStation:
Highlight the directory DistributingStation and click onto the Open
button.
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3. Highlight the file DistributingStation.mod and click onto the Open
button.
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4. The process model for the Distribution station is now loaded and is
displayed in the View window.
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Once loaded, the process is displayed, but simulation is not active.
If a process model, controlled via the internal S7 PLC, has been loaded,
a sample PLC program will have been downloaded to the internal S7 PC
at the same time.
This is essential to facilitate the operation of a process model.
As soon as simulation is active, you can monitor the visual simulation
and as such the function sequence of the process model in the activity
window.
5.2
Simulating a process
model
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Certain information is always available to you.
In the header you will see the file name with path details of the process
model loaded.
The status line informs you of the operational status of the process
model:
The field to the far left shows whether simulation is active or stopped.
Stopped:
Simulation mode is not active. The process model is not simulated.
Cycle:
The process model is simulated.
Sequence:
The process model is simulated.
The field to the right indicates the simulation time.
In COSIMIR PLC , both simulation modes Cycle and Sequence are
identical.
Note
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This is how you switch simulation on and off again
1. Click onto Start in the Execute menu.
Simulation is active. In the status bar, the simulation mode is
displayed via Sequence.
Alternatively, you can also activate simulation via the menu option
Start Cycle or via the Stopped button in the status bar.
2. You can stop simulation by clicking onto Stop in the Execute menu.
Alternatively, you can also click onto the Cycle field.
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A process model controlled via a PLC program is operated via the keys
and switches of the control console. To do so, simulation must be
active. The simulation status can be established via the information in
the status bar.
5.3
Displaying and operating
a process model
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This is how you operate a process model controlled via the sample PLC
program
1. Start simulation by clicking onto Start in the Execute menu.
2. The illuminated Reset button now requests the Reset function.
Failing this, put the process model into the initial position. To do so,
activate the simulation. Then click onto the command Work Cell
Initial Position in the Processing menu.
Now restart simulation.
3. Carry out the Reset function by clicking onto the Reset button.
4. The illuminated Start button indicates that the process model is in
the initial position and the start condition is fulfilled.
5. Make sure that workpieces are available. For the process model
Distribution, you fill the magazine with workpiece by clicking onto
the different coloured symbolic workpieces on the slotted assembly
board.
6. Start the cycle by clicking onto the Start button.
If the process model is to be controlled via your own PLC program, then
you will know how the process and operation are defined.
If the process model is not controlled via a PLC program, then you can
manually activate specific actuators of the process. You will need the
functions of the Manual Operation window for this.
This is how the status of the process model is displayed
The electrical status of the process components is displayed via the
LEDs on the sensors and valves.
If pressure is applied to a cylinder connection, then this connection
is highlighted in blue.
The pneumatic tubing itself is not shown.
The status of the PLC signals is displayed in the Inputs and Outputs
windows.
The Manual Operation window provides an overview of all process
statuses and process events.
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The designation of components is shown by clicking onto the
connection or LED of a process component. This designation is
identical to the designation in the circuit diagram.
An exception to this are the designations of compressed air
connections. These pertain to the valves which supply the
compressed air connections with air.
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The perspective view of a process model is freely adjustable and you
can turn, move, enlarge or minimise the process model representation
by means of a few central commands.
5.4
Changing the view of a
process model
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The perspective view is defined by the coordinates of the viewer (=
angle) and a reference point of the process model (= centre).
Z
Reference pointAngleTurn
Y
X
Definition of perspective view
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This is how you move the process model
1. Click onto the Move command in the View menu.
This changes the mouse pointer into a small coordinate system,
which indicates the direction in which the angle and reference point
can be moved. A dashed arrow means that it is not possible to move
in the respective direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in Z- or X-direction.
4. Release the mouse pointer again. The view will then change
accordingly.
You can also activate the Move command by holding down the Shift key
and pressing the left mouse button.
This is how you turn the process model
1. Click onto Turn in the View menu.
The mouse pointer now changes into a small coordinate system,
which indicates the direction in which the angle and reference point
can be moved. A dashed arrow means that it is not possible to move
in the respective direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in Z-or X-direction.
4. Release the mouse pointer again.
The view will then change accordingly.
You can also activate the Turn command by holding down the Ctrl key
and then pressing the left mouse button.
This is how you enlarge or minimise the view
1. Activate the Zoom command in the View menu.
The mouse pointer now changes into two squares.
2. To enlarge the view, hold down the left mouse button and move the
mouse pointer in the direction of the arrow.
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3. To reduce the view, hold down the left mouse button and move the
mouse pointer in the opposite direction of the arrow.
You can also activate the Zoom command by holding down the Shift +
Ctrl key combination and then pressing the left mouse button.
This is how you enlarge a particular section
1. Position the mouse pointer on a corner of the section.
2. Hold down the Shift + Ctrl key combination.
3. Press the right mouse button and move the mouse. A frame is then
displayed.
4. Place the frame around the section you would like to enlarge by
moving the mouse.
5. Release the right mouse button. The view is now enlarged.
This is how you enlarge the view
Click onto Zoom-In in the View menu. The image is now enlarged to
125%.
This is how you minimise the view
Click onto Zoom-Out in the View menu. The picture is minimised to
80%.
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The Inputs and Outputs windows indicate which signals are applied at
the inputs and outputs of the PLC. 0-signals are displayed in red and
1-signals in green. If the input or output signal is forced, the value is
shown in angle brackets, e.g. .
This is how you open the Inputs window
Click onto the option Inputs/Outputs in the Options menu and select
Display Inputs.
So that you know which process signal you are dealing with, the signal
names include the relevant designation from the circuit diagrams.
Example: STATION_1B2: PLC input, which is connected to the sensor
1B2.
This is how you open the Outputs window
Click onto the option Inputs/Outputs in the Options menu and select
Display Outputs.
So that you know which process signals you are dealing with, the signal
names contain the relevant designations from the circuit diagrams.
Example: STATION_1Y1: PLC output, which is connected to the valve
coil 1Y1.
5.5
The Inputs and Outputs
windows
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You can however also open the Inputs and Outputs windows via Work
Areas in the Windows menu, where you will often find the required
window combinations.
The Manual Operation window offers various functions
Display of process statuses and process activities,
Controlling individual actuators of the process model,
Setting breakpoints in the process model simulation.
In the lefthand section of the window you can see the process activities.
These include mainly the actuation of valves. An applied 1-signal is
represented by a red illuminated LED.
In the righthand section of the window you can monitor all process
statuses.
Process statuses include the status of the sensor and valve coils. Here,
1-signals are represented by a green illuminated LED.
The signal statuses are also shown in the Value column. If the signal is
forced, the value is shown in angle brackets. If the Value column is now
shown, activate the item in the context sensitive menu via the right
mouse button.
Notes
5.6
The Manual Operation
window
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The following additional information is displayedi: If a signal status has
changed since the last simulation cycle, then the respective line is
highlighted in colour. Process activities are shown in red and process
statuses in green. This method enables you to easily identify and track
any signals which have changed.
This is how you open the Manual Operation window
In the Execute menu, click onto Manual Operation.
Alternatively , open the window by clicking onto Manual Operation
under Work Areas in the Windows menu.
This is how you control individual actuators in the process model
If you want to actuate individual actuators of a process model manually,
we recommend that you disconnect the process model from the PLC.
Only those commands will then be executed which have been initiated
via manual operation since the PLC program is no longer active.
If you wish to terminate manual operation and control the process
model via a PLC program once again, you will need to reconnect the
process model to the PLC.
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1. Make sure that simulation is stopped.
2. Isolate the process model from the PLC.
Move the mouse pointer to the left section of the Manual Operation
window and the process activities. Press the right mouse button to
open the context sensitive menu and select Disconnect Controllers.
Or:Click onto the left section of the Manual Operation window and
open the context sensitive menu via the right mouse button and
then select Disconnect Controllers.
3. Start the simulation.
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4. Double click onto the process activity line you wish to execute. The
double click causes the signal to change.
If you double click onto a line with a valve activation, this causes the
value of the respective valve coil to change. If the value 0 is applied,
this will be set to 1 or vice versa. The double click therefore has a
toggle function.
Please note: To switch a valve with two valve coils to a particular
position, the appropriate electrical signal must be applied to both
valve coils.
5. Stop simulation, if you wish to end Manual Operation.
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6. To control the process model via a PLC program again, move the
mouse pointer to the left section of the Manual Operation window
to the process activities. Now press the right mouse button to open
the context sensitive menu and select Restore I/O Connections.
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This is how you set breakpoints during the operation of the process
model
To stop the process model operation at defined points, you will need to
set breakpoints in the process model simulation. You can stop the
process run whenever the value of a process signal is changing.
Breakpoints merely influence process model simulation; the PLC
program for the control of the process model remains unaffected. If a
breakpoint is set at a signal, this causes the process model simulation
to stop when the value of the signal changes. The changed value is
transmitted to the PLC as soon as simulation is restarted.
1. Make sure that a process model is loaded.
2. Start the process model simulation and establish that the process
model is controlled via a PLC program.
3. Open the Manual Operation window. To do so, click onto Manual
Operation in the Execute menu.
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4. Click onto the line of the desired process activity. In this case, for
example, line 2 to control valve coil 1Y1 for the magazine ejector.
Click onto the right mouse button to open the context sensitive
menu and select Stop at Value Change.
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5. The Stop sign in the line in the Manual Operation window indicates
that a breakpoint is set at this signal.
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6. Activate the process. As soon as the PLC generates a 1-signal at the
valve coil, simulation stops. You can follow the simulation status in
the status bar.
7. If you restart simulation of the process model, this causes the
process run to continue and the magazine ejector to eject a
workpiece.
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8. To delete the breakpoint, click onto the line with the breakpoint with
the right mouse button. This opens the context sensitive menu of
the right mouse button. Select Stop at Value Change. This command
is realised in the form of a toggle function. The breakpoint is
removed. Alternatively, you can select the command Delete all
Stops.
Please note that you can also set breakpoints at signals in the Process
Status window section.
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This is how you control the process model step-by-step
If you want to execute the process stepwise, then use the Manual
Operation window as a tool to control simulation. You can stop the
process at defined points by setting breakpoints.
To execute the process step-by-step, set breakpoints against all process
activities. In this way, the process will be stopped whenever an actuator
changes its status.
1. Make sure that a process model is loaded.
2. Start the process model simulation and make sure that the process
model is controlled via a PLC program.
3. Open the Manual Operation window. To do so, click onto Manual
Operation in the Execute menu.
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4. Under Process Activities, highlight all lines containing signals for
valve coils by pressing the Ctrl key and clicking onto the desired
lines with the left mouse button.
Open the context sensitive menu via the right mouse button and
select Stop at Value Change.
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5. All lines with valve coils now indicate breakpoints.
6. Control the process by using the keys and switches of the control
console. Whenever the status of a process signal changes,
simulation stops. The process is continued if you restart simulation.
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7. To remove the breakpoints again, open the context sensitive menu
via the right mouse button and select Delete all Stops.
Please note that you can also set breakpoints at signals in the Process
Status window section.
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The internal S7 simulator interprets executable S7 programs. A sample
PLC program for S7-300 is available for each of the more complex
process models. When you load a model, the respective S7 program is
also downloaded. You can exchange this S7 program with another S7
program, if required.
Only complete project files with the file extension S7P can be
downloaded. The project will need to have been created via the SIMATIC
Manager and must be in accordance with the Siemens MC7 code at
binary level.
5.7
Controlling a process
model via the internal
S7 PLC
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This is how you control a process model via the relevant sample PLC
program
1. Click onto Open in the File menu.
2. Load the desired process model, for example the Distribution
process model. The file name of the model is
DistributingStation.mod.
The process models are stored under a default setting
c:\Programme\didactic\COSIMIR PLC \samples.
When a process model is loaded, the respective S7 program is also
downloaded.
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3. As soon as simulation of the process model is started, the execution
of the S7 is also started.
To do so, click onto Start in the Execute menu.
This is how you control a process model via a newly created S7 PLC
program
1. Load the desired process model. The process model is to be
controlled via the internal PLC. The file names of process models for
the internal PLC do not end in OPC.
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2. Make sure that simulation has stopped.
3. Select Open in the File menu to open the Open File window.
4. Under File Type, select S7 Project (*.S7P).
All files of this format available in the current directory are
displayed.
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5. Navigate to the directory which contains your S7 project.
Select the required S7 project and click onto the Open button.
6. If the project you have selected contains several S7 programs, then
select one for simulation and confirm your choice with OK.
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7. Start the process model simulation. Select Start in the Execute
menu. As soon as the simulation of the process model is started, the
internal S7 simulator is also started and the loaded PLC program is
executed.
This is how you estalish which S7 program is currently loaded
1. Click onto the S7 Program Manager option in the Execute menu.
2. The name and the structure of the PLC program are displayed in a
clearly set out tree structure.
The PLC program may consist of the following blocks: Organisation
blocks, function blocks, data blocks, functions and system
functions.
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3. Click onto the +-symbol to display the PLC program.
You can view the contents of a block by clicking onto a block.
4. In the absence of a loaded PLC program, the window S7 Program
Manager looks as follows:
Further information regarding the display of S7 programs in STL or for
the display and use of timing diagrams is available via the on-line Help.
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This is how the sample programs are filed on the computer
1. Select Open in the File menu to open the Open File window.
2. Under File Type, select S7 Project (*.S7P).
All the files in this format available in the current directory will be
displayed.
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3. Navigate to the directory c:\Programme\didactic\COSIMIR
PLC\samples\S7\MPSC. This directory contains the S7 project with
all the sample PLC programs for the stations, provided that you have
transfered all the preset directories when installing COSIMIR PLC .
The sample program for the stacker store is stored in the Store
subdirectory.
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4. Select the S7 project and click onto the Open button.
The program name provides information about the PLC program and the
process model to which it belongs:
The initial digit corresponds to the station number.
The two letters after this digit designate the station:
DI: Distribution station
TE: Testing station
PR: Processing station
HA: Handling station
BU: Buffer station
SO: Sorting station
The letters beginning with underscore designate the programming
language of the PLC program:
AS: Programming language GRAPH,
KFA: Programming languages LDR, FCH and STL,
KFAFF: Programming languages LDR, FCH and STL. The step
structure of the process activity is simulated with flipflops.
Please note that the internal S7 PLC can only execute LDR, FCH or STL
programs.
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S7-PLCSIM is a Soft PLC, which executes the PLC programs created in
STEP 7. Within STEP 7, comprehensive testing and diagnostic functions
are available to you for fault finding in the PLC program. They include,
for instance, the status display of variables or the on-line display of the
PLC program. You can make use of these functions when creating the
PLC program for a process model in STEP 7 and subsequently when
testing the PLC program during interaction with the process model.
The exchange of the PLC input/output signals between the process
model simulation and the Soft PLC S7-PLCSIM is effected via the EzOPC
program. EzOPC must be installed on your computer. Should this not be
the case, you will need to carry out the installation of the COSIMIR PLC
CD-ROM now.
5.8
Controlling a process
model via the external
Soft PLC S7-PLCSIM
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Following successful installation, EzOPC is automatically called up by
COSIMIR PLC as soon as you start the process model simulation.
The following requirements must be fulfilled in order for the PLC
input/output signals to be correctly exchanged:
When EzOPC is started, both communication users S7-PLCSIM and
the process model simulation- must already be active. Only then can
EzOPC set up the communication link to both stations.
The EzOPC must be correctly configured for the data exchange.
Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with S7-PLCSIM
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This is how you control a process model with S7-PLCSIM
1. Start STEP 7 or the STEP 7 Manager and open the required
S7 project.
2. Start S7 PLCSIM by clicking onto Simulate Modules under Options.
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3. The S7-PLCSIM window now opens.
4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
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5. Download the desired PLC program in S7-PLCSIM by highlighting the
Modules folder. Then click onto Download in the menu Target
System.
6. Load the appropriate process model in COSIMIR PLC . The file name
of the process model must end in OPC, since it is to be controlled via
the external PLC S7-PLCSIM.
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7. Start the process model simulation by clicking onto Start under
Execute.
As soon as simulation starts, the EzOPC program is automatically
called up and you will see this from the item EzOPC displayed in the
Start bar.
If EzOPC is not called up, you will need to check whether the
program is installed. Failing this, now carry out the installation.
When EzOPC is started, both communication users - S7-PLCSIM and the
process model simulation must already be active. Only then are the
communication links correctly set up.
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8. Click onto the EzOPC button in the Start bar. This opens the EzOPC
window, where you configure the communication between
COSIMIR PLC and S7-PLCSIM.
The EasyPort D16 interface is crossed out. This indicates that the
communication link between EasyPort and EzOPC does not exist.
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9. Click onto Communication Setup under Configuration.
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10. The window Communication Setup is now displayed.
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11. Carry out the necessary settings.
Select Not Connected in the EasyPort section for EasyPort 1.
Now select Installed in the section PLCSIM for Step 7 PLCSIM V5.x.
Accept the preset values for Start Byte and End Byte without
changing them, although only the first four bytes are required.
In the section VirtualPLC, select PLCSIM for Connect VirtualPLC to:
and confirm the settings with OK.
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12. The changes require EzOPC to be restarted. Acknowledge this
message with OK.
13. Close the EzOPC program and restart it.
You will find EzOPC under the default setting Programs Festo
Didactic EzOPC V4.9.2 .
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14. EzOPC displays the new configuration:
EzOPC does not use the serial interface.
EzOPC has set up a communication link with S7-PLCSIM. The data
bytes from S7-PLCSIM shown are exchanged.
15. Minimise the EzOPC window.
16. Make sure that the process model simulation in COSIMIR PLC is
active.
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17. Start S7-PLCSIM by clicking onto the box next to RUN in the window
CPU 300/400. The LED for RUN should now start flashing.
18. Operate the process model as planned and programmed in the PLC
program.
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19. If faults still exist in the PLC program, then the on-line
representation in STEP 7 will provide you with excellent support
during fault finding. To do so, call up the program block in which you
suspect the fault. Then click onto Monitor in the Test menu. You can
now monitor in parallel with simulation, which PLC program sections
are or are not being executed.
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If you are creating and testing your own PLC program, we recommend
that you load the programs to an external PLC and have these executed
from there.
You can use the Soft PLC S7-PLC SIM as external PLC, if you are
programming in STEP 7, in which case you will not require any
additional hardware components.
You can however also use any other control or programming system, in
which case you download the PLC program to your hardware PLC. The
exchange of the PLC input/output signals between the process model
simulation and your external PLC is effected via the serial interface of
the PC and via the EasyPort interface. Also included in the exchange of
process signals is the EzOPC program.
The advantage of this configuration is that you can use the PLC and
programming system of your choice. Also available for fault finding in
the PLC program are the testing and diagnostic functions intended for
this purpose in the programming system.
We recommend that you install the simulation software COSIMIR PLC
and the PLC programming system on different computers.
5.9
Controlling a process
model via an external PLC
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Possible configuration with a hardware PLC and two PCs
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However, you can also choose a different configuration and install the
two software packages on one PC. Your PC will need to be equipped
with two serial interfaces if you intend to make use of the testing and
diagnostic functions during the process model simulation .
The following can be used as EasyPort interface:
EasyPort D16 interface box for 16 digital I/O (Order No.. 1676 121)
The following data cables are required:
PC data cable RS232 (Order No. 162 305)
For PLC EduTrainer of Festo Didactic: I/O data cable with SysLink
plugs at both ends to IEEE 488, cross paired (Order No.. 167 106)
For any PLC: I/O data cable with SysLink plug at one end to IEEE 488
and open cable end sleeves (Order No. 167 122)
The EzOPC program
The EzOPC program organises the exchange of PLC input/output signals
between the process model simulation and the external PLC. EzOPC
does not access the external PLC signals directly, but via the EasyPort
interface.
EzOPC must be installed on your computer. If this is not the case, you
will need to install the COSIMIR PLC CD-ROM now. Once the installation
has been successfully completed, EzOPC will be automatically called up
by COSIMIR PLC as soon as you start the process model simulation.
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The following requirements must be fulfilled in order for the PLC
input/output signals to be correctly exchanged:
When starting EzOPC, both communication users EasyPort and the
process model simulation - must be active. Only then can EzOPC set
up the communication link to the two users.
In the case of EasyPort this means that EasyPort must be connected
to the PC via the serial interface and voltage applied to EasyPort.
The EzOPC program must be correctly configured for the data
exchange. Therefore check the configuration as soon as EzOPC is
started.
Configuration of EzOPC for data exchange with an external PLC via EasyPort
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This is how you control a process model via an external PLC
1. Connect the PC with COSIMIR PLC to the external PLC via the
EasyPort interface.
The data cable with Order No. 162 305 connects the serial
interface of the PC to the serial interface RS232 of EasyPort.
The PLC input/output signals for the process are applied at port 1
of EasyPort.
The PLC input/output signals for the control console are
transmitted via port 2.
For the DIP switches under Mode at EasyPort, select the following
setting: 1 ON, 2 OFF, 3 OFF.
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Configuration with PLC EduTrainer
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Configuration with PLC board
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2. Switch on the power supply for EasyPort.
3. Load the desired process model to COSIMIR PLC . The file name of
the process model must have the ending OPC, since it is to be
controlled via an external PLC.
4. Start the simulation of the process model by clicking onto Start
under Execute.
The EzOPC program is called up automatically when simulation
starts. You will see EzOPC displayed in the Start bar.
If EzOPC is not shown in the Start bar, you need to install it now from
the COSIMIR PLC CD-ROM.
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When EzOPC is started, both communication users - EasyPort and the
simulation of the process model must already be active. Only then can
the communication link be correctly set up.
5. Click onto the EzOPC button in the Start bar to open the EzOPC
window, where you configure the communication between
COSIMIR PLC and EasyPort.
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6. Carry out the settings for the serial interface. To do so, click onto
Serial Interface in the Configuration menu.
7. Under COM Port , enter the serial interface of your PC, to which
EasyPort is connected and confirm this setting with OK.
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8. Under Configuration, click onto Communication Setup.
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9. This opens the Communication Setup window.
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10. Carry out the necessary settings.
Select the entry EasyPort in the section VirtualPLC for Connect
VirtualPLC to: and confirm this with OK.
11. Minimise the EzOPC window.
12. Download the PLC program to the PLC.
13. Start up the PLC.
14. Start the process model simulation.
15. Operate the process model according to how you have planed and
programmed it in the PLC program.
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Use the Fault Setting window to set specific faults in the functional
sequence of a process model. Use the internal PLC and the sample PLC
program provided to control the process model. This ensures that a
potential fault behaviour is caused solely by process components. The
PLC program is operating error-free.
The setting of faults is permissible by authorised users only. This is why
the dialog for fault setting is password protected. The default for the
password is didactic. The password can be changed at any time.
Each process model contains a list of possible faults.
5.10
Setting faults in a
process model
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The following data is required if you want to generate a fault for one of
the listed process components
Type of fault
Start of fault
Duration of fault
With some components, different faults can occur and you can select
these faults from a list of options.
The following mean:
Reed switch displaced: Reed Switch is mechanically displaced.
Reed switch jammed: A 1-signal is continually applied at the reed
switch.
Cable break: A 0signal is continually applied at a component.
Short circuit - voltage: A 1-signal is continually applied at
component.
Malfunction: Complete failure of component.
Tubing defective: Pneumatic tubing is defective, operating pressure
not achieved.
Compressed air supply malfunction: Pressure failure.
Power supply malfunction: Voltage not available.
The time stated for the start of malfunction refers to the simulation time
after the fault is set.
The duration of the fault is to be indicated in seconds.
Error statuses influence the simulation of the process model as soon as
the Fault Simulation is active.
The fault function remains active even if COSIMIR PLC is terminated or
restarted. It remains active until it is deactivated in the Fault Setting
window.
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This is how you set faults in the process model
1. Make sure that a process model is loaded. The process model is to
be controlled via the internal PLC.
2. Open the Fault Setting window by activating Fault Setting in the
Execute menu.
You can also open the Fault Setting via Window Workspaces Teacher
mode. Under Teacher mode are frequently-needed window
combinations for the Fault operation.
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3. A dialog box is displayed for the password to be entered.
Enter the password. Provided that you have not changed the
password since COSIMIR PLC has been installed, then the standard
specified password is still valid.
Enter didactic in the Password box.
Note that the password is case-sensitive.
Confirm your entry with OK.
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4. The Fault Setting window is now displayed.
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5. Set a fault function for example for the PLC input 1B1.
Double click onto the appropriate field in the Type column to display
a list of options. Open the list and select the type of fault, e.g. Cable
break.
The fault is to become active with the start of simulation and to
remain so until the fault is cancelled in Fault Setting. No entry is
therefore required in the Begin column field.
The duration