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  • 682526 EN

    06/04

    COSIMIR PLC

    Manual

  • 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.

  • 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

  • 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

  • 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

  • 6 Festo Didactic GmbH & Co. KG COSIMIR PLC

  • 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

  • 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

  • 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 .

  • 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

  • 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

  • 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

  • 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.

  • 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.

  • 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.

  • 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

  • 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.

  • 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

  • 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:

  • 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.

  • 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

  • 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:

  • 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.

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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.

  • 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.

  • 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

  • 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.

  • 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.

  • 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.

  • 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

  • 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.

  • 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

  • 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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    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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    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

  • 4. The COSIMIR PLC system

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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.

  • 50 Festo Didactic GmbH & Co. KG COSIMIR PLC

    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

  • 5. Important control functions of COSIMIR PLC

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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.

    Note

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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.

    Note

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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.

    Note

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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