This Guide was prepared by Tonmoy Bokshi, Roll- 1703098 and

Md. Ismail Hossain, Roll - 1703109

Chapter 2 Hardware Description

The experiments will be performed in this thesis all are based on Siemens S7-1200 PLC module
along with Analog I/O, Digital I/O, HMI and different sensors. A brief description of these modules
is given here.

2.1 : Power Supply Module

The PLC CPU which will be used is basically a DC/DC/DC PLC. That’s why a power supply module
is used. It is a stabilized power supply which has input: 120/230 V AC, output: DC 24 V/10A. It has
3 ports for giving AC input and 4 DC output ports (two positive and two negative). For input
connection, use a 3 pin power cable as shown in the figure.

Specification
Device name : Power Supply Model
No : SITOP PSU100L

Fig 2.1: Power Supply Module

For connecting the cable to the power supply, remove the back portion of the cable and separate three
wires of three colors as shown in the figure.

Fig 2.2: 3 wire connector and cables

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  Connect the plug in a 3 pin socket and L, N, E to the phase, neutral and ground of the power
supply module respectively.
 The output section has 2 positive (+) and 2 negative (-) ports. One supply of DC 24V is
obtained from one positive and one negative. Another supply of DC 24V is obtained from
another positive and negative. These are the input of PLC CPU and all Signal modules.

2.2 : PLC CPU Module

The PLC module which will be available is Siemens S7-1200. SIMATIC S7-1200 controllers arethe
intelligent choice for compact automation solutions with integrated IOs, communication and
technology functions for automation tasks in the low to medium performance range. They are
available in standard and fail-safe versions. The scalable SIMATIC S7-1200 controllers have
integrated inputs and outputs as well as communication options and are modularly expandable.
Digital and analog input and output modules as well as a wide variety of communication modules
enable flexible adaptation to the respective automation task. With integrated technologies such as
high-speed counters, pulse width modulation, pulse sequence outputs, speed control and positioning,
SIMATIC S7-1200 controllers are suitable for temperature control, pump and fan control, conveyor
technology and even packaging machines. The detailed description of the module is given below:

Fig 2.3: Front and side view of the PLC module

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Specification
Device name : SIMATIC S7-1200, CPU 1214C, COMPACT CPU, DC/DC/DC
Model No : 6ES7214 -1AG40- 0XB0
Power Supply : DC 20.4 - 28.8 V DC, 1.5A
Digital Input : 14 Digital Input, 24V DC
Digital Output : 10 Digital Output, 24 V DC
Analog Input : 2 Analog Input, 0 - 10V DC
Memory : 100 KB

Connection of CPU
This is basically a DC/DC/DC PLC, so the input and output of the CPU will be 24VDC. For
powering the CPU properly, see the diagram below:

Fig 2.4: Pin diagram of the CPU 1214C DC/DC/DC PLCFollow these steps
carefully:

 Keep the power supply disconnected from the socket.

 Take a positive terminal of 24VDC from power supply and connect it to the leftmost L+
of the CPU and connect the negative of the supply to the M of the CPU.

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  Now, put a wire to the 2nd L+ of the CPU and connect it with the one terminal of all switches
as a switch needs only phase connection not neutral. But in this case one terminal of all
switches and push buttons are internally shorted and a point is connected to a female port.
So just put a wire from L+ and connect with that specific female port where the shorted
terminals come. Connect the 2nd M and 1M terminal by a wire. In the board three inputs
from the CPU are taken to the female connector.
 The other terminals of switches will be connected to that specific port as which input tag
is defined in the Ladder Diagram. For example, if input I0.0 is taken in program then the
terminal of a switch will be connected in port 0 in 24VDC input section.
 For analog input connection, you may use a potentiometer or a DC power supply module
which are normally used in our laboratory (Not PLC Power Supply Module because it
provides a fixed voltage of 24V, but we need a variable voltage of 0 to 10V for analog
inputs). If potentiometer is used you have to connect another 24V DC to the two terminals
of the potentiometer and vary the voltage within 0-10V by potentiometer. But if power
supply is used directly then potentiometer is useless. Just simply connect the positive of
the supply or potentiometer to the 0 or 1 port in analog input section and connect the
negative of supply or potentiometer to the 2M port.
 For digital output connection, take another power supply from the power supply module
and connect the positive to 3L+ and connect the negative terminal to the 3M port. The one
terminal of a output (LED) is connected with respective port(0 or 1 or 2 ; based on the
program) and the negative terminals of all LEDS are internally shorted and connected in a
female port. Just connect it with the 3M of the output section where the supply negative
comes.

2.3 : Digital Input-Output Module

The module SM-1223 is used for both input and output connection. The input section is on the topside
and the output section is in bottom side as indicated by arrows. It has 8 input and 8 output.
Specification
Model No : 6ES7 223-1BH32-0XB0
 The top section is for input. The power supply input of 24VDC is connected to L+ and M.
The one terminal of all switches is shorted and a positive 24VDC is given as mentioned

10
earlier. The port M and 1M is shorted. Now the other terminals of respective switches areconnected
to their respective ports e.g. 0,1,2 of the SM-1223 module. In the board two inputs are taken from
the module.
 The bottom section is for output connection, no power supply is required here. Just simply
short the one terminals of all LED and connect with the M (Which are previously done).

Fig 2.5: Pin diagram of the SM-1223 DI/DQ module

2.4 : Analog Input Module

The analog input module is used for using analog inputs more than two. There two analog inputs are
in the CPU. But if the no of input is required more than two then the module can be used. Theanalog
data can be obtained from any temperature sensor or pressure sensor. The figure shows thefront side
of the module:

Fig 2.6: Front side of the Analog Input Module

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Specification

 SM 1231, 4 AI Analog Input Module - 6ES7 231-4HD2-0XB0

 SIMATIC S7-1200, Analog input, SM 1231, 4 AI, +/-10 V, +/-5 V, +/-2.5 V, or 0-20 mA/4-
20 mA, 12 bit+ sign (13 bit ADC)

Connection of the module

The module SM-1231 indicates the analog input module. This module takes analog data from sensor
like temperature sensor or pressure sensor in industry. But in this case, a external power supply is
taken for working as a sensor. A potentiometer also can be used. In that case a 24V mustbe supplied
in the two terminals of the potentiometer. But for better visualization power supply can be used. The
supply voltage is varied and check the same voltage in output. But here one thingmust be noticed that
we can’t visualize the output in the board because LED works on basically digital mode. The working
of analog module will be described in the Experiment subsection in theMethodology section. The
main CPU module has also analog input section but here analog input is taken from the module.

Fig 2.7: Pin diagram of the Analog input moduleThe module has basically

four inputs. Now read the instructions carefully,

 Connect the supply in L+ and M. Ground connection is not necessary. Now connect the
positive terminal of the power supply to 0+ and negative to 0- or 1+ and 1- and so on.
 Here V or I indicates that that the analog data may be a voltage of 0 to 10V or a current of
4 to 20 mA.

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 2.5 : Analog Output Module
The CPU 1214C doesn’t support any analog output. The analog output module consists of two
sections. The top section is used for power supply as shown in figure.

Fig 2.8: Pin diagram of Analog output module

Specification
Model No : 6ES7 232-4HD32-0XB0
For connecting the module,

 The 24VDC is connected to L+ and M

 If port 2 is selected then the positive terminal of the output will be connected to port 2 and
the negative will be connected to 2M and for port 1 it will be 1 and 1M and so on.

2.6 : Analog RTD module

RTD stands for Resistance Temperature Detector. It is basically a PT100 temperature sensor which has
3 wires. When temperature changes the resistance varies. This type of sensors are widely usedin the
industry. But for experimental purpose here a potentiometer is used in stead of a sensor.

Specification
Model No : 6ES7 231-5PD32-0XB0

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Fig 2.9: Pin diagram of Analog RTD module

 Connect the power supply to L+ and M.

 Now connect a terminal of the potentiometer to I+. Connect another terminal to the I-.
Remember these two terminals must be those at which resistance varies with varying the
screw of potentiometer.
 Connect another terminal to M- and do short I+ and M+. Input connection is ready
 Now simply take a digital output from CPU or DI/DQ module
 Notice that the input to the module is analog but the output is digital. The A/D conversion
will be done by the code.

2.7 : SIMATIC HMI KTP400 Module

The device is used for visualization. The program which is running in the hardware that can be
checked by HMI screen. But one thing must be remembered that the same program which is uploaded
in PLC CPU also needs to be uploaded in HMI . A power supply is to be given through

14
the connector which is given in the module box. The same ethernet cable may be used for uploading
the program in PLC CPU as well as HMI. For visualizing the logic, some animation ordesigns are to
be drawn in the code which will be shown in the experiment section.

Fig 2.10: Overview of the SIMATIC HMI KTP400 Module

Specification
SIMATIC HMI KTP400 Basic Panel
4” display
Model No: 6AV2-123-2DB03-0AX0

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Chapter 3 Software Description
3.1 : Installation and Activation

Download Link:

https://support.industry.siemens.com/cs/document/109761045/simatic-step-7-and-wincc-v15-1-trial-
download?dti=0&lc=en-WW
The following files needed to be downloaded.

Fig. 3.1 Files needed for TIA Portal and PLCSim

Software named “ TIA_Portal_STEP_7_Pro_WINCC_Pro_V15_1.exe ”
and “SIMATIC_S7PLCSIM_V15_1.exe” has to be installed.

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 Fig 3.2: .Downloaded files. Sim_EKB_Install_2018_11_14 is license
key file and will be found in plc4me.com

You can extract the installation files without installation in two different folders for TAI
Portal and PLCSim. For that, creat two folders first. Then right click on the
“TIA_Portal_STEP_7_Pro_WINCC_Pro_V15_1.exe” file and run as administrator. Then follow
the following steps:

Yes>Next>Next>Click/Check the option “Extract the setup files without being installed”
and browse and choose the folder which was created to save the installation files for TIA
Portal.

After the files are extracted in the folder, do the same for the
“SIMATIC_S7PLCSIM_V15_1.exe” file.

Then start the installation process.

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Fig 3.5: may be asked for restart

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 Fig 3.6: few steps

Here in fig 3.7, must have to select all options.

Select all files

Fig 3.7: select all files

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 Thus following few steps, TIA Portal installation is completed.

Fig 3.8: TIA Portal is installed

Now, “ SIMATIC_S7PLCSIM_V15_1 ” has to be installed for simulation.

PLCSIM file

Fig 3.9: .exe file for simulation

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Thus following few steps, simulation part is also completed.

Select here

Fig 3.10: notice all options

Now, SIM_EKB file is needed for key.

But before that, virus & threat protection settings and windows defender firewall settings must be
turned off.

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Fig 3.2: virus and threat protection settings are off

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Fig 3.3: windows defender firewall settings are off

Key file

Fig 3.11: key installation

Open this

Fig 3.12: open the marked file

Find “ Required keys ” and select all keys and click on “ Install Long ” .

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 Click here

Fig 3.13: select all keys

After that, find “ Automation License Manager ” and may follow next few steps.

Fig 3.14: Automation License ManagerThen go to My Computer >

select drive C: > select License Keys.

Fig 3.15: select “ license keys ”

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 Fig 3.16: select all

Fig 3.17: press “ check ”

Fig 3.18: installation complete

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 3.2 : Creating a Project in TIA Portal V15.1
To create a project, open TIA Portal V15.1 and a portal like fig 3.19 will pop up. To run a new code,
open “ create new project ” and to view previous codes, go to “ open existing project ”. In creating
new project, select a project name and set the file location and then create new project.

Fig 3.19: create new project

Next step is configure devices that we need in this project. As we have built a kit box using all
modules, so let’s configure all here.
Configure a device > add new device > controller > SIMATIC S7-1200 > CPU >CPU
1214C DC/DC/DC > 6ES7 214-1AG40-0XB0 > ADD

Fig 3.20: configure a device

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 Fig 3.21: select cpu model
Now other modules have to be selected, so click on “ Hardware catalog ” and select DI/DQ, AQ,
AI, AI RTD specified models as shown below.

Fig 3.22: select hardware modules

Fig 3.23: DI/DQ module selection

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 Fig 3.24: AQ module selection

Fig 3.25: AI module selection

Fig 3.26: AI RTD module selection

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Fig 3.27: complete configuration

Device configuration is complete here. Now we will try a simple ladder diagram.
PLC_1 > Program blocks > Main [OB1]

Then a page like fig 3.28 will pop up and we will design ladder diagram on it.

Fig 3.28: Main program block

Our next target is to draw a simple ladder diagram and learn to download to device, start
simulation, PLCSIM simulation etc.

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 3.3 : Simulation Process in PLCSIM
Let’s take a simple ladder diagram in fig 3.29 of a output (LED) on/off with input switch. Then
press “start simulation”.

Start
simulation

Fig 3.29: Ladder diagram

Fig 3.30: download to device

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Fig 3.31: load to device

Fig 3.32: load again

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 Fig 3.33: start module

Press here

Fig 3.34: starting PLCSIM

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Fig 3.35: open new project on PLCSIM

Fig 3.36: create project

Fig 3.37: open SIM table_1

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Fig 3.38: load tag table in PLCSIM

Fig 3.39: go online

Fig 3.40: monitor

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Fig 3.41: input switch closed (true)

Fig 3.42: output (LED) on

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Fig 3.43: input switch open (false)

Fig 3.44: output (LED) off

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 3.4 : Interfacing HMI

To add HMI on your code, click ”Add new device” from left side.

Fig 3.45: Click the part as indicated by arrowsThen, Select our HMI with
proper model

Fig 3.46: Selecting our device model

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Next, click “Browse” and then the CPU will be connected to the HMI virtually.

Fig 3.47: Click “Browse”

Then the HMI window will appear ,Now draw your desired shape by using different icons/graphics
from the right side. Watch a tutorial in youtube for detailed explanation.

Fig 3.48: HMI Window

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 Chapter 4 Methodology
This chapter will describe the main training board and it’s accessories. All things–how connectionsare
provided between the modules are provided, how to upload code and how the output can be checked
etc. will be discussed in this chapter.

4.1 : Introduction to the Training Board

The board mainly consists of 3 sections. There are: modules, input/output in Veroboard, a female
port. The description of each section is described below:

In the upper side all modules are fixed in the board by a rail. The rail is commercially called MCB
channel mainly. There are 5 modules on each board. They are: PLC CPU (S7-1214C DC/DC/DC,
Digital Input/Output Module (SM-1223), Analog Output Module (SM-1232), Analog InputModule
(SM-1231) and Analog RTD Module (SM-1231) and finally a Power Supply Module (SITOP
PSU100L).

Fig 4.1: A sample training board and its 3 sections as indicated by arrows

The input output section is made by a Veroboard. It has 3 switches and 4 push buttons as input.
There is an indicator LED is used in every switch and push button. When the switch/push button

39
is pressed the blinking of LED will indicate that logic is working. It also helps in finding the faultof
the system. The output section has 6 LED which will work based on the logic.

Fig 4.2: Input Output section in the Veroboard

The female connector is provided to avoid the opening of PLC screws all times for experiments. It
has 18 holes in each board. In one side of the holes, connections from the Veroboard are given and
in other side the connections from the different modules is given.

There are 3 switches and 4 push buttons can be used as input. For providing experience of working
with all modules, 2 push buttons and one switch is taken from CPU and 1 push button and 1 switchis
taken from DI/DQ module. So, there are 5 inputs are connected in the female connector. But if you
need more inputs, you can use the other two input by connecting via the female connector.

In the output section, there are 6 LEDs. Two of them are taken from CPU and other two are taken
from DI/DQ module. To avoid confusion, see the picture and description below:

We have 18 ports in female port segment, where first 8 ports (from left) are used for inputs like
switch or push button and then 2 ports are used as power supply of 24V ( positive and negative), next
port is unused and last 7 ports are used for LEDs section or outputs.

40
Female Connector Pin Assignment

Starting from the left side,

Table 1 : Female Connector Pin Assignment

Port Number I/O Assignment Comment

Port 1 I0.0 1st switch taken from CPU
Port 2 I8.0 2nd switch taken from DI/DQ
Port 3 I0.3 3rd switch taken from CPU
Port 4 I0.1 1st push taken from CPU
Port 5 I0.2 2nd push taken from CPU
Port 6 I8.1 3rd push taken from DI/DQ
Port 7 I8.2 4th push taken from DI/DQ
Port 8 24V Common terminal of all inputs
Port 9 L+ Positive terminal from power
supply
Port 10 M Negative terminal from power
supply
Port 11 Blank Any connection can be given
Port 12 3M of CPU Common terminal of all LEDs
Port 13 Q0.0 1st LED taken from CPU
Port 14 Q0.1 2nd LED taken from CPU
Port 15 Q8.0 3rd LED taken from DI/DQ
Port 16 Q8.1 4th LED taken from DI/DQ
Port 17 Q8.2 5th LED taken from DI/DQ
Port 18 Q8.3 6th LED taken from DI/DQ

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4.2 : Experiment 1 : Metal Element Sensing by SIEMENS S7-1200 PLC

Problem Description

There will be one push button as metal sensor. When the push button will be pressed, the LED willbe
ON, a timer will be used to keep ON the LED for 5 seconds.

Experimental Setup

Latching is not needed so much because when the push button is pressed, timer will keep the output
LED on for 5 seconds and then output LED will be turned off.

Table 2 : Modules for exp-1

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0

All connections are given in the board. Just make the I/O assignments:

Table 3 : exp-1 pin assignment

I0.1 Metal sensor push button

Q0.0 LED_1 as metal indicator

Ladder Diagram

Fig 4.3: Ladder diagram of Metal sensor

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 Experimental Results

When “Metal sensor” is not pressed, LED_1 is OFF and when push button is pressed, LED_1 is
ON for 5 seconds.

Fig 4.4: Output of exp. 1

4.3 : Experiment 2 : Automated Quiz Competition Arrangement

Problem Description

The game buzzer control requirement:

1. After the Host has finished with question.
2. The 3 players will press the switch in front of them to fight to be first to answer the question.
3.The buzzer will sound for 10 sec after any one of the players has touched the switch.
4.The light indicator in front of each player will light-up and only reset by the Host switch.

43
Fig 4.5: Block diagram of given problem

Experimental Setup

3 push button is used as player 1,2,3 and RST (reset) as host switch. Latching is very important here
to keep the LEDs ON. If any player presses his push button, his LED will be ON and buzzerLED
will be ON for 10 seconds. Full system will shut down when RST switch is pressed.

Table 4 : Modules for exp-2

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0

Table 5 : exp-2 pin assignment

Input Device
I1 PB1
I2 PB2
I3 PB3
I4 RST (Reset)

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 Output Device
Q1 Buzzer
Q2 Player 1 light
Q3 Player 2 light
Q4 Player 3 light

Ladder Diagram

Fig 4.6: Ladder diagram of Quiz

Experimental Results

When any player will push his button, his LED and buzzer LED will be ON for 10 seconds. When
host switch will be pressed, full system will shut down like reset.

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Fig 4.7: ‘player 1’ push is pressed and Buzzer is ON

Fig 4.8: all pressed push and buzzer also ON

46
 Fig 4.9: RST is pressed and LEDs are OFF

4.4 : Experiment 3 : Analog Input to Digital Output Conversion by SIEMENS S7-1200 PLC

Problem Description

This problem is about analog to digital data conversion. Here we will take voltage from power supply
at a range of 0 – 10 V as analog data. Then a comparator is used as if voltage is less than 5V, then
digital output is high (24V) and otherwise output is low (0V) to show digital output.

Experimental Setup

Voltage from power supply is given in AI port 0+, 0_ ( address-128, but this may change later as the
sequence of modules). Then it is compared with fixed Value as given logic and out is observedin Q0.1.

47
 Table 6 : Modules for exp-3

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 AI 6ES7 231-4HD2-0XB0
4 AQ (Optional) 6ES7 232-4HD32-0XB0

Table 7 : exp-3 pin assignment

Input %W128 (0 – 10 V)
Output Port Q0.1

Ladder Diagram

Fig 4.10: Ladder diagram of A/D converter

Experimental Results

This is DC/DC/DC PLC, so AQ port can be used but can’t check voltage here. That’s mean we can’t
observe analog output, we have to shift it into digital output ports. And here, output is observed in
Q0.1 port. If analog output module someone want to add, just replace the memory location %MD24
with analog output port address and all connection is unchanged.

48
Fig 4.11: Analog voltage is greater than fixed value

Fig 4.12: Input is lower than fixed value

49
4.5 : Experiment 4 : Direction Control of DC Gear Motor by SIEMENS S7-1200 PLC

Problem Description

DC gear motor has to operate on forward or reverse mode. And must have to check that motormust
be stopped first, then have to shift on other mode.

Experimental Setup

We need 4 inputs as forward start, stop and reverse start, stop. So, let’s take 4 push buttons. And we
need 2 output to show that the motor is in forward or reverse mode. That’s why take just 2 LEDs.
Here we also add HMI to observe and compare with physical connection.

Table 8 : Modules for exp-4

No. Module Needed Model No.

1 Power Supply PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0
4 HMI 6AV2-123-2DB03-0AX0

Table 9 : exp-4 pin assignment

Input Device
I0.1 Start Forward
I0.2 Stop Forward
I8.1 Start Reverse
I8.2 Stop Reverse

Output Device
Q0.0 Forward Motor
Q0.1 Reverse Motor

50
Ladder Diagram

Fig 4.13: Ladder diagram of DC gear motor

Fig 4.14: HMI test

51
Experimental Results

Fig 4.15: Forward Gear

Fig 4.16: Reverse Gear

52
4.6 : Experiment 5 : Automatic Electrical Interlocking in Power System

Problem Description

We know that to activate a line to power grid, we must open the earthing switch, then close the
isolator and at last circuit breaker has to be closed. If we don’t follow the sequence, system must
detect it and the line should not be active or connect to grid.

Experimental Setup

We need 3 inputs for ES, CB and Isolator and 3 LEDs for indicating ES, CB or Isolator is open or
closed and finally one LED for indicating that line is ready to connect with grid or not.

Table 10 : Modules for exp-5

No. Module Needed Model No.

1 Power Supply PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0

Table 11 : exp-5 pin assignment

Input Device
I0.0 Earthing Switch
I8.0 Circuit Breaker
I0.3 Isolator

Output Device
Q0.0 ES LED
Q0.1 CB LED
Q8.0 Iso LED
Q8.1 Line LED

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Ladder Diagram

Fig 4.17: Ladder diagram of Interlocking

Experimental Results

Fig 4.18: Earthing Switch closed

Fig 4.19: Earthing Switch open

54
 Fig 4.20: Isolator closed

Fig 4.21: Circuit Breaker closed

Fig 4.22: Reverse Logic Check

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4.2 : Experiment 1 : Metal Element Sensing by SIEMENS S7-1200 PLC

Problem Description

There will be one push button as metal sensor. When the push button will be pressed, the LED willbe
ON, a timer will be used to keep ON the LED for 5 seconds.

Experimental Setup

Latching is not needed so much because when the push button is pressed, timer will keep the output
LED on for 5 seconds and then output LED will be turned off.

Table 2 : Modules for exp-1

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0

All connections are given in the board. Just make the I/O assignments:

Table 3 : exp-1 pin assignment

I0.1 Metal sensor push button

Q0.0 LED_1 as metal indicator

Ladder Diagram

Fig 4.3: Ladder diagram of Metal sensor

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 Experimental Results

When “Metal sensor” is not pressed, LED_1 is OFF and when push button is pressed, LED_1 is
ON for 5 seconds.

Fig 4.4: Output of exp. 1

4.3 : Experiment 2 : Automated Quiz Competition Arrangement

Problem Description

The game buzzer control requirement:

1. After the Host has finished with question.
2. The 3 players will press the switch in front of them to fight to be first to answer the question.
3.The buzzer will sound for 10 sec after any one of the players has touched the switch.
4.The light indicator in front of each player will light-up and only reset by the Host switch.

40
Fig 4.5: Block diagram of given problem

Experimental Setup

3 push button is used as player 1,2,3 and RST (reset) as host switch. Latching is very important here
to keep the LEDs ON. If any player presses his push button, his LED will be ON and buzzer LED
will be ON for 10 seconds. Full system will shut down when RST switch is pressed.

Table 4 : Modules for exp-2

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0

Table 5 : exp-2 pin assignment

Input Device
I1 PB1
I2 PB2
I3 PB3
I4 RST (Reset)

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 Output Device
Q1 Buzzer
Q2 Player 1 light
Q3 Player 2 light
Q4 Player 3 light

Ladder Diagram

Fig 4.6: Ladder diagram of Quiz

Experimental Results

When any player will push his button, his LED and buzzer LED will be ON for 10 seconds. When
host switch will be pressed, full system will shut down like reset.

42
Fig 4.7: ‘player 1’ push is pressed and Buzzer is ON

Fig 4.8: all pressed push and buzzer also ON

43
 Fig 4.9: RST is pressed and LEDs are OFF

4.4 : Experiment 3 : Analog Input to Digital Output Conversion by SIEMENS S7-1200 PLC

Problem Description

This problem is about analog to digital data conversion. Here we will take voltage from power supply
at a range of 0 – 10 V as analog data. Then a comparator is used as if voltage is less than 5V, then
digital output is high (24V) and otherwise output is low (0V) to show digital output.

Experimental Setup

Voltage from power supply is given in AI port 0+, 0_ ( address-128, but this may change later as the
sequence of modules). Then it is compared with fixed Value as given logic and out is observed in Q0.1.

44
 Table 6 : Modules for exp-3

No. Module Needed Model No.

1 Power Supply SITOP PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 AI 6ES7 231-4HD2-0XB0
4 AQ (Optional) 6ES7 232-4HD32-0XB0

Table 7 : exp-3 pin assignment

Input %W128 (0 – 10 V)
Output Port Q0.1

Ladder Diagram

Fig 4.10: Ladder diagram of A/D converter

Experimental Results

This is DC/DC/DC PLC, so AQ port can be used but can’t check voltage here. That’s mean we can’t
observe analog output, we have to shift it into digital output ports. And here, output is observed in
Q0.1 port. If analog output module someone want to add, just replace the memory location %MD24
with analog output port address and all connection is unchanged.

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Fig 4.11: Analog voltage is greater than fixed value

Fig 4.12: Input is lower than fixed value

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4.5 : Experiment 4 : Direction Control of DC Gear Motor by SIEMENS S7-1200 PLC

Problem Description

DC gear motor has to operate on forward or reverse mode. And must have to check that motor must
be stopped first, then have to shift on other mode.

Experimental Setup

We need 4 inputs as forward start, stop and reverse start, stop. So, let’s take 4 push buttons. And we
need 2 output to show that the motor is in forward or reverse mode. That’s why take just 2 LEDs.
Here we also add HMI to observe and compare with physical connection.

Table 8 : Modules for exp-4

No. Module Needed Model No.

1 Power Supply PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0
4 HMI 6AV2-123-2DB03-0AX0

Table 9 : exp-4 pin assignment

Input Device
I0.1 Start Forward
I0.2 Stop Forward
I8.1 Start Reverse
I8.2 Stop Reverse

Output Device
Q0.0 Forward Motor
Q0.1 Reverse Motor

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Ladder Diagram

Fig 4.13: Ladder diagram of DC gear motor

Fig 4.14: HMI test

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Experimental Results

Fig 4.15: Forward Gear

Fig 4.16: Reverse Gear

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4.6 : Experiment 5 : Automatic Electrical Interlocking in Power System

Problem Description

We know that to activate a line to power grid, we must open the earthing switch, then close the
isolator and at last circuit breaker has to be closed. If we don’t follow the sequence, system must
detect it and the line should not be active or connect to grid.

Experimental Setup

We need 3 inputs for ES, CB and Isolator and 3 LEDs for indicating ES, CB or Isolator is open or
closed and finally one LED for indicating that line is ready to connect with grid or not.

Table 10 : Modules for exp-5

No. Module Needed Model No.

1 Power Supply PSU 100L
2 CPU 6ES7214 -1AG40- 0XB0
3 DI/DQ 6ES7 223-1BH32-0XB0

Table 11 : exp-5 pin assignment

Input Device
I0.0 Earthing Switch
I8.0 Circuit Breaker
I0.3 Isolator

Output Device
Q0.0 ES LED
Q0.1 CB LED
Q8.0 Iso LED
Q8.1 Line LED

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Ladder Diagram

Fig 4.17: Ladder diagram of Interlocking

Experimental Results

Fig 4.18: Earthing Switch closed

Fig 4.19: Earthing Switch open

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 Fig 4.20: Isolator closed

Fig 4.21: Circuit Breaker closed

Fig 4.22: Reverse Logic Check

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