Training Curriculum

TIA Portal Module 009

Analog Values
for SIMATIC S7-1500

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Table of contents
1 Goal................................................................................................................................................. 287
2 Prerequisite...................................................................................................................................... 287
3 Required hardware and software..................................................................................................... 288
4 Theory.............................................................................................................................................. 289
4.1 Analog signals......................................................................................................................... 289
4.2 Measuring transducers............................................................................................................ 289
4.3 Analog modules – A/D converter............................................................................................. 289
4.4 Data types of the SIMATIC S7-1500........................................................................................290
4.5 Reading/outputting analog values............................................................................................ 291
4.6 Normalizing analog values....................................................................................................... 292
5 Task................................................................................................................................................. 292
6 Planning........................................................................................................................................... 292
6.1 Analog control of the conveyor speed......................................................................................292
6.2 Technology diagram................................................................................................................ 293
6.3 Reference list........................................................................................................................... 293
7 Structured step-by-step instructions................................................................................................. 295
7.1 Retrieve an existing project...................................................................................................... 295
7.2 Create the "MOTOR_SPEEDCONTROL" function..................................................................296
7.3 Configuration of the analog output channel.............................................................................303
7.4 Expand the tag table to include analog signals........................................................................304
7.5 Call the block in the organization block....................................................................................305
7.6 Save and compile the program................................................................................................ 307
7.7 Download the program............................................................................................................. 308
7.8 Monitor program blocks........................................................................................................... 308
8 Checklist.......................................................................................................................................... 310

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ANALOG VALUES FOR SIMATIC S7-1500

1 Goal
In this chapter, you will become acquainted with the analog value processing of the SIMATIC
S7-1500 with the TIA Portal programming tool.
The module explains the acquisition and processing of analog signals and gives a step-by-
step description of read and write access to analog values in the SIMATIC S7-1500.
The SIMATIC S7 controllers listed in Chapter 3 can be used.

2 Prerequisite
This chapter builds on the chapter IEC Timers and Counters with the SIMATIC S7 CPU1516F-
3 PN/DP. You can use the following project for this chapter, for example: 032-300 IEC Timers
and Counters.zap13

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3 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)

2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13

3 SIMATIC S7-1500/S7-1200/S7-300 controller, e.g. CPU 1516F-3 PN/DP –

Firmware as of V1.6 with memory card and 16DI/16DO and 2AI/1AO
Note: The digital inputs and analog inputs and outputs should be fed out to a control panel.

4 Ethernet connection between engineering station and controller

2 SIMATIC STEP 7
Professional (TIA
1 Engineering station
Portal) as of V13

4 Ethernet connection

Control panel
3 SIMATIC S7-1500 controller

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4 Theory
4.1 Analog signals
In contrast to a binary signal, which can assume only two signal states (“Voltage present +24
V” and “Voltage not present 0 V”), analog signals can assume any value within a defined
range. A typical example of an analog sensor is a potentiometer. Depending on the position of
the knob, any resistance can be set, up to the maximum value.

Examples of analog quantities in control engineering:

- Temperature -50 to +150 °C
- Flow rate 0 to 200 l/min
- Speed -500 to +50 rpm
- etc.

4.2 Measuring transducers

These quantities are converted to electrical voltages, currents or resistances with the help of a
measuring transducer. If, for example, a speed is to be measured, the speed range of 500 to
1500 rpm can be converted to a voltage range of 0 to +10 V using a measuring transducer. At
a measured speed of 865 rpm, the measuring transducer would output a voltage value of
+3.65 V.
500 865 1500 U/min

365 1500 rpm

10 V:1000
10V: 1000U/min
rpm ==0.01
0,01V/rpm
V/U/min
1000
1000rpm
U/min 365 rpm x 0.01 V/rpm = 3.65 V
365 U/min x 0,01 V/U/min = 3,65
10V

0V +10V
+10 V

4.3 Analog modules – A/D converter

These electrical voltages, currents or resistances are then connected to an analog module that
digitizes this signal for further processing in the PLC.
If analog quantities will be processed with a PLC, the read-in voltage, current or resistance
value must be converted to digital information. The analog value is converted to a bit pattern.
This conversion is referred to as analog-to-digital conversion (A/D conversion). This means,
for example, that the voltage value of 3.65 V is stored as information in a series of binary
digits.
The result of this conversion is always a 16-bit word for SIMATIC products. The integrated
ADC (analog-to-digital converter) of the analog input module digitizes the analog signal being
acquired and approximates its value in the form of a stepped curve. The most important
parameters of an ADC are its resolution and conversion rate.
The more binary digits the digital representation uses, the finer the resolution is. For example,
if only 1 bit was available for the voltage range of 0 to +10 V, you would only know whether the
measured voltage is between 0 and +5 V or between +5 V and +10 V. With 2 bits, the range
can be divided into 4 individual ranges, i.e., 0 to 2.5 / 2.5 to 5 / 5 to 7.5 / 7.5 to 10 V.
Conventional A/D converters in control engineering use 8 or 11 bits for converting.

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1: Analog value
2. Digital value
With 8 bits you have 256 individual ranges, while 11 bits provide a resolution of 2048
individual ranges.

0A/0V 20mA/10V
10 V: 2048 = 0.0048828
 Voltage differences of <5 mV can be
11-bit detected

2048

4.4 Data types of the SIMATIC S7-1500

The SIMATIC S7-1500 has many different data types for representing different numerical
formats. A list of some of the elementary data types is given below.

Data type Size (bits) Range Example of constant entry

Bool 1 0 to 1 TRUE, FALSE, O, 1
Byte 8 16#00 to 16#FF 16#12, 16#AB
Word 16 16#0000 to 16#FFFF 16#ABCD, 16#0001
DWord 32 16#00000000 to 16#FFFFFFFF 16#02468ACE
Char 8 16#00 to 16#FF 'A', ‘r’, ‘@’
Sint 8 -128 to 127 123,-123
Int 16 -32,768 to 32,767 123, -123
Dint 32 -2,147,483,648 to 2,147,483,647 123, -123
USInt 8 0 to 255 123
Ulnt 16 0 to 65,535 123
UDInt 32 0 to 4,294,967,295 123
Real 32 +/-1.18 x 10 -38 to +/-3.40 x 10 38 123.456, -3.4, -1.2E+12, 3.4E-
3
LReal 64 +/-2.23 x 10 -308 to +/-1.79 x 10 308 12345.123456789
-1.2E+40
Time 32 T#-24d_20h_31 m_23s_648ms to T#5m_30s
T#24d_20h_31 m_23s_647ms 5#-2d
Saved as: -2,147,483,648 ms to T#1d_2h_15m_30x_45ms
+2,147,483,647 ms
String Variable 0 to 254 characters in byte size 'ABC'

Note: The 'INT' and 'REAL' data types play a large role in analog value processing. This is
because read-in analog values exist as 16-bit integers in the 'INT' format, and in order to
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ensure exact further processing only 'REAL' floating-point numbers should be used due to
rounding errors in the case of 'INT'.

4.5 Reading/outputting analog values

Analog values are read into the PLC or output from the PLC as word information. These words
are accessed, for example, with the following operands:

%IW 64 Analog input word 64

%QW 64 Analog output word 64

Each analog value (“channel”) occupies one input or output word. The format is ‘Int’, an
integer.

The addressing of input and output words conforms to the addressing in the device overview.
For example:

Here, the address of the first analog input would be %IW 64, that of the second analog input
%IW 66, that of the third analog input %IW68, that of the fourth analog input %IW70, that of
the fifth analog input %IW72, that of the sixth analog input %IW74, that of the seventh analog
input %IW 76 and that of the eighth analog input %IW78.

The address of the first analog output would be %QW64, that of the second analog output
%QW66, that of the third analog output %QW 68 and that of the fourth analog output %QW70.

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The analog value transformation for further processing in the PLC is the same for analog
inputs and analog outputs.
The digitized value ranges are as follows:

Nominal range of the analog

0A/0V 10 mA/5 V 20mA/10V value

Digitalized value for further

13824 27648 processing in the PLC

Often, these digitized values still have to be normalized by further processing them in the PLC
in an appropriate manner.

4.6 Normalizing analog values

If an analog input value exists as a digitized value in the range +/- 27648, it must usually still
be normalized so that the numerical values correspond to the physical quantities in the
process.
Likewise, the analog output usually results from setting of a normalized value that then still has
to be scaled to the output value +/- 27648.
In the TIA Portal, ready-made blocks or arithmetic operations are used for normalizing and
scaling.
For this to be carried out as exactly as possible, the values for the normalizing must be
converted to the REAL data type to minimize rounding errors.

5 Task
In this chapter, a function for analog control of the conveyor speed will be added to the
program from chapter "SCE_EN_032-300 IEC Timers and Counters".

6 Planning
The analog control of the conveyor speed will be programmed in the
"MOTOR_SPEEDCONTROL" [FC10] function as an expansion of the "SCE_EN_032-300 IEC
Timers and Counters" project. This project must be retrieved from the archive in order to add
this function. The "MOTOR_ SPEEDCONTROL" [FC10] function will be called in the "Main“
[OB1]" organization block and wired. The control of the conveyor motor must be changed
to - Q3 (conveyor motor -M1 variable speed).

6.1 Analog control of the conveyor speed

The speed will be set at an input of the "MOTOR_SPEEDCONTROL" [FC10] function in
revolutions per minute (range: +/- 50 rpm). The data type is 32-bit floating-point number
(Real).
First, the function will be checked for correct entry of the speed setpoint in the range +/- 50
rpm.

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If the speed setpoint is outside the range +/- 50 rpm, the value 0 with data type 16-bit integer
(Int) will be output at the output. The return value of the function (Ret_Val) will then be
assigned the value TRUE (1).

If the speed setting is within the range +/- 50 rpm, this value will first be normalized to the
range 0…1 and then scaled to +/- 27648 with data type 16-bit integer (Int) for output as the
speed manipulated value at the analog output.
The output will then be connected with signal U1 (manipulated value speed of the motor in 2
directions +/- 10V corresponds to +/- 50 rpm).

6.2 Technology diagram

Here you see the technology diagram for the task.

Figure 1: Technology diagram

Figure 2: Control panel

6.3 Reference list

The following signals are required as global operands for this task.

DI Type Identifier Function NC/NO

I 0.0 BOOL -A1 Return signal emergency stop OK NC
I 0.1 BOOL -K0 Main switch "ON" NO
Manual = 0
I 0.2 BOOL -S0 Mode selector manual (0)/ automatic (1)
Auto = 1

I 0.3 BOOL -S1 Pushbutton automatic start NO

I 0.4 BOOL -S2 Pushbutton automatic stop NC

I 0.5 BOOL -B1 Sensor cylinder -M4 retracted NO

I 1.0 BOOL -B4 Sensor part at slide NO

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I 1.3 BOOL -B7 Sensor part at end of conveyor NO

DO Type Identifier Function

Q 0.2 BOOL -Q3 Conveyor motor -M1 variable speed

Manipulated value speed of the motor in 2

QW 64 BOOL -U1
directions +/- 10V corresponds to +/- 50 rpm

Legend for reference list

DI Digital Input
DO Digital Output
AI Analog Input
AO Analog Output
I Input
Q Output
NC Normally Closed

NO Normally Open

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7 Structured step-by-step instructions

You can find instructions on how to carry out planning below. If you already have a good
understanding of everything, it will be sufficient to focus on the numbered steps. Otherwise,
simply follow the detailed steps in the instructions.

7.1 Retrieve an existing project

 Before we can expand the "SCE_EN_032-300_IEC_Timers_Counters.zap13 project from
chapter "SCE_EN_032-300_IEC_Timers_Counters", we must retrieve this project from
the archive. To retrieve an existing project that has been archived, you must select the
relevant archive with  Project  Retrieve in the project view. Confirm your selection
with Open.
( Project  Retrieve  Select a .zap archive  Open)

 The next step is to select the target directory where the retrieved project will be stored.
Confirm your selection with "OK".
( Target directory  OK)

 Save the opened project under the name 032-500_Analog_Values.

( Project  Save as …  032-500_Analog_Values  Save)

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7.2 Create the "MOTOR_SPEEDCONTROL" function

 Select the 'Program blocks' folder of your CPU 1516F-3 PN/DP and then click "Add new
block" to create a new function there.

( CPU_1516F [CPU 1516F-3 PN/DP]  Add new block)

 Select in the next dialog and rename your new block to:
"MOTOR_SPEEDCONTROL". Set the language to FBD and manually assign the number
"10". Select the "Add new and open" check box. Click "OK".

(  Name: MOTOR_SPEEDCONTROL  Language: FBD  Number: 10 Manual

 Add new and open  OK)

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 Create the local tags with their comments as shown here and change the data type of the
'Return' tag from 'Void' to 'Bool'.
( Bool)

Note: Be sure to use the correct data types.

 Insert an Assignment ' ' in the first network and an 'And' ' in front of it. Then use
drag-and-drop to move the 'Comparator operation' 'Less or equal' from the 'Basic

instructions' onto the first input of the AND logic operation.

(   Basic instructions  Comparator operations CMP<=)

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 Next use drag-and-drop to move the 'Comparator operation' 'Greater or equal' onto the

second input of the AND logic operation.

( Basic instructions  Comparator operations CMP>=)

 Connect the contacts in Network 1 with the constants and local tags as shown here. The
data types in the comparator operations are automatically adapted to 'Real'.

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 Use drag-and-drop to move the 'Conversion operation' 'NORM_X' into Network 2 in order
to normalize the speed setpoint of +/- 50 rpm to +/- 1.
( Basic instructions  Conversion operations  NORM_X)

 Connect the contacts in Network 2 with the constants and local tags as shown here. The
data types in 'NORM_X' are automatically adapted to 'Real'.

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 Use drag-and-drop to move the 'Conversion operation' 'SCALE_X' into Network 3 in order
to scale the speed setpoint from the normalized +/- 1 onto the range for the analog output
+/- 27468.
( Basic instructions  Conversion operations  SCALE_X)

 Connect the contacts with the constants and local tags in Network 3 as well, as shown
here. The data types in 'SCALE_X' are automatically changed to 'Real' or 'Int'.

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 Insert an Assignment ' ' in the fourth network. Use drag-and-drop to move the 'Move'
command from the 'Move operations' folder under 'Basic instructions' in front of the
Assignment.

(  Basic instructions  Move operations  MOVE)

 The contacts in Network 4 will now be connected with constants and local tags as shown
here. If the speed setpoint is not within the range +/- 50 rpm, the value '0' is output at the
analog output and the value TRUE is assigned to the return value (Return) of the
"MOTOR_SPEEDCONTROL“ function.

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 Do not forget to click . The finished function "MOTOR_SPEEDCONTROL"

[FC10] in FBD is shown below.

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7.3 Configuration of the analog output channel

 Double-click the 'Device configuration' to open it.

 Check the address setting and the configuration of the analog output channel 0.
( Q address: 64…71  Properties  General  Output 0 - 3  Outputs  Channel 0
 Output type: Voltage  Output range: +/- 10 V  Reaction to CPU STOP: Shutdown)

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7.4 Expand the tag table to include analog signals

 Double-click the 'Tag table_sorting station' to open it.

 Add the global tags for the analog value processing to the "Tag table_sorting station". An
analog input B8 and an analog output U1 must be added.
( U1  %QW64  B8  %IW64)

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7.5 Call the block in the organization block

 Open the "Main [OB1]" organization block with a double-click.

 Add the temporary tag 'Motor_speed_monitoring_Ret_Val' to the local tags of OB1. These
will be needed in order to interconnect the return value of the
"MOTOR_SPEEDCONTROL" function.
( Temp  Motor_speed_monitoring_Ret_Val  Bool)

 Select the block title of OB1 and then click ' ' to insert a new Network 1 in front of the
other networks

( )

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 Use drag-and-drop to move your "MOTOR_SPEEDCONTROL [FC10]" function onto the

green line in Network 1.

 Connect the contacts with the constants and global and local tags here as shown.

 Change the connection of output tag "Conveyor_motor_automatic_mode" in Network 2 to

'-Q3' (Conveyor motor -M1 variable speed) so that the conveyor motor is controlled taking
the analog speed setting into consideration.
( -Q3)

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7.6 Save and compile the program

 To save your project, select the button in the menu. To compile all blocks,

click the "Program blocks" folder and select the icon for compiling in the menu.

(  Program blocks  )

 The "Info", "Compile" area shows which blocks were successfully compiled.

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7.7 Download the program

 After successful compilation, the complete controller with the created program including
the hardware configuration can, as described in the previous modules, be downloaded.

( )

7.8 Monitor program blocks

 The desired block must be open for monitoring the downloaded program. The monitoring

can now be activated/deactivated by clicking the icon.

( Main [OB1]  )

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 The "MOTOR_SPEEDCONTROL" [FC10] function called in the "Main [OB1]" organization

block can be selected directly for "Open and monitor" after right-clicking and the program
code in the function can thus be monitored.
( "MOTOR_SPEEDCONTROL" [FC10]  Open and monitor)

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8 Checklist
No. Description Completed

1 Compiling successful and without error message

2 Download successful and without error message

Switch on station (-K0 = 1)

Cylinder retracted / Feedback activated (-B1 = 1)
EMERGENCY OFF (-A1 = 1) not activated
AUTOMATIC mode (-S0 = 1)
Pushbutton automatic stop not actuated (-S2 = 1)
3 Briefly press the automatic start pushbutton (-S1 = 1)
Sensor part at slide activated (-B4 = 1)
then Conveyor motor M1 variable speed (-Q3 = 1)
switches on and stays on.
The speed corresponds to the speed setpoint in the range +/-
50 rpm
Sensor part at end of conveyor activated (-B7 = 1)  -Q3 = 0
4
(after 2 seconds)
Briefly press the automatic stop pushbutton (-S2 = 0)  -Q3 =
5
0

6 Activate EMERGENCY OFF (-A1 = 0)  -Q3 = 0

7 Manual mode (-S0 = 0)  -Q3 = 0

8 Switch off station (-K0 = 0)  -Q3 = 0

9 Cylinder not retracted (-B1 = 0)  -Q3 = 0

10 Project successfully archived

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