HPR4738: Programmable Logic Controls - Episode 4

-------------------- 01 Introduction This is the fourth episode in an 8 part series. 02 In the previous episode we looked at the Allen Bradley PLC2, one of the very early successful Programmable Logic Controllers. In this episode we will look at another early PLC, the Siemens S5 series, and use it as an example of both how PLCs became more sophisticated, as well as an example of a different approach to the overall software architecture. Again, I will only touch on this topic lightly, this is not a course on how to program PLCs. However, I will give you enough technical detail to give you are rough idea of what they were like. -------------------- 03 S5 Historical Background Siemens are the largest PLC vendor on a global basis, and have been since the early days. Their first PLC was the S3, released in 1975, two years before Allen Bradley released the PLC2. There seems to be almost no information available on the S3, so I can't say much about it. In 1978 or 1979, sources are unclear about the exact date, Siemens released the S5 series. This was a huge step forward in capability and was the foundation of their PLC product line until replaced by the S7 series in the mid 1990s. In this episode I will focus on the U series, which were an upgrade to the original S5. -------------------- 04 A Complete Family of PLCs Fully developed, the Siemens S5 series was a complete family of products covering the entire size spectrum from smallest to largest. Siemens covered the entire industrial control market, and there was almost nothing they didn't have somewhere in their catalogue. You could spend an entire career using nothing but Siemens products for everything. 05 At the lowest end were the S5-100 series, consisting of the S5-100, 102, 103, 90, and 95. These covered everything from the small "shoebox" all in one form factor to ones which overlapped the mid range in terms of capability except for their compact I/O cards which were smaller and slower than the full size models. The S5-115 formed the mid range, coming in a "full size" form factor in terms of packaging and rack size. The S5-135 and S5-155 extended the S5-115 in terms of speed and memory. 06 In this episode I will focus on the lower end S5-100 series for the sake of simplicity, and will not make any reference to any additional capabilities of the larger models. It will be much too time consuming and confusing to try to cover everything, and there wouldn't be much point to it. -------------------- 07 Data Memory Types If you recall the previous episode, the Allen Bradley PLC2 had a data table, or memory system, that was a single linear range of memory with all I/O and internal capabilities mapped into fixed numerical addresses. Allen Bradley were to abandon this approach in their later PLC5 series introduced in the mid to late 1980s, but we won't cover that here. The Siemens S5 series however took the approach of having different types of memory addresses for different purposes. I will describe those for the S5-100 series now. 08 Input and Output Addresses The standard I/O modules for these compact PLCs had 8 inputs or 8 outputs per I/O module. These module plugged into a flat bus (as opposed to an enclosed rack) with slots numbered from 0 through 31 in decimal. Each of these slots had an asso