PLC — Programmable Logic Controllers
Programming and configuration guides for the main industrial PLC manufacturers on the market.
Within the Simatic PLC family, we trace their evolution from the early S5 to the latest S7-1500.
To program an S5 family PLC you need Step 5 software; the latest version 7.23 can run on Windows XP. The required interface is RS-232/TTY.
To program an S7-200 family PLC, the required software is Microwin; the latest version is v4.SP9 and can run on 64-bit Windows 7. This PLC has entered the discontinuation phase; its replacement is the S7-1200. The required interface is the PC-Adapter RS-232/PPI or USB/PPI.
To program an S7-300/400 family PLC, you need the Simatic Manager; the latest version is V5.6 for Windows 10. With the evolution, migration to TIA Portal has taken place. The required interface is the PC-Adapter/TC-Adapter RS-232 or USB/MPI, or a CP such as the CP5512/CP5611.
To program S7-300/400, S7-1200/1500 PLCs, you need TIA Portal (Totally Integrated Automation). Since the entire S7-1200/1500 family has a built-in Ethernet port, the required interface is an Ethernet cable.
Within the Schneider (Telemecanique) PLC family there is a great variety, evolving from one of the first PLCs, the Modicon 084, to the current Quantum range.
The programming software varies depending on the PLC model: for a legacy Quantum, Momentum or Atrium, the required software is Concept. For older Modicon Micro or Modicon Premium models, PL7 is needed.
For the new generation of PLCs, the software is Unity Pro (currently EcoStruxure Control Expert), used with Modicon Premium, Atrium and Quantum.
The required interface varies by PLC; the most common is serial, and for the latest models, Ethernet.
Within the Allen Bradley (Rockwell) PLC family, we trace their evolution from the early PLC-2 to the new Logix5000 family.
To program a PLC-5 family controller, you need RSLogix 5 (V7.40 allows installation on Windows 7). The simulator is RSLogix Emulate 5. Interfaces: serial cable, DH+/ControlNet/Ethernet depending on the processor. For DH+ networks, a PCMK card or a USB to DH+ converter (1784-U2DHP) is used.
For the SLC-500 / MicroLogix family, the software is RSLogix 500 (latest version V9.0). The simulator is RSLogix Emulate 500. The required interface is a serial cable or Ethernet (for processors like SLC500/05).
For the Logix5000 family (CompactLogix, ControlLogix, SoftLogix, FlexLogix), the software is RSLogix 5000 (latest version was V20), and from there, Studio 5000. The required interface is a serial cable, Ethernet, or the new USB port that newer controllers include.
Within the Omron PLC family, there is also a great variety. Omron classifies them by characteristics into Compact PLCs (CPMxx, CP1x), Modular (CJxx), and Rack-mounted (CSxx).
The programming software may vary by model and year; as CX-Programmer was updated, earlier versions could be programmed to unify them in a single software. The oldest software is Sysmac.
Within Beckhoff, the Embedded PC category is subdivided into: CX8000, CX9000, CX1010, CX5000, CX1020-30, CX2000.
The most current programming software is TwinCAT V.3, which integrates directly into Visual Studio. TwinCAT 3 supports IEC 61131-3 programming, C++, and EtherCAT as native fieldbus.
Other PLC manufacturers: ABB, GE Fanuc, CodeSys, B&R Automation Studio.
CodeSys is the software for programming controllers according to the IEC 61131-3 standard. It supports all 6 programming languages (IL, ST, LD, FBD, SFC, CFC). Based on CodeSys, we find major brands like ABB, Beckhoff, Wago, Moeller.
GE Fanuc: Within the GE Fanuc PLC family, we can subdivide them into three categories: VersaMax Micro/Modular, Series 90-30, and PAC800. All of them can be programmed with Proficy Machine Edition. For older PLCs, the required software is Versa Pro.
ABB: The legacy AC31 series with 07Cx4x (Series 40), 07Kx51 (Series 50), and 07Kx9x-Rxxx (Series 90) requires 907AC1131 software based on CodeSys. The AC500/AC500 eCo series is programmed with Control Builder Plus PS501. The Compact AC800 series is programmed with Control Builder AC800. There is also the AC800F series and the new AC700F Freelance series.
B&R Automation Studio: Within B&R, ControlSystems are subdivided into X20 System, System 2003, and System 2005. The most current programming software is Automation Studio 4.