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s7-1500/demo-advance-scl-contol.md
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s7-1500/demo-advance-scl-contol.md
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# README — S7-1500 SCL Sequencer (AUTO / INCR) with Pause vs Stop, Stop Categories, Skip/Disable, Safety-Locked Steps
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This project shows a Siemens S7-1500 step sequencer in SCL with:
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- AUTO mode (advance automatically)
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- INCR mode (advance only on operator NEXT pulse)
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- Pause vs Stop
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- Stop categories (immediate / end-of-step / end-of-cycle / no-stop)
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- Per-step UDT configuration (timeout + operator text)
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- Skip/disable steps (optional steps can be disabled)
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- Prevent disabling safety steps (PLC forces critical steps enabled)
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You can paste the TYPES into "PLC data types" and the FB code into an SCL FB.
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------------------------------------------------------------
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1) Concepts / How it works
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------------------------------------------------------------
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1. Step machine (FSM)
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- Variable "Step" defines the state:
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Step = 0 -> IDLE
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Step = 1..10 -> execute step logic
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- Each step has:
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- Actions (outputs to command)
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- Done condition (when it is allowed to advance)
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- Timeout (if not done within time -> Error)
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2. Modes
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We use enum E_Mode:
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- MODE_STOP = 0 (not running, safe outputs)
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- MODE_AUTO = 1 (auto advance)
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- MODE_INCR = 2 (manual advance with NEXT)
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Mode selection priority:
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- If Enable=FALSE OR Cmd_Stop=TRUE OR ErrorActive=TRUE => MODE_STOP
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- Else if Mode_Auto=TRUE => MODE_AUTO
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- Else if Mode_Incr=TRUE => MODE_INCR
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- Else MODE_STOP
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3. Pause vs Stop
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- STOP:
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- forces safe outputs (FALSE)
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- typically sets Step=0 (IDLE)
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- PAUSE:
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- freezes step progression and timer
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- keeps outputs frozen at last values (freeze outputs)
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Pause is implemented by:
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- PauseLatched toggled by Cmd_Pause edge
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- when pause becomes TRUE, capture current outputs into Frozen_* variables
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- while paused, outputs are forced to Frozen_* values
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4. Stop categories (StopReq + StopCat)
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Enum E_StopCat:
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- STOPCAT_IMMEDIATE:
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stop instantly (Step=0 + safe outputs)
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- STOPCAT_END_OF_STEP:
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finish current step then stop
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- STOPCAT_END_OF_CYCLE:
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continue until the configured end-of-cycle step completes, then stop
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- STOPCAT_NO_STOP:
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info only (never stops)
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Stop requests are latched:
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- STOPCAT_IMMEDIATE / END_OF_STEP / END_OF_CYCLE -> latched in PLC
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- STOPCAT_NO_STOP -> not latched (only displayed as info)
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5. Per-step configuration via UDT array Cfg[1..10]
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Each step stores:
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- Text: shown to operator
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- Timeout: step timeout
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- IsEndOfCycle: marks the “cycle end” step
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- ReqEnabled: HMI requested enable
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- Enabled: PLC effective enable used by sequencer
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- SafetyLocked: if TRUE, cannot be disabled
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- NextStep: optional jump target (0 means normal next)
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The PLC NEVER trusts ReqEnabled directly.
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PLC computes Enabled every scan:
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- if SafetyLocked => Enabled := TRUE (and optionally ReqEnabled forced TRUE too)
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- else Enabled := ReqEnabled
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6. Skip/Disable steps
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Instead of Step := Step + 1, we compute "next enabled step":
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- If operator disables a step, sequence jumps over it
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- A helper FC_NextEnabledStep finds the next enabled step
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- In AUTO mode we wrap 10->1, in INCR mode we can end at 0
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Optional routing:
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- If Cfg[Step].NextStep <> 0 then jump to that step (if enabled).
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------------------------------------------------------------
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2) PLC Data Types (copy into "PLC data types")
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------------------------------------------------------------
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TYPE E_Mode : USINT (
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MODE_STOP := 0,
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MODE_AUTO := 1,
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MODE_INCR := 2
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);
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END_TYPE
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TYPE E_StopCat : USINT (
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STOPCAT_NONE := 0,
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STOPCAT_IMMEDIATE := 1,
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STOPCAT_END_OF_STEP := 2,
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STOPCAT_END_OF_CYCLE := 3,
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STOPCAT_NO_STOP := 4
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);
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END_TYPE
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TYPE UDT_StepCfg :
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STRUCT
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Text : STRING[80]; // Operator text for HMI
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Timeout : TIME; // Per-step timeout
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IsEndOfCycle : BOOL; // Marks end-of-cycle step (e.g., step 10)
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ReqEnabled : BOOL; // From HMI/DB (operator request)
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Enabled : BOOL; // PLC effective enable (used by sequencer)
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SafetyLocked : BOOL; // If TRUE, PLC forces Enabled := TRUE always
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NextStep : INT; // 0 = normal next enabled step, else jump to 1..10
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END_STRUCT
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END_TYPE
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------------------------------------------------------------
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3) Helper FC: Next enabled step (skip disabled steps)
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------------------------------------------------------------
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FUNCTION FC_NextEnabledStep : INT
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{ S7_Optimized_Access := 'TRUE' }
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VAR_INPUT
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CurrentStep : INT;
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MaxStep : INT; // 10
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Wrap : BOOL; // TRUE in AUTO (10->1), FALSE in INCR (end->0)
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Cfg : ARRAY[1..10] OF UDT_StepCfg;
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END_VAR
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VAR
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s : INT;
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i : INT;
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END_VAR
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BEGIN
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s := CurrentStep;
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FOR i := 1 TO MaxStep DO
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s := s + 1;
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IF s > MaxStep THEN
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IF Wrap THEN
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s := 1;
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ELSE
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FC_NextEnabledStep := 0;
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RETURN;
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END_IF;
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END_IF;
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IF Cfg[s].Enabled THEN
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FC_NextEnabledStep := s;
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RETURN;
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END_IF;
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END_FOR;
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FC_NextEnabledStep := 0; // none enabled
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END_FUNCTION
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------------------------------------------------------------
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4) Main FB: Sequencer (AUTO/INCR + Pause/Stop + Stop categories)
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------------------------------------------------------------
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FUNCTION_BLOCK FB_Seq10_Adv
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{ S7_Optimized_Access := 'TRUE' }
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VAR_INPUT
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Enable : BOOL;
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Mode_Auto : BOOL;
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Mode_Incr : BOOL;
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Cmd_Start : BOOL;
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Cmd_Stop : BOOL; // hard stop (safe outputs)
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Cmd_Pause : BOOL; // toggle pause (freeze)
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Cmd_ResetErr : BOOL;
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Cmd_Next : BOOL; // NEXT pulse in increment mode
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StopReq : BOOL; // stop request flag
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StopCat : E_StopCat; // stop request category
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// Example process inputs (replace with real ones)
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In_Ready : BOOL;
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In_ClampClosed : BOOL;
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In_ProcessDone : BOOL;
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In_EjectDone : BOOL;
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// Step config from DB/HMI/recipe
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Cfg : ARRAY[1..10] OF UDT_StepCfg;
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END_VAR
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VAR_OUTPUT
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Step : INT; // 0..10
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Running : BOOL;
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Paused : BOOL;
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ErrorActive : BOOL;
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ErrorCode : WORD;
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HMI_StepText : STRING[80];
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HMI_StopInfo : STRING[80];
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// Example outputs (replace)
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Out_ClampClose : BOOL;
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Out_ProcessOn : BOOL;
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Out_Eject : BOOL;
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END_VAR
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VAR
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Mode : E_Mode;
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rStart : R_TRIG;
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rNext : R_TRIG;
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rReset : R_TRIG;
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rPause : R_TRIG;
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StepPrev : INT;
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StepEntry : BOOL;
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tStep : TON;
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AllowAdvance : BOOL;
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StopLatched : BOOL;
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StopLatchedCat : E_StopCat;
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PauseLatched : BOOL;
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Frozen_ClampClose: BOOL;
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Frozen_ProcessOn : BOOL;
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Frozen_Eject : BOOL;
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Cmd_ClampClose : BOOL;
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Cmd_ProcessOn : BOOL;
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Cmd_Eject : BOOL;
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i : INT;
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nxt : INT;
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END_VAR
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BEGIN
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// --------- edges ----------
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rStart(CLK := Cmd_Start);
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rNext(CLK := Cmd_Next);
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rReset(CLK := Cmd_ResetErr);
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rPause(CLK := Cmd_Pause);
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// --------- sanitize step config (prevent disabling safety steps) ----------
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// IMPORTANT: HMI should write ONLY ReqEnabled, not Enabled or SafetyLocked.
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FOR i := 1 TO 10 DO
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IF Cfg[i].SafetyLocked THEN
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Cfg[i].Enabled := TRUE;
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Cfg[i].ReqEnabled := TRUE; // reflect back to HMI (optional)
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ELSE
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Cfg[i].Enabled := Cfg[i].ReqEnabled;
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END_IF;
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END_FOR;
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// --------- reset error ----------
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IF rReset.Q THEN
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ErrorActive := FALSE;
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ErrorCode := WORD#0;
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Step := 0;
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StopLatched := FALSE;
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StopLatchedCat := STOPCAT_NONE;
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PauseLatched := FALSE;
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END_IF;
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// --------- mode selection ----------
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IF (NOT Enable) OR Cmd_Stop OR ErrorActive THEN
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Mode := MODE_STOP;
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ELSIF Mode_Auto THEN
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Mode := MODE_AUTO;
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ELSIF Mode_Incr THEN
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Mode := MODE_INCR;
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ELSE
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Mode := MODE_STOP;
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END_IF;
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// --------- start ----------
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IF rStart.Q AND (NOT ErrorActive) THEN
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IF Step = 0 THEN
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// start at first enabled step
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IF Cfg[1].Enabled THEN
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Step := 1;
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ELSE
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Step := FC_NextEnabledStep(CurrentStep := 0, MaxStep := 10, Wrap := TRUE, Cfg := Cfg);
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END_IF;
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END_IF;
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END_IF;
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// --------- latch stop request (category-aware) ----------
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IF StopReq THEN
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CASE StopCat OF
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STOPCAT_IMMEDIATE, STOPCAT_END_OF_STEP, STOPCAT_END_OF_CYCLE:
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StopLatched := TRUE;
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StopLatchedCat := StopCat;
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STOPCAT_NO_STOP:
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// info only; do not latch stop
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ELSE
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// none
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END_CASE;
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END_IF;
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// --------- pause toggle ----------
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IF rPause.Q THEN
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PauseLatched := NOT PauseLatched;
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// capture outputs when entering pause
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IF PauseLatched THEN
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Frozen_ClampClose := Out_ClampClose;
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Frozen_ProcessOn := Out_ProcessOn;
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Frozen_Eject := Out_Eject;
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END_IF;
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END_IF;
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Paused := PauseLatched;
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// --------- running ----------
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Running := (Mode <> MODE_STOP) AND (Step > 0) AND (NOT ErrorActive) AND (NOT Paused);
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// --------- step entry ----------
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StepEntry := (Step <> StepPrev);
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StepPrev := Step;
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// --------- HMI step text ----------
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IF (Step >= 1) AND (Step <= 10) THEN
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HMI_StepText := Cfg[Step].Text;
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ELSE
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HMI_StepText := 'IDLE';
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END_IF;
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// --------- stop info ----------
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HMI_StopInfo := '';
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IF StopReq AND (StopCat = STOPCAT_NO_STOP) THEN
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HMI_StopInfo := 'INFO: stop request is NO_STOP (alarm/info only)';
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ELSIF StopLatched THEN
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CASE StopLatchedCat OF
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STOPCAT_IMMEDIATE: HMI_StopInfo := 'Stop requested: IMMEDIATE';
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STOPCAT_END_OF_STEP: HMI_StopInfo := 'Stop requested: END_OF_STEP';
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STOPCAT_END_OF_CYCLE: HMI_StopInfo := 'Stop requested: END_OF_CYCLE';
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ELSE
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HMI_StopInfo := 'Stop requested';
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END_CASE;
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END_IF;
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// --------- if current step disabled -> jump immediately ----------
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IF (Step >= 1) AND (Step <= 10) THEN
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IF NOT Cfg[Step].Enabled THEN
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Step := FC_NextEnabledStep(CurrentStep := Step-1, MaxStep := 10, Wrap := (Mode = MODE_AUTO), Cfg := Cfg);
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END_IF;
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END_IF;
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// --------- default commanded outputs ----------
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Cmd_ClampClose := FALSE;
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Cmd_ProcessOn := FALSE;
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Cmd_Eject := FALSE;
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AllowAdvance := FALSE;
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// --------- step timer (does not run while paused) ----------
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IF StepEntry THEN
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tStep(IN := FALSE, PT := Cfg[Step].Timeout);
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END_IF;
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IF (Step >= 1) AND (Step <= 10) THEN
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tStep(IN := Running, PT := Cfg[Step].Timeout);
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ELSE
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tStep(IN := FALSE, PT := T#0S);
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END_IF;
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// --------- step logic (demo steps, replace with your real logic) ----------
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CASE Step OF
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0:
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;
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1: // WAIT READY
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IF In_Ready THEN AllowAdvance := TRUE; END_IF;
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2: // CLOSE CLAMP
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Cmd_ClampClose := TRUE;
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IF In_ClampClosed THEN AllowAdvance := TRUE; END_IF;
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3: // PROCESS
|
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Cmd_ProcessOn := TRUE;
|
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IF In_ProcessDone THEN AllowAdvance := TRUE; END_IF;
|
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|
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4: // EJECT
|
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Cmd_Eject := TRUE;
|
||||||
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IF In_EjectDone THEN AllowAdvance := TRUE; END_IF;
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5,6,7,8,9:
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// demo pass-through steps
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||||||
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AllowAdvance := TRUE;
|
||||||
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||||||
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10: // END OF CYCLE
|
||||||
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AllowAdvance := TRUE;
|
||||||
|
|
||||||
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ELSE
|
||||||
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ErrorActive := TRUE;
|
||||||
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ErrorCode := WORD#16#9001; // invalid step
|
||||||
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END_CASE;
|
||||||
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||||||
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// --------- timeout -> error ----------
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||||||
|
IF tStep.Q AND Running THEN
|
||||||
|
ErrorActive := TRUE;
|
||||||
|
ErrorCode := WORD#16#8000 + WORD_TO_WORD(INT_TO_WORD(Step));
|
||||||
|
Mode := MODE_STOP;
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
// --------- stop category enforcement: immediate stop ----------
|
||||||
|
IF StopLatched AND (StopLatchedCat = STOPCAT_IMMEDIATE) THEN
|
||||||
|
Step := 0;
|
||||||
|
StopLatched := FALSE;
|
||||||
|
StopLatchedCat := STOPCAT_NONE;
|
||||||
|
PauseLatched := FALSE;
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
// --------- step advance ----------
|
||||||
|
IF (NOT ErrorActive) AND (NOT Paused) THEN
|
||||||
|
|
||||||
|
// Evaluate "advance permission" depending on mode
|
||||||
|
IF (Mode = MODE_AUTO AND AllowAdvance)
|
||||||
|
OR (Mode = MODE_INCR AND AllowAdvance AND rNext.Q) THEN
|
||||||
|
|
||||||
|
// Handle stop-after conditions
|
||||||
|
IF StopLatched AND (StopLatchedCat = STOPCAT_END_OF_STEP) THEN
|
||||||
|
Step := 0;
|
||||||
|
StopLatched := FALSE;
|
||||||
|
StopLatchedCat := STOPCAT_NONE;
|
||||||
|
|
||||||
|
ELSIF StopLatched AND (StopLatchedCat = STOPCAT_END_OF_CYCLE) AND Cfg[Step].IsEndOfCycle THEN
|
||||||
|
Step := 0;
|
||||||
|
StopLatched := FALSE;
|
||||||
|
StopLatchedCat := STOPCAT_NONE;
|
||||||
|
|
||||||
|
ELSE
|
||||||
|
// Compute next step:
|
||||||
|
// 1) optional jump if NextStep configured
|
||||||
|
IF (Step >= 1) AND (Step <= 10) AND (Cfg[Step].NextStep <> 0) THEN
|
||||||
|
nxt := Cfg[Step].NextStep;
|
||||||
|
|
||||||
|
IF (nxt >= 1) AND (nxt <= 10) AND Cfg[nxt].Enabled THEN
|
||||||
|
Step := nxt;
|
||||||
|
ELSE
|
||||||
|
ErrorActive := TRUE;
|
||||||
|
ErrorCode := WORD#16#9100; // invalid NextStep config
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
ELSE
|
||||||
|
// 2) normal: next enabled step
|
||||||
|
nxt := FC_NextEnabledStep(
|
||||||
|
CurrentStep := Step,
|
||||||
|
MaxStep := 10,
|
||||||
|
Wrap := (Mode = MODE_AUTO),
|
||||||
|
Cfg := Cfg
|
||||||
|
);
|
||||||
|
Step := nxt;
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
END_IF;
|
||||||
|
END_IF;
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
// --------- output policy: STOP vs PAUSE vs NORMAL ----------
|
||||||
|
IF (Mode = MODE_STOP) OR (Step = 0) OR ErrorActive THEN
|
||||||
|
Out_ClampClose := FALSE;
|
||||||
|
Out_ProcessOn := FALSE;
|
||||||
|
Out_Eject := FALSE;
|
||||||
|
|
||||||
|
ELSIF Paused THEN
|
||||||
|
Out_ClampClose := Frozen_ClampClose;
|
||||||
|
Out_ProcessOn := Frozen_ProcessOn;
|
||||||
|
Out_Eject := Frozen_Eject;
|
||||||
|
|
||||||
|
ELSE
|
||||||
|
Out_ClampClose := Cmd_ClampClose;
|
||||||
|
Out_ProcessOn := Cmd_ProcessOn;
|
||||||
|
Out_Eject := Cmd_Eject;
|
||||||
|
END_IF;
|
||||||
|
|
||||||
|
END_FUNCTION_BLOCK
|
||||||
|
|
||||||
|
------------------------------------------------------------
|
||||||
|
5) Recommended usage in OB1
|
||||||
|
------------------------------------------------------------
|
||||||
|
|
||||||
|
- Create an instance DB for FB_Seq10_Adv.
|
||||||
|
- Fill Cfg[1..10] with texts/timeouts and safety locks.
|
||||||
|
|
||||||
|
Typical values:
|
||||||
|
- Step 1: Text='Wait Ready', Timeout=T#10S, SafetyLocked=TRUE (if required)
|
||||||
|
- Step 2: Text='Close Clamp', Timeout=T#5S, SafetyLocked=TRUE
|
||||||
|
- Step 10: Text='Cycle End', Timeout=T#2S, IsEndOfCycle=TRUE
|
||||||
|
|
||||||
|
Operator can only toggle:
|
||||||
|
- Cfg[i].ReqEnabled for optional steps (SafetyLocked=FALSE)
|
||||||
|
|
||||||
|
Run modes:
|
||||||
|
- AUTO: Mode_Auto=TRUE
|
||||||
|
- INCR: Mode_Incr=TRUE and use Cmd_Next pulses
|
||||||
|
|
||||||
|
Stop:
|
||||||
|
- Cmd_Stop -> immediate safe stop
|
||||||
|
- StopReq+StopCat:
|
||||||
|
- END_OF_CYCLE for "stop after part"
|
||||||
|
- END_OF_STEP for "stop after step"
|
||||||
|
- IMMEDIATE for urgent stop
|
||||||
|
- NO_STOP for warnings/info
|
||||||
|
|
||||||
|
Pause:
|
||||||
|
- Cmd_Pause toggles pause/resume (outputs frozen + timer frozen)
|
||||||
|
|
||||||
|
------------------------------------------------------------
|
||||||
|
6) What to customize next (common in production)
|
||||||
|
------------------------------------------------------------
|
||||||
|
|
||||||
|
1) Split outputs into "Freeze on pause" and "Force safe on pause" groups.
|
||||||
|
2) Add per-step "StopAllowed" (some steps must never stop mid-step).
|
||||||
|
3) Add alarm integration with FIFO + timestamps (your previous alarm project).
|
||||||
|
4) Add step entry actions (run once on step change):
|
||||||
|
- reset internal flags
|
||||||
|
- start motion commands
|
||||||
|
- log step start time
|
||||||
|
5) Add interlocks:
|
||||||
|
- if safety chain open -> force STOPCAT_IMMEDIATE
|
||||||
|
|
||||||
|
END OF README
|
||||||
Loading…
Reference in a new issue