Experiment 8 Programmable Logic Controller

8.0 Objective
This experiment aims to: Present the background for Programmable Logic Controllers (PLCs). Build a PLC application.

8.1 Relays and Ladder Diagrams

8.1.1 Relays
A relay (also known as contactor) is a switch, where a high power signal or supply to a load is controlled by small signal (see figure 8-1). The small control signal (5 or 12V for example) is applied to a coil thus magnetizing it. The magnetized coil attracts the common (C) contact of the switch from the normally closed (NC) contact to the normally open (NO) contact. This connects the supply (220V for example) to the load which could be a large motor.

Figure 8-1. Structure of a relay diagram (shaded) with external connections.

8.1.2 Ladder Diagrams

An industrial process, such as an assembly line, uses many relays to control the various motors, heaters, spray painters, presses, etc Each relay is enabled or disabled according to input conditions such as temperature, pressure, etc As industrial processes grew in size and complexity the number of relays used grew to large numbers. The need for a clear and easy to
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understand schematics for such systems arose. The solution developed and adopted by the industry was the ladder diagram. Figure 8-2 shows a simple ladder diagram.

Figure 8-2. Simple ladder diagram. A ladder diagram consists of two vertical rails that represent the power lines. The left rail is the live (L) line and the right rail is the neutral (N) line. Each rung (step) in the ladder represents an action. The left side of the rung contains the input conditions that activate a single output placed on the right side of the rung. When all conditions are closed the power is applied to the output element. In figure 8-2, when the operator presses the momentary normally open pushbutton PB1 the coil of the relay CR1, represented by a circle, on the right side of rung 1 is activated. This will close the normally open contacts of CR1 represented by two small vertical lines. The closure of CR1 contacts in rung 1 lower branch will latch its coil. Thus CR1 will remain energized indefinitely. Also the contact of CR1 in rung 2 will close thus switching on the red lamp. To switch off the system the normally closed momentary switch PB2 is activated by the operator thus de-energizing the coil of the relay CR1. Standard symbols exist for many hardware components used in industrial processes. The symbols for the relay are shown in the following table. Table 8-1. Some standard symbols for ladder diagrams.

Control Relay

NO Control Relay Contacts

NC Control Relay Contacts

8.1.3 Time Delay Relays (Timers)

Three types of timers are available for use in the lab. Each timer is different in contacts start and stop times and their relation to the trigger signal. Timers are best understood by their timing diagrams. Table 8-2 shows the different timers and their timing diagrams. Table 8-2. PLC delay timers. Timer Type Trainer Symbol Timing Diagram

OnDelay

OffDelay

Pulse

8.2

PLCs

A PLC is a computer (see figure 8-3) used for automation of electromechanical processes, such as control of machinery in a factory assembly line. A PLC is designed for multiple inputs and outputs. Since a PLC controls a process by coded software it is easy to implement many functions such as timers, counters, mathematical formulas etc

Figure 8-3. Basic structure of a PLC. The input modules of a PLC are designed in a variety of forms such as analog voltage, analog current, bipolar inputs (0/24V or 0/12V, etc), and some have serial or parallel inputs. In a similar fashion, output modules could be analog voltage and current or bipolar outputs of various levels. The PLC to be used in this lab is a Colter FMT-200J specially setup for training (see figure 8-4). The PLC has the following modules: 32 0/24V bipolar inputs, addresses I0000-I0031. o 8 of the bipolar inputs have sockets, addresses I0000-I0007. o 8 of the bipolar inputs have switches, addresses I0008-I0015. 8 analog inputs (set to 0/10V, 0/24V or 0/20mA), addresses AI0000-AI0007. o 2 of the analog inputs are sockets, addresses AI0000 & AI0001. o 2 of the analog inputs are potentiometers, addresses AI0002 & AI0003. 24 0/24V bipolar outputs, addresses Q0000-Q0023. o 8 of the bipolar outputs are relays, addresses Q0000-Q0007. 4 0/24V analog outputs, addresses AQ0000-AQ0003. o 2 of the analog outputs are sockets, addresses AQ0000 & AQ0001.

Figure 8-4. PLC training module. This PLC can be programmed using the Flex-32 software provided by the manufacturer. The software enables the user to design his process control program and download it to the PLC either using a graphical ladder diagram or by writing a code somewhat similar to C.

8.3

Practice

A simple project will be prepared and downloaded to the PLC in this session (see figure 8-5). The project toggles an output relay for 1 or 4 seconds depending on the state of a digital input. The overall system is switched on or off by the state of another digital input. Figure 8-6 shows the ladder diagram to be implemented.

8.4

Procedure
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Make sure the serial cable between Port 0 of the controller and the PC is connected. Start the computer and switch on the trainer. Start Flex 32 software. Start a new project: File New Project. Set the Project Name : dayGrroupnumber. Set FMT Type: FMT 200J. Set Programming Station Number: 0. Accept the directory suggested by the software. From the Project Configuration window select: Create new module (See fig. 8-5 below).

Figure 8-5. Project Configuration window. 10- Enter the ladder steps as in figure 8-6.

Figure 8-6. Simple ladder diagram. 11- Save your ladder: Save As: Example1, make sure you are saving in your project folder (step 5). 12- Compile and download your ladder to the PLC by pressing: Run. See figure 8-7.

Figure 8-7. Compile and download of ladder. 13- Press OK when download finishes and the PLC starts to beep. 14- Connect the 0V COM socket in the DIGITAL INPUTS panel to the 0V OUT socket in the AUXILIARY 24Vdc OUTPUT SUPPLY panel. 15- Place the COM switch in the DIGITAL INPUTS panel to the 0V position. 16- Close switch I8 in the DIGITAL INPUTS panel to switch on the system. 17- Toggle switch I9 to energize the relay for 1 or 4 seconds. 18- Try to modify the ladder and see what happens. 19- Add the timers in table 8-2 to your ladder and test how they work. 20- Use the help to read about the Counter Function. 21- Implement the counter application shown in figure 8-8 on your PLC.

Figure 8-8. Counter Implementation

22- What is the count stored in the counter at start of run? Is the output on or off? 23- Load the counter. 24- Test how the output can be switched on after loading. 25- What is the effect of switch I11.

8.5 Hand in
Hand in a complete report, and describe your observations about the functioning of your ladder diagram and PLC. You must include clearly all your results.
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