DAY - 1

PLC WORKSHOP

Basics of Programmable Logic Controllers

SAJID ALI

Presentation Sequence
Basics of PLCs

Functions of PLCs Applications of PLCs Components of PLCs Programming Devices Symbols Programming modes PLC program creation Documentation PLC addressing Programming logic functions Q&A

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Programmable Logic Controllers

PLC( programmable logical controller) is a computer type device used in an industrial environment to control various types of machines or processes through digital or analogue inputs and outputs. PLCs are similar to computers except, computers are optimised for calculation and display, PLCs are optimised for control tasks and the industrial environment. Thus PLCs are: Rugged and designed to withstand vibrations, temperature, humidity and noise. Have interfacing for inputs and outputs already inside the controller. Easily programmed and have an easily understood programming language which primarily concerned with logic and switching operations

Why PLCs

PLC is a microprocessor based, reprogrammable device that is used for Industrial Automation In addition to the programming flexibility PLCs offer other advantages over traditional control systems. These advantages include:

high reliability small space requirements computing capabilities reduced costs ability to withstand harsh environments expandability

History
Conventional control panel
At the outset of industrial revolution, especially during sixties and seventies, relays were used to operate automated machines, and these were interconnected using wires inside the control panel. In some cases a control panel covered an entire wall.

History
Disadvantages of Conventional control panel
z z z z z z z z

Too many wiring work. Difficult to modify and troubleshoot => Long down time. Power consumption can be quite high Drawings are usually not updated. Lifetime of relay contacts was limited, so some relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also, it could happen that there was not enough room for necessary changes. As far as maintenance, electricians had to be very skillful in finding errors.

When a problem occurs, hold-up time is indefinite, usually long.

History
In the late 1960's PLCs were first introduced. The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems. Bedford Associates (Bedford, MA) proposed something called a Modular Digital Controller (MODICON) to a major US car manufacturer. Other companies at the time proposed computer based schemes, one of which was based upon the PDP-8. The MODICON 084 brought the world's first PLC into commercial production. In the mid70's the dominant PLC were Modicon and A-B PLCs. The AMD 2901 and 2903 were quite popular in these PLCs Communications abilities began to appear in approximately 1973. The first such system was Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from the actual machine they were controlling. They could also now be used to send and receive varying voltages to allow them to enter the analog world.

History
The 80's saw an attempt to standardize communications with General Motor's manufacturing automation protocol (MAP). It was also a time for reducing the size of the PLC and making them software programmable through symbolic programming on personal computers instead of dedicated programming terminals or handheld programmers.
The 90's have seen a gradual reduction in the introduction of new protocols, and the modernization of the physical layers of some of the more popular protocols that survived the 1980's. The latest standard (IEC 1131-3) has tried to merge PLC programming languages under one international standard.

History
Advantages of PLC based control system
Compared to a conventional process control system, number of wires needed for connections is reduced by 80% Diagnostic functions of a PLC controller allow for fast and easy error detection. Change in operating sequence or application of a PLC controller to a different operating process can easily be accomplished by replacing a program through a console or using a PC software (not requiring changes in wiring, unless addition of some input or output device is required).

Needs fewer spare parts.

It is much cheaper compared to a conventional system, especially in cases where a large number of I/O instruments are needed and when operational functions are complex. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.

PLC Architecture
Typically a PLC system has five basic components. These are the processor unit, memory, the power supply unit, input/output interface section and the programming device. Figure shows the basic arrangement. Programming Device

Memory

Input Interface

Processor

Output Interface

Power Supply

PLC Architecture

PLC Architecture
CPU
The processor unit or central processing unit (CPU) is the unit containing the microprocessor and this interprets the input signals and carries out the control actions, according to the program stored in its memory, communicating decisions as a action signals to the output.

Power Supply Unit

The power supply unit is needed to convert the main a.c. voltage to the low d.c. voltage (5V,24V etc) necessary for the processor and the circuits in the input and output interface modules.

PLC Architecture
Programming Device
The Programming device is used to enter/edit the required program into the memory of the processor. The program is developed in the device and then transferred to the memory unit of the PLC.

Memory Unit
Program is stored in memory unit, and is used for the control actions to be exercised by the microprocessor.

Input and Output Sections

The input and output sections are where the processor receives information form external devices and communicates information to external devices

PLC Architecture
The essential elements of a CPU are:

Registers
A register is a byte (8 bits), word ( 16 bits ) or long word (32 bits) of memory which is part of the microprocessor as opposed to general purpose memory. A register is used for temporary storage of data and addresses within the CPU.

ALU
The ALU performs arithmetic and logical operations such as addition and subtraction on data stored in registers.

Control Unit
The control unit is basically a set of counters and logic gates which is driven by the block. Its function is to control the units within the microprocessor to ensure that operations are carried out in the correct order.

Functions of PLCs

Functions of PLC: Function of a PLC is to provide a reprogrammable, reliable, upgradable control solution for Industrial Automation The function of an input module is to convert incoming signals into signals, which can be processed by the PLC, and to pass these to the central control unit. The reverse task is performed by an output module. This converts the PLC signal into signals suitable for the actuators

Applications of PLCs
...over 1,000,000 applications world wide
Overview

Woodworking

Conveyor systems Pump controls

Filling plants

Vacuum suction systems/elevators

Application examples

Applications of PLC are wide ranging as it is designed for Industrial Applications As the Industry is diversified so is the application of PLC. A reliable controller for every machine & system . Where frequent process changes are required. In harsh environments. Where the whole plant is to be controlled by central controller with multiple loops. Accurate Timer and counter functions, memory setting and resetting, mathematical computing operations when required. For reliable, accurate and economical automation

Control of a Sequence (Conveyor Unit)

Here a PLC is controlling the conveyor unit (Diversion & Speed) PLC is getting info from:
Sensors for workpiece detection Sensors for conveyor speed detection

1.

And controlling:
Diversion device (pneumatic based) Conveyor speed

2.

Monitoring a Chemical Plant

Here a PLC is controlling a process PLC gathers information from level sensors According to the level definition of the reservoirs opens or closes the respective valves All of the actions are executed according to the program that is written in the PLC PLC can also control the flowrate of the fluids.

Interface Control in CNC machine

A CNC machine requires a variety of sequential control applications like:

Interface control in CNC machine

Coolant on / off Door open / close Tool changing Vise / chuck open / close

Program

Program

PLC Interface Control

CNCController

A PLC is used here in connection with CNC controller that enables the machine to execute the fore stated steps

Machine Tool

Replacing Relays by PLC

Replacing Relays by PLC Continue:

Components of a PLC
Basics of PLC

Hardware

Functions of PLC

Applications of PLC

Power supply Processor Input module Output module Special modules

Symbols

Components of PLC

Programming Devices

Temperature sensing Motor control

PLC Program creation

Programming Modes

Software

Documentation

PLC programming software Linking software HMI development software

PLC addressing

Programming Logic Functions

Q&A

Components of a PLC

The Base For PLC

Components of a PLC

The Power Supply Mounted On The Base Plate

Components of a PLC

The Processor Module Mounted on the Base Plate

Components of a PLC

The Input Module Mounted on the Base Plate

Components of a PLC

The Output Module Mounted on the Base Plate

Block Diagram of PLC

Types of PLC
There are two types of PLC 1) Fixed PLC

Fixed PLC combine all of the main components into a single unit that contains the CPU, input/output sections, and power supply. The number of inputs and outputs cannot be expanded.
2) Modular PLC

A PLC configuration in which each component is split into a separate unit. A modular PLC lets you have as many inputs and outputs as you want.

PLC Available in market

Following models of PLC are commonly available in the market.

Basics of PLC

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Programming Devices

Processor Module can be programmed via

Computer PLC programmer Hand Held Programmer

Processor Module can give output to

Printer HMI panel Computer

It can communicate with other devices as well

Basics of PLC

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Programming languages
Basics of PLC

Ladder Diagram Function Block Diagram Instruction List Structured Text Sequential Function Chart

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Ladder diagram

A graphic programming language Derived from relay logic Contact Rails to the left and the right These contact rails are connected to switching elements

Function block diagram

Graphical Method of programming Various Function blocks are provided for the ease of programmer, e.g.

Logic Functions Math Functions Special Functions

Functions blocks are interconnected into networks, to form a PLC program. Even Ladder Diagram can be used with function blocks

Instruction List

Instruction list is a textual assembler-type language Instruction list is formulated from control instructions consisting of an operator and an operand.

LD

Part_TypeA

OR
AND AND ST

Part_TypeB
Part_present Drill_ok Sleeve_in

Structured Text

Structured text programming is similar to high-level language Loops, control statements and function blocks can be used Structured text enables the formulation of numerous applications, beyond pure function technology,

algorithmic problems (Control) data handling (data analysis, processing of complex data structures etc.).

Sleeve_in :- (Part_TypeA OR Part_TypeB) And Part_present AND Drill_ok;

Sequential Function Chart

Used for structuring of sequence-oriented control programs. The elements SFC are

steps, transitions, alternative and parallel branching.

Hierarchical structure of a control program is developed.

Why there are a number of programming options for a PLC?

To gain popularity!

Basics of PLC

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Procedure for Creating a PLC Program

Specification:

Description of the task

Description of the solution

Design:

Realization:

Implementation of the solution

Incorporating into environment and testing

Integration / commissioning:

Documentation

One important and crucial component of a system is documentation, Documentation is required for Maintenance Expansion of the system PLC Program Troubleshooting creation Individually these are: Problem description Documentation Positional sketch or technology pattern Circuit diagram Terminal diagram Printouts of control programs in SFC, FBD etc.. Allocation list of inputs and outputs Additional documentation

PLC addressing
Basics of PLC

Input and output Assignment Electrical and pneumatic circuit diagrams

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

PLC addressing
Memory Area Structure OF FATEK PLC

PLC addressing
Memory Area Structure OF FATEK PLC

PLC addressing
Memory Area Structure OF SIEMENS PLC

PLC addressing Memory Area Structure OF SIEMENS PLC

PLC addressing
Memory Area Structure OF SIEMENS PLC
z Physical Input Contacts()These are the external physical inputs contacts of the PLC. Its Address in Siemens PLC is I0.. In and for Fatek PLC is X0.Xn. z Physical Output Coils()These are the external physical Outputs Coils/Relays of the PLC. Its Address in Siemens PLC is Q0.. Qn and for Fatek is Y0.Yn.

PLC addressing
Memory Area Structure PLC
Internal Relay ()Do not have any specific function, and they can be freely used within the program (except those assigned to Input or Output Cards and Special I/O Cards). Known as M area in Fatek PLC. Retentive M(M800-1399), Internal Relay(M0-799) and Special relays (M1912-2001) Work Area/Data Register (D) can be used only in the program; not for I/O exchange with external I/O terminals. D (D0-D4095), R(R0-4168)

PLC addressing
Memory Area Structure PLC

Step Relays (S)

These are the step relays of PLC. Known as Retentive S(S500-999) and S(0-499) of Fatek PLC.

Timers(T)/ Counters(C)-

I/O Assignment

The I/O assignment table indicates which PLC inputs are connected to which input devices And which PLC outputs drive which output devices. The assignment of internals, including timers and counters also takes place here.

Electrical and pneumatic circuit diagrams

Integration of PLC with mechanical system.

the electrical circuit is replaced with the ladder diagram of PLC and is connected to the pneumatic circuit accordingly Here a solenoid operated valve is connected to the PLC.

Basics of PLC

Functions of PLC

Applications of PLC

Symbols

Components of PLC

Programming Devices

PLC Program creation

Programming Modes

Documentation

PLC addressing

Programming Logic Functions

Q&A

Programming of logic functions

Ladder Diagram

A graphical representation use by engineers for their relay logic.

Adopted by PLC makers as a programming language due to its simplicity. Thus the term Ladder Programming shown in figure.

Fatek PLC programmer WinProLadder.

Symbols of Ladder Diagram

Symbols of Ladder Diagram

Y0

This is a representation of a relay coil. The number represents the relay.

X0

This is a normally open contact symbol. It will be closed if the coil of the same number is energised. This is a normally closed contact symbol. It will open upon the energising of the coil of the same number

X0

SIMATIC S7-200

S7-200 Second Generation Overview

CPU 221 (10 I/O Points)
Overview

CPU 222
(14 I/O Points)

) CPU 224 (24 I/O Points)

CPU 224XP (24 I/O Points)

CPU 226 (40 I/O Points)

Built-in Features
CPU Status LEDs
Overview

I/O Point Status LEDs

Cartridge Slot

Internal: - Power Supply - Super Capacitor - Clock

(224(XP),226)

Communication Port(s)

Removable Terminal Blocks

24V Sensor Power Output

Mounting Holes for Panel Installation

(224(XP),226)

Snap-On Clip for DIN Rail Mounting

Please sit infront of Individual PCs and Open WinProLadder placed on DeskTop. Practice on Simple Ladder Logic Programming

Review on Logic Gates

NOT Gate, OR Gate, Nor Gate, And Gate, Nand Gate, XOR Gate, Multiplexers Etc. Equation & Truth Table of Gates

Practice Session

Programming of logic functions

Basic Logic Functions

Not Or And Memory

The figure is showing the relay logic for AND and OR operation

Negation (NOT Gate)

The output signal assumes the value 1, if the input signal has the value 0 and vice versa.

Negation (NOT Gate)

Exercise 1:

Lamp H1 is illuminated as long as switch S1 is not actuated; It is extinguished, if the switch is closed. The purpose of S1 is therefore to switch off the lamp.

Negation (NOT Gate)

Solution:

AND-Operation

The output signal only assumes the value 1, if all input signals have the value 1.

AND-Operation

Exercise 2:

Lamp H1 is to be switched on only if the two switches S1 and S2 are actuated.

AND-Operation

Solution:

NAND-Operation

The output signal only assumes the value 1, if all input signals have the value 1.

NAND-Operation

Exercise 3:

The output signal only assumes the value 1, if all input signals have the value 1.

Lamp H1 is to be switched on only if the two switches S1 and S2 are actuated.

NAND-Operation

Solution 3:

OR-Operation

The output signal assumes the value 1, if at least one input signal has the value 1.

OR-Operation

Example 4:

Lamp H1 is to be switched on, if at least one switch, S1 or S2 is actuated.

OR-Operation

Solution 4:

NOR-Operation

The output signal assumes the value 1, if at least one input signal has the value 1.

NOR-Operation

Example 5:

Lamp H1 is to be switched on, if at least one switch, S1 or S2 is actuated.

NOR-Operation

Solution 5:

Exclusive OR-Operation

The output signal assumes the value 1, if at least one input signal has the value 1.

Exclusive OR-Operation

Example 6:

Lamp H1 is to be switched on, if at least one switch, S1 or S2 is actuated.

Exclusive OR-Operation

Solution 6:

Memory Function

The standard function block SR

a dominant setting flipflop (bistable memory with preferred status 1). A 1-signal at S1 sets the value of Q1 A 1-signal at R only brings output Q1 to value 0

The standard function block RS

a dominant resetting flipflop (bistable memory with preferred status 0).

Memory Function

Exercise:

If sensor B1 has a 1-Signal, this indicates an error status in the system. A horn H1 is sounded. The horn can only be switched off by actuating push-button S1. It is possible to switch off the horn, even if the B1signal continues to be applied.

Memory Function

DAY-2 Programming Techniques

Symbolic Addressing Latches Timers Single Shot Pulse Counters

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Symbolic Addressing

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Symbolic Addressing

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Latches
Latch circuit is used to maintain the status of output based on two execution conditions. These conditions are SET & RESET. When SET condition is true, output turns ON and stay ON, until reset condition is true. When RESET condition is true, output turns OFF and stay OFF, until SET condition is true.
SET condition RESET condition Output
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Latches

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Latches

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TIMER

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TIMER

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TIMER

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Timers and Creating Delay

A timer is activated when its execution condition goes ON. If the execution condition remains ON long enough for TIM to time down to zero, the output for the TC number used will turn ON and will remain ON, until TIM is reset. TIM measures in units of 0.1 second from the Set Value.

Input Condition Output

T1

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Timers and Creating Delay

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DELAY ON TIMER

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DELAY ON TIMER

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DELAY ON TIMER

EXAMPLE: Write a program to on a motor after 10 seconds

When switch S1 is on

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DELAY ON TIMER Solution:

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DELAY OFF TIMER

EXAMPLE: Write a program to on a motor for 100 seconds When switch S1 is on.

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DELAY OFF TIMER Solution:

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Retentive or Accumulating timer

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Retentive or Accumulating timer Example:

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TIMER

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Single-Shot Circuit

This circuit is used to keep the ON time of an input signal.

Input Signal

Output
T1 T1

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Single-Shot Circuit

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COUNTER

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COUNTER

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COUNTER

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COUNTER

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COUNTER

EXAMPLE: Write a program to count a number of samples ( box, apples, bottles etc) up to 10 and then stop the conveyor motor.

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COUNTER

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COUNTER

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COUNTER

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Retentive or Accumulating timer

EXAMPLE: Write a program to count the existing bottles on a conveyor belt by using S1 at the entrance and S2 at outlet. If bottles are 4 then on alarm AL1. Use S3 pushbutton for reset.

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COUNTER

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