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
National Institute of Design & Analysis
88
Symbolic Addressing
National Institute of Design & Analysis
89
Symbolic Addressing
National Institute of Design & Analysis
90
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
National Institute of Design & Analysis
91
Latches
National Institute of Design & Analysis
92
Latches
National Institute of Design & Analysis
93
TIMER
National Institute of Design & Analysis
94
TIMER
National Institute of Design & Analysis
95
TIMER
National Institute of Design & Analysis
96
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
National Institute of Design & Analysis
97
Timers and Creating Delay
National Institute of Design & Analysis
98
DELAY ON TIMER
National Institute of Design & Analysis
99
DELAY ON TIMER
National Institute of Design & Analysis
100
DELAY ON TIMER
EXAMPLE: Write a program to on a motor after 10 seconds
When switch S1 is on
National Institute of Design & Analysis
101
DELAY ON TIMER Solution:
National Institute of Design & Analysis
102
DELAY OFF TIMER
EXAMPLE: Write a program to on a motor for 100 seconds When switch S1 is on.
National Institute of Design & Analysis
103
DELAY OFF TIMER Solution:
National Institute of Design & Analysis
104
Retentive or Accumulating timer
National Institute of Design & Analysis
105
Retentive or Accumulating timer Example:
National Institute of Design & Analysis
106
TIMER
National Institute of Design & Analysis
107
Single-Shot Circuit
This circuit is used to keep the ON time of an input signal.
Input Signal
Output
T1 T1
National Institute of Design & Analysis
108
Single-Shot Circuit
National Institute of Design & Analysis
109
COUNTER
National Institute of Design & Analysis
110
COUNTER
National Institute of Design & Analysis
111
COUNTER
National Institute of Design & Analysis
112
COUNTER
National Institute of Design & Analysis
113
COUNTER
EXAMPLE: Write a program to count a number of samples ( box, apples, bottles etc) up to 10 and then stop the conveyor motor.
National Institute of Design & Analysis
114
COUNTER
National Institute of Design & Analysis
115
COUNTER
National Institute of Design & Analysis
116
COUNTER
National Institute of Design & Analysis
117
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.
National Institute of Design & Analysis
118
COUNTER
National Institute of Design & Analysis
119
