PLC in AUTOMATION

Industrial Automation
● Automation generally means dedication of the work to
machine.
● Industrial Automation generally comes under the Engineering
field of Mechatronics.
MECHATRONICS

AUTOMATION ( Industrial )

' PLC ' in Automation.

' Robotics ' in Automation.

 Mechatronics in Automation
● Mechatronics is the synergistic combination or Integration of
– Mechanical Engineerring ( "mecha" for mechanism, i.e., machines that 'move'),
– Electronics Engineering ( "tronics" for electronics), and
– Software Engineering.

● The purpose of Mechatronics is study of 'automata' (means

Automation) to serve the purpose of controlling advanced systems.
PLC in Automation
 Introduction to PLC
● What is a PLC ?
– Programmable Logic Controller is a solid state device
designed to perform logic functions that were previously
accomplished by Electromagnetic relays.
– PLC's are event driven devices, which implies that an
event taking place in the field will result in an operation
or output taking
place.
– Any Applications that needs some type of electrical
control has a need for PLC.
 Evolution of PLC's
● In 1960's - The PLCs were first introduced.
- Modular Digital Controller (MODICON) brought
the world's first PLC into Commercial
production.

● In 1970's - Communications abilities began to appear. The first

such system was Modicon's
Modbus.
● In 1980's - The first PC based programmable languages were
developed which replaced the dedicated terminals
or hand held devices.
● In 1990's - Merge of plc programming languages into one
complete software.
- Such as function block diagrams, instruction lists,
structured list.
Manufactures of PLC (Micro)
Controllers

Motorola Siemens ( Hitachi ( JAPAN)

(America) EUROPE)
Architecture of PLC
 Modes of Operation
● Modes of PLC Operations are,

– Run Mode
– Program Mode
– Monitor Mode
 Run Mode Position

This PLC mode enables program to be executed as basic

operation. It is used in final testing, after a program has
been tested in detail, and errors have been eliminated.
Executes the ladder and energize the output devices.
Prevents online program editing.

Run mode in Siemens S7- 200 PLC....,(Next)

 Run Mode in Siemens (PLC)

● Once the downloading

process is over select,

● Click RUN icon on the

Standard tool bar to make
the Program to run in the
PLC,
or

● Select the RUN command

from PLC menu option.
Program/Stop Mode Position
Places the processor in program Mode.
Prevents the processor from scanning or executing the
ladder diagram.

Allows program entry and editing.

 Program/Stop Mode in
Siemens

● Click STOP icon on the

Standard tool bar to Stop the
execution of the program while
it is in RUN mode,
or

● Select the STOP command

from PLC menu option.
Monitor(Status) Mode Position

In this mode, program execution is possible, as well as

and monitoring during operation.

All changes in inputs and outputs can be viewed on the

screen,
Status of variables and program locations used in the
program are registered and memorized.
 Monitor(Status) Mode in
Siemens

● Click PROGRAM STATUS

icon on the Standard tool bar
to visualize the program status
in the window,
or

● Select the PROGRAM

STATUS command from
Debug menu option.
PLC Working Principle
 How does a PLC Works....
● Step 1of 3
:

● Testing input status. First, a PLC check each of the inputs status ON
or OFF.

● In other words, it checks whether a sensor, or a switch etc. connected

with an input is activated or not.
● Information that processor thus obtains through this step is stored in
memory in order to be used in the following step.
 How does a PLC Works...
● Step 2 of 3
:

● Program execution. Here a PLC executes a program, instruction by

instruction.

● Based on input as obtained in the preceding step, an appropriate

action is
performed.

● Such as certain output, or results can be put on / off or stored in

memory to be retrieved later.
 How does a PLC Works..
● Step 3 of 3
:

● Checkup and correction of output status. Finally, a PLC checks up

output status and adjusts it as
needed.

● This change is performed based on the input status (step 1) and

execution in (step2),

● Following the execution of step 3 PLC returns to the beginning of this

cycle and continually repeats these
steps.
● This time generally taken to execute the
above three steps is known as
Scan Time of the PLC .
(Depends upon type of PLC)
Basic Circuitry connections in
PLC
 Input/Output Adjustment
Interface in PLC
● PLC's are not directly
connected to interface with
the input or output.
● They are connected
through “Opto-Isolated
circuits.
– No electrical,
– Signal through
Light,
– Prevent from
damaging the
PLC.
 Sinking- Sourcing Concept
● These two concepts are very important in connecting a PLC
correctly with external environment.
● The most brief definition of these two concepts would be:
● SINKING = Common GND line (-)
● SOURCING = Common VCC line (+)
Types of PLC Programming
Languages
 PLC Programming Languages
(Siemens)
● According to International Electronics Commission
(IEC)

● Ladder Logic Programming (LAD)

● Function Block Diagram programming (FBD)

● Statement List programming (STL)

Ladder Programming Language
(LAD)
● Ladder Logic programming is similar to relay ladder wiring
making the programming
simpler.

● It is nothing but a symbolic representation of electric

circuits.
● Since the instruction set is composed of Symbols, Ladder
Logic diagram it is also called as Contact Symbology.

LADDER
 Function Block Diagram
Language (FBD)

● The Function Block diagram incorporates the symbolic

Functions for representing the
Instructions.
● In this type of Programming each instructions are
represented as a single Function or combination of blocks,

FBD
 Statement List Programming
(STL)
● The Statement List Programming was originally developed in
Europe
● This method uses a Structured
Approach.
● In this method the scan time is reduced as it doesn't even
scans the inactive parts of the programs.

STL
Programming a PLC using
Ladder Language
 Conventional
Schematic diagram Vs Ladder Diagram

● Power
Terminals

● Inputs
– Switches

– Relays
 Elements of Ladder Diagram
● The bus-bar denotes the starting of rung i.e power line (+),

● The I0.0 denotes the switch (NO) connected with one end on the (+)
and other end (-) thus making the circuit closed.

● This I0 denotes the word and 0.0 denotes the '0' bit.
Cascading of Multiple inputs for
a Single Output
● First arrange the inputs with energising output in there
ascending
values.
● Neglect the De-energising (Zero)
outputs.
● Now draw the ladder for these Output
Sequence.
● Group the similar first order inputs, and reduce it to
equivalents
groups.
● Then repeat the same step for remaining group, Finally
combine all the input groups to the output.
 Main Types of Instructions
● Input Instructions (I0.0......I0.7)
● Output Instructions (Q0.0...Q0.7)
● Internal Relay Instructions (M0.0...M0.7)
● Timer Instructions (T0.....T255)
● Counter Instructions (C0....C255)
● Advanced Instructions
● One Shot (Positive Transition)

● MATH (Math )
● PLS (Pulse)
● INT (Interrupt)
 Input Instructions
● Input instructions are broadly of two types,
● Normally Open Contact. (NO)
● Normally Closed Contact. (NC)

Load State Normally Open Normally Close

0 False True
1 True False
 Output Instructions
● The Output (=) instruction writes the new value for the
output bit in the process image register ( i.e. On or
off)

● The output bits are normally represented by coil

symbol,

● Output(=)

● Set(S)

● In general mostly output are

Actuators,

● Actuator is a device that converts the electric signal into

mechanical
motion.
Example of Contacts & Set/Reset Coils
 Internal Relay Instructions
● Internal relays or coils are an area of the memory allocated
by the PLC for internal storage
bits.

● Internal outputs operate on the same way as output,but it is

strictly restricted for internal purposes
only.

● These can be programmed by the user to perform relay

functions without occupying a physical
output.

● Internal Relay (S)

 Timer Instructions
● PLC Timers are output instructions that provide delay for
opening and closing of contact.

● They are used for to activate or de-activate a device after a

preset interval of time.
● There are three different types of Timers namely,

● On – Delay Timer - On after preset interval Time.

(Ex..,)
● Off – Delay Timer – On only during the interval
Time.

● Retentive Timer – The elapsed value of Time is

NOTE : Timers needs continuous Input for doing its allocated Functions.
Retained
 Timer Instructions
● The timer instructions are usually associated with the
following
terms,

● Preset Time : It is the Time Duration for the timing

circuit.
● Accumulated Time : It is the amount of time
elapsed.
● Timer Base : The intervals that the timers time-out. Such as
(1s, 0.1s, 0.01s)
Time Delay = Preset Time * Time Base
Example of ON Delay Timers in PLC
Example of Retentive Timers in PLC
 Counter Instructions
● The counter instruction do not operate on internal clock but
are dependent on external or program sources for
counting.

● These counters can count Up, count down or combined to

count up and down, based on the negative to positive
transition.

● There are three types of counters namely,

● Up
Counters,

● Down
Counters,

● Up and Down Counters.

Example of Counters in PLC

Q 0.0
 One Shot / Positive Transition
Instructions
● It is similar to a contact but the only difference is that it will
be closed only during the Rising / Falling Edge of the
Signal.
● The contacts which closes during the Rising Edge of the
signal is called Positive Transition (or
DIFU).
● The contacts which closes during the Falling Edge of the
signal is called Negative Transition (or DIFD).
Example of one Shot / Positive
Transition Instruction in PLC
 Examples of Simple
PLC- Automations & Programs
 Example of Water level Tank

I0.1 I0.0 M0.0

I0.0 I0.1
M0.0
Q 0.0
M0.0

Q 0.0
 Automation for Garage Door
Ladder Diagram
Automation of product packaging
 Automation of product packaging
Ladder Diagram
Automation for
Parking Station
Reaction chamber
Charge/Discharge
Hard Ware Connection Details of
SIEMENS S7-200 PLC
 How to make hardware connection
between PC to PLC?

● Connect the “Serial Port to USB converter” cable from

PLC control box ( RS232 – 2nd pin from top) to PC (USB),

● Connect the “MMI cable” Male pin to the PLC control box
and Female end to the MMI unit.
 How to Open the Siemens Step-7 Micro
Win Software?

● Double Click the V4.0

STEP-7 icon shown in the
Desktop to open the
Software,
or
● Press the START menu
 Simatic  Step 7
Micro Win V4.0 STEP 7
MicroWin.
 How to open the Program Block Window
in the Software?

● Once the Software is

opened,

● Click the PROGRAM

BLOCK icon in the Side
of the Window to open the
Programming Window.
 How to open an already Programmed
File into the Software?

● Click the OPEN icon to

open an already existing
Step-7 MicroWin Program
File from the Directory
then,

● Select the ***.mwp and

click open button.
 How to bring a New Programming File
into the Software?

● Click the NEW icon on

the Standard Toolbar to
bring a new file into the
Window of Step-7
MicroWin,
 How to Save the changes made in the
Programming File into the Software?

● Click the SAVE icon on

the Standard Toolbar to
save all the changes
made in the file into Step-
7 MicroWin,

● Type the Filename

(***.mwp) then click save
button.
 How to Compile the Program for Errors?

● Click the COMPILE ALL

icon on the Standard
Toolbar to check for any
errors in the Program,

● The Result will be

Displayed in the Status
bar of the Window.
 How to check the communications link
between PLC to PC?

● Click the Communication

command the side of the
screen to check the
communication,

● It will be displayed in the

box else Double click to
Refresh the connection
status.
 How to Download the program to the
PLC?

● Click the DOWNLOAD

icon on the Standard
Toolbar to download the
Program to the PLC,
or
● Select DOWNLOAD
Command from the FILE
Menu,
 How to Upload already existing File in
the PLC to PC ?

● Click the UPLOAD icon

on the Standard Toolbar
to Upload the Program
from the PLC to PC,
or
● Select UPLOAD
Command from the FILE
Menu,
 How to make the program to Run in
the PLC ?

● Once the downloading

process is over select,

● Click RUN icon on the

Standard tool bar to make
the Program to run in the
PLC,
or

● Select the RUN command

from PLC menu option.
 How to check the Program Status
while in run mode ?

● Click PROGRAM
STATUS icon on the
Standard tool bar to
visualize the program
status in the window,
or

● Select the PROGRAM

STATUS command from
Debug menu option.
 How to STOP the Program Execution in
the PLC while in RUN mode ?

● Click STOP icon on the

Standard tool bar to Stop
the execution of the
program while it is in RUN
mode,
or

● Select the STOP

command from PLC
menu option.
THANKYOU