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INTRODUCTION TOINTRODUCTION TOPROGRAMMABLEPROGRAMMABLE
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Automation Systems (Pvt.) Ltd.
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Overview
Introduction to automation technology Introduction to micro PLC systems
General Structure of PLC System
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Installing PLC and configuring hardware CPU memory and data types
Basic programming concepts
Programming languages Programming instructions
Programming of control systems
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Automation Technology
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What is automation?
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Automation is aimed at reducing human effort in
performing a task.
Manual Process
Mechanized Process
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What is automation?
Automation (ancient Greek: = self dictated)or industrial automation is the use of
electronic controllers to control industrial
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machinery and processes, replacing humanoperators.
It is a step beyond mechanization, wherehuman operators are provided with
machinery to help them in their jobs.
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Where used?
Production Industry Offices
Buildin s
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Construction Industry
Medical field
Household equipment
Aerospace Industry
???
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Example of a Manual process
Drillin machine
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Manual Process of Drilling a work piece
Work piece
Clamping device
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Processes carried out
Keeping the work piece Clamp the work piece
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Un clamp work piece
Remove the work piece
Sensing each operation
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Elements of the manual system
Actuators
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Decision making element
Sensors
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Automating the Process:
Step 1 :Replacement of humans muscles (hands) by someactuators, e.g. the pneumatic cylinders
Ste 2 :Re lacement of humans brain b a lo ic si nal
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processing device, e.g. PLC, electrical relay circuit.
Step 3 :Replacement of humans senses (eyes, ears, etc.)by some input devices (electrical sensors).
Step 4 :Use set of instructions to control output elementaccording to the signal inputs present.
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Automated SystemDrill Cylinder Limit switches/
sensors to detectend limits of
cylinder movement
Clamp
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Operator panel Signal Processor
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Industrial Automation
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Pentagon ofAutomation
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Signal Processors
Pro rammable Lo ic
Hard-wired Control Programmable Control
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Controller (PLC)Electrical
Pneumatics
Hydraulic
DigitalElectronics Embedded Controller
Micro controller (PIC)
Industrial PC
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Hardwired Control &Programmable Control
Hard-wired control Wiring of mechanical, electrical, electro-
mechanical or electronic com onents to obtain
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desired control
Programmable control
Programming and reprogramming of an
electronic component to obtain desired control
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Introduction to PLC
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PLC is an abbreviation for Programmable LogicController.
PLC is a microprocessor-based electronic device.
What is PLC?
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This equipment controls a process/ machine. a printing machine for printing newspapers, a bagging
plant to bag cement, a press for pressing plastic-shaped
parts, This process occurs according to the instructions
of a program in the memory of the equipment.
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What is PLC?
PLC is primarily used as an Industrial MachineController.
PLC is a small, but powerful Computer which is
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.
To control process/ Machine Sensors
Control switches (Push buttons, Switches)
Actuators (Solenoid Valves, Motor controllers)
should be wired to the PLC
Program with instructions stating how the process/
machine works should be written into the PLC memory
Signal Inputs
SignalOutputs
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Basic Principle of a PLC
Program (Instructions)Program (Instructions)Program (Instructions)Program (Instructions)
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Input SignalsInput SignalsInput SignalsInput Signals Signal ProcessingSignal ProcessingSignal ProcessingSignal Processing Output SignalsOutput SignalsOutput SignalsOutput Signals
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Advantages of PLC
Greater Flexibility and reliability
Changes to the design can easily be made on thero ram.
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Easy debugging Error detection program available.
Low power consumption & space requirement
Based on solid-state electronics rather than electro-mechanical technology.
Little maintenance
No moving parts.
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Advantages of PLC
No special programming skills required
Computer programming knowledge is not required.
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Prices of microprocessor-based devices reduced morethan those of electro-mechanical devices.
Easy Archiving & Documentation Programming, Parameter changes, etc. can be noted and stored in
the computer and documented without effort.
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The SIMATIC S7-200 is the CPU for the lower levelperformance range.
It is available in various grades.
S7-200
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machines and system construction. It is real time capable and offers extensive communication
possibilities over a PROFIBUS or PC/PPI cable and over a free
programmable interface protocol.
The SIMATIC S7-200 offers modular extensibility and integratedPID closed loop control functions.
The program software STEP 7 Micro/Win enables a quick
introduction in the programming and configuration.
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The SIMATIC S7-300 family offers the automationsolutions for the lower and middle performance range.
Properties of the SIMATIC S7-300
S7-300
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Up to 1024 digital in- and outputs
Multipoint capable interface for the configuration of smaller
networks and for configuration with help of a PC/PG.
Quick execution time in which the performance capable CPU
executes 1024 binary instructions inside of 0.1 ms. Modular configuration and quick enhancements are possible
through interface modules with an integrated back plane bus.
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The CPUs of the family SIMATIC S7-400 build thesolutions for the middle and higher performance range(e.g. automobile and machine tool construction orinstrumentation and control).
S7-400
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Properties of the SIMATIC S7-400 Program memory up to 660 K instructions.
Up to 131056 digital in- and outputs.
Multipoint capable interface for the configuration of smallernetworks and for configuration with help of the PC/PG.
Quick execution time that the performance capable CPU executes1024 binary instructions inside of 0.1 s.
Modular configuration and quick enhancements are possiblethrough interface modules with integrated back plane bus.
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Hardware Components of a PLC
A PLC is made up of two basic sections Input/Output (I/O) Interface
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CPU consists of two main parts
Processor
Memory
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Cartridge
Portable EEPROM Battery
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Wiring PLC
Follow the instructions/ manual given bythe manufacturer
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, .
Find the required type of inputs (Voltage,
current, etc)
Connect all the modules and wire themodules as pre given instructions
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Hardware Configuration
Configuring connected hardware units anddownloading the firmware into CPU.
Enables CPU to identify the connected
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hardware modules and their capabilities.This is essential for using the modules.
S7 200 provides facility to read the PLC
rather than manually configuring eachconnected unit.
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Hardware Configuration
1. Connect wired PLC to Computer2. Set PLC & PG (Computer) Interface
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3. Set communication with PLC
4. Configure connected components (or
identify PLC type)5. Download the settings to PLC
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PLC Programming
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Programming Concept
1. Specification: Description of the task2. Design: Description of the solution
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solution
4. Integration/commissioning: Incorporating
into environment and testing the solution
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Prepare flow chart or ladder
program
Assign Input/ Output terminal
addresses
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Write program into PLC
Simulate operation and
debug program
Correct program
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Connect external devices
Trial Run Correct program
Is program correct?
Yes
No
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Store program
Run
Is program correct?
Yes
No
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Programming Method
Console orProgramming Keypad
PLCPeripheral DeviceConnecting Cable
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Link with Console / Programming Keypad
ProgrammingSoftware
Computer
Link with Computer
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Programming Languages
IEC 61131-3 LanguagesLadder diagram (LD)
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Instruction list (IL) Structured text (ST)
Sequential function chart (SFC)
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Comparison of ProgrammingMethodsGraphical Programming (LD, FBD, SFC)
Windows-based graphical programming environment on a
computer, to compose the ladder diagram.
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qu ppe w t goo mon tor ng too s an programm ng a s.
Good for program development.
Mnemonic Code Programming (IL, ST)
Compact handheld device to key in programming instructions in
mnemonic codes.
Ideal for on-site debugging and minor circuit modification.
Requires knowledge of the programming codes.
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Example
Actuation of a push button (S1) is to cause a lamp (B1) to
be switched on.
The lamp is to be illuminated as long as the push button is
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B1S1
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YES Function+24V
STARTInput Output
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Electrical Circuit
0V
0 (Off) 0 (Off)1 (On) 1 (On)
Truth Table
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Symbolic Addressing For symbolic addressing, the symbol table must be
filled in. Select the symbol table from the operations tree or
by selecting Symbol table in the View menu.
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Example of a Ladder Program
Networks
Contact Coil
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Box
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Memory AddressingInputs
I0.0
I0.1
Outputs
Q0.0
Q0.1
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.
.
.
.
I0.7
.
.
.
.
Q0.5
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Ladder Programming Rules
Rules about Placing Contacts Each network must begin with a contact.
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Rules about Placing Coils
You cannot begin a network with a coil Coils are used to terminate a network of logic.
Ladder Programming Rules
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coils exist on parallel branches of that particularnetwork. Otherwise there can be only one coil per
network.
You cannot place more than one coil in a series
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Rules about Placing Boxes You cannot begin a network with a box.
Boxes are used to terminate a network of logic.
Ladder Programming Rules
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,
after the box. You can have several boxes with ENO in a series on the
same network.
If a box does not have ENO, rules are similar to that of
a coil. There cannot be more than one box in a network.
You cannot place any instructions after it
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Number of contacts for I / Os , timers, counters, etc. is
unlimited.
Ladder Programming Guide
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An output coil name can only be assigned once. There cannot
be two (or more) coils (or boxes) with same name.
Ladder Programming Guide
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A network of the ladder diagram is keyed into PLC from
left to right.
Programming for counter and other modules having more
than one input must be performed in a pre-determined order.
Ladder Programming Guide
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Timer & counter data should be entered at the time of
programming.
Ladder Programming Guide
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Input/output number, step number, timer/counter values,
etc. can be written with only the significant digits.
Timer call with a pre-set
time of 5.5 seconds
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Drawing Lines
You can use the horizontal and vertical lines from
the Program toolbar, or hold down the CTRL key
and press the LEFT, RIGHT, UP, or DOWN
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ey on your ey oar , to raw nes
between the elements of your network and the left-hand power rail when necessary to complete a
network.
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Assigning Addresses
To assign a constant value (such as 100) or an absolute
address (such as I0.1), simply type the desired value in theaddress area of the instruction. (Use the mouse or the
ENTER ke to select the address area for t in .
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Compile in LAD
You can compile by using the toolbar
buttons or the PLC menu.
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Example: Burglar Alarm
A thin wire has been stretched behind a display window,
which breaks if a burglary is attempted. A closed circuit is interrupted as a result of this and a
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Press with protective guard
A press stamp 1.0 is to advance
only if a push button S1 isactuated and a protective guard
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If one of these conditions is notmet, the press tool is to returnimmediately.
The position of the closedprotective guard B1 is monitoredby a proximity switch B1.
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A i
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AND Function+24V
S1
Input 1 Input 2 Output
0 0 0
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0V
S2
Electrical Circuit
1 0 0
1 1 1
Truth Table
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AND F i
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AND Function
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Ladder Diagram
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B ll
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Bell system
An apartment bell is to ring if bell button S1 at the front
door is pressed or bell button S2 at the apartment door.
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OR F ti
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OR Function
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Ladder Diagram
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F ti Bl k Di
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Function Block Diagram
There are no contacts and coils, but there are
equivalent instructions that appear as boxinstructions.
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The program logic is derived from the connections
between these box instructions.
The output from one instruction (such as an AND
box) can be used to enable another instruction
(such as a timer) to create the necessary controllogic.
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YES Function
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YES Function
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Functional Block Diagram
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NOT Function
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NOT Function
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Functional Block Diagram
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AND Function
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AND Function
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Functional Block Diagram
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OR Function
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OR Function
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Functional Block Diagram
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Statement List
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Statement List
Statement List (STL) editor allows to create
control programs by entering the instructionmnemonics.
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This text-based concept is very similar to
assembly language programming.
The CPU executes each instruction, in the order
dictated by the program, from top to bottom, and
then restarts at the top.
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Example
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Example
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Ladder DiagramStatement List
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YES Function
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Statement Logic
YES Function
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= Q0.0
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NOT Function
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Statement Logic
NOT Function
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= Q0.0
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AND Function
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Statement Logic
AND Function
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A I0.1= Q0.0
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AND Function
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Statement Logic
AND Function
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LD I0.1ALD
= Q0.0
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OR Function
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Statement Logic
OR Function
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O I0.1= Q0.0
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OR Function
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Statement Logic
OR Function
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LD I0.1OLD
= Q0.0
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LD Language
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LD Language
Ladder logic is easy for beginning programmers to
use. Graphical representation is often easy to
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understand, and is popular around the world.
The LAD editor can be used with both theSIMATIC and IEC 1131-3 instruction sets.
You can always use the STL editor to display a
program created with the LAD editor.
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FBD Language
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FBD Language
The graphical logic gate style of representation is
good for following program flow. The FBD editor can be used with both the
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SIMATIC and IEC 1131-3 instruction sets.
You can always use the STL editor to display aprogram created with the LAD editor.
The expandable AND/OR boxes make it easier to
draw complex input combinations.
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STL Language
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STL Language STL is most appropriate for experienced programmers.
STL sometimes allows you to solve problems that youcannot solve easily with the LAD or FBD editor.
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program that was created with the SIMATIC LAD or FBD
editors, the reverse is not always true.
You cannot always use the SIMATIC LAD or FBD editors
to display a program that was written with the STL editor.
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PLC Exercises
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PLC Exercises
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Exercise 1: NAND
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S1 S2 B10 0 1
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0 1 1
1 0 1
1 1 0
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Exercise 1: NOR
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S1 S2 B10 0 1
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0 1 0
1 0 0
1 1 0
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Exercise 1: X-OR
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S1 S2 B10 0 0
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0 1 1
1 0 1
1 1 0
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Exercise 2-Logic
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Input 1 Input 2 Input 3 Output 1 Output 21 1 0 1 0
g
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0 1 1 1 0
1 0 1 0 1
1 1 1 0 1
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NikiniNikiniNikiniNikiniSilo control system for two bulk
materials
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A mixing plant permits a selection between two
bulk materials per selector switch (S2). In switch position 1 (S2 = 0 signal), bulk material
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,actuated simultaneously.
If selector switch S2 is in position 2 (S2 = 1signal) and push button S1 is actuated bulkmaterial B is conveyed.
Silo A is opened via cylinder 1A (solenoid 1M1),Silo B via cylinder 2A (solenoid 2M1).
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Programming Concept
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g g p
1. Specification: Description of the task
2. Design: Description of the solution
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.
solution4. Integration/commissioning: Incorporating
into environment and testing the solution
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Design steps
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1. Sketch the system
2. Identify the sequence3. Design the power circuits
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4. Identify the input signals & Output Signals
5. Design the control circuit according to thecontrol requirement
6. If there are signal overlaps, necessary actions
should be taken to overcome signal overlapproblems
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materials
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S2 S1 Y1 Y20 0 0 0
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0 1 1 0
1 0 0 0
1 1 0 1
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Heavy Work piece feeding
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Exercise 3
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1. Piston moves forward when
Start button Pressed
2. Return to initial osition when
A1
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Reset button pressed
Y1
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START RESET
1 2 3 4 5
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24V I0 I1 I3I2 I4 I5 I6 I7
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0V Q0 Q1 Q3Q2 Q4 Q5 Q6 Q7
0V
Y1
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PLC Hardware Components
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Hardware Components of a PLC
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A PLC is made up of two basic sections
Input/Output (I/O) Interface
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CPU consists of two main parts Processor
Memory
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Input Modules
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Input Modules
Interface for input devices.
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DC (or higher voltage) to 5V DC.
Isolate Signal given to the CPU.
Input delay to screen input signals.
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Types of Input modules
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Sink-type input module interfaced with drycontact switches and PNP sensor
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Types of Input modules
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Source-type input module interfaced withdry contact switches and NPN sensor
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Output Modules
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Output Modules
The signals coming from CPU are 0V or 5V.
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Relay/ Transistor/ Triac Output.
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Types of output modules
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Transistor Output (Source Type)
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Types of output modules
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Relay Output
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Types of output modules
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Triac Type Output
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Basic Memory AreasThe Basic memory areas of a PLC :The Basic memory areas of a PLC :
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Work Memory (RAM)Work Memory (RAM)
contains the executable user program
CPU
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Load MemoryLoad Memory
(EEPROM/RAM)(EEPROM/RAM)
Contains the entireUser Program
System Memory (RAM)System Memory (RAM)
Block stack, Interrupt stack
Diagnostic buffer, Local data stack
process image input/output tables,
bit memory, timers, counters
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PLC Memory Bit is the abbreviation for binary digit
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Bit is the abbreviation for binary digit.
The BIT is the smallest binary (bivalent) informationunit.
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.
BYTE. A byte has the size of 8 bits.
0 1 0 0 11 1 0
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MSB LSB2021222324252627
PLC Memory
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ByteByte MB100
MS Byte
BitBit 20 0 1 0 0 11 1 0
0
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MW100WordWord
Double WordDouble Word MD100MS Byte
LS Byte
LS Byte
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Memory addressing Byte/ Word/ Double word addressing
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Byte/ Word/ Double word addressing
MB0
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MB1
VW10VD100
Timer and Counter addressing are different
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How the Control Program WorksPLC performs the following operations repeatedly:
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Read the states of the input devices.
-
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(PII) register.
CPU execute the user program stored in the LoadMemory and stores the results of the programlogic in various memory areas including Process-
Image Output (PIQ) register. Transfer status from the PIQ to the field outputs.
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O S C l
Scan Cycle of the PLC
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One Scan Cycle
Reading the inputs
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Executing the program
Process any communication requests
Executes the CPU self test diagnostics
Writing to the outputs
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Scan Cycle of the PLC Reading the inputs: The S7-200 copies the state of the physical
i h i i i
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inputs to the process-image input register.
Executing the control logic in the program: The S7-200 executesthe instructions of the program and stores the values in the
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.
Processing any communication requests: The S7-200 performs
any tasks required for point-to-point or networkcommunications.
Executing the CPU self-test diagnostics: The S7-200 ensuresthat the firmware, the program memory, and any expansion
modules are working properly. Writing to the outputs: The values stored in the process-image
output register are written to the physical outputs.
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The execution of the scan cycle is dependent upon whether the S7-200
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is in STOP mode or in RUN mode. In RUN mode, your program is
executed; in STOP mode, your program is not executed.
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The time that the processor requires for this
PLC scan cycle time
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The time that the processor requires for this
execution is called a cycle time.
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instructions and types of commands.
Also cycle time is dependent on CPU speed
and I/O conversion time delay
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Exercise 41 Piston moves forward when1B2
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1. Piston moves forward when
Start button Pressed
2. Return to initial osition
1B2
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automatically when piston
moved to 1B2
1M1
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START A2
1 2 3 4 5
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24V I0 I1 I3I2 I4 I5 I6 I7
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0V Q0 Q1 Q3Q2 Q4 Q5 Q6 Q7
0V
Y1
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1. Piston moves forward when it1B1 1B2
Exercise 5
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. sto oves o wa d w e t
reaches to 1B1
2. Return to initial osition
1B1 1B2
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automatically when piston
moved to 1B23. Continuous cycle starts with
S1 (Start) push button
4. Continuous cycle stops withS2 (Stop) push button
1M1
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START A1 A2RESET
1 3 4 5 6 7
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24V I0 I1 I3I2 I4 I5 I6 I7
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0V Q0 Q1 Q3Q2 Q4 Q5 Q6 Q7
0V
Y1
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Counters
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Up Counter (CTU)
Counters
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Down Counter (CTD)
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-
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Up Counter Counts up from the current value each time thecount-up input CU makes the transition from off toon
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on.
When the current value (Cxxx) is greater than or
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,(Cxxx) turns on.
The counter is reset when the Reset (R) input turnson, or when the Reset instruction is executed.
The counter stops counting when it reaches the
maximum value (32,767). Counter ranges:Cxxx=C0 through C255
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Example-LAD
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Example-FBD
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Example-STL
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Down Counter Counts down from the current value of thatcounter each time the count down input CD makes
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the transition from off to on. When the current value Cxxx is equal to zero, the
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counter bit (Cxxx) turns on.
The counter resets the counter bit (Cxxx) andloads the current value with the preset value (PV)
when the load input (LD) turns on.
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Example-LAD
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Example-FBD
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Example-STL
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Up Down Counter Counts up each time the count-up input CU makes the transition fromoff to on.
Counts down each time the count-down input CD makes the transition
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from off to on. The current value Cxx of the counter maintains the current count.
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The preset value PV is compared to the current value each time the
counter instruction is executed.
When the current value Cxx is greater than or equal to the preset valuePV, the counter bit Cxx turns on.
Otherwise, the counter bit turns off.
The counter is reset when the Reset (R) input turns on, or when the
Reset instruction is executed. The CTUD counter stops counting whenit reaches PV.
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Example-LAD
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Example-FBD
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Example-STL
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Timers
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Timer Types Delay On timer (TON)
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Delay OFF timer (TOF)
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Timer NumbersTimer Type Resolution Maximum Time Timer Number
TONR
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1 ms 32.767 s T0, T64
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. - , -
100 ms 3276.7 s T5-T31, T69-T95
TON, TOF 1 ms 32.767 s T32, T96
10 ms 327.67 s T33-T36, T97-T100
100 ms 3276.7 s T37-T63, T101-T255
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Counts time when the enabling input is ON.
Wh h l (T ) i h
On Delay Timer
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When the current value (Txxx) is greater than orequal to the preset time (PT), the timer bit is ON.
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Current value is cleared when the enabling input is
OFF. This timer continues counting after the Preset is
reached, and it stops counting at the maximum
value of 32767.
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Example-FBD
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Example- STL
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Delay Off Timer
Delay turning an output OFF for a fixed period of
time after the input turns OFF.
When the enabling input turns ON the timer bit
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When the enabling input turns ON, the timer bitturns ON immediatel and the current value is set
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to 0.
When the input turns OFF, the timer counts untilthe elapsed time reaches the preset time.
When the preset is reached, the timer bit turns
OFF and the current value stops counting.
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Example-FBD
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Example-STL
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Counts time when the enabling input is ON.
When the current value (Txxx) is greater than orl t th t ti (PT) th ti bit i ON
Retentive On Delay Timer
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When the current value (Txxx) is greater than orequal to the preset time (PT), the timer bit is ON.
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The current value of the Retentive On-Delay timer
is maintained when the input is OFF. A Reset instruction (R) is used to clear the current
value of the Retentive On-Delay timer.
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Example-FBD
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Example-STL
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Exercise 6
1. Delay 3s at 1B1 and move
forward
1B1 1B2
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.
backward
3. Continuous Cycle with S1(Start) push button
4. Stop when 10 cycles
completed5. Stop with S2 (Reset) push
button immediately
1M1
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24V I0 I1 I3I2 I4 I5 I6 I7
+24V
START A1 A2RESET
1 3 4 5 6 7
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0V Q0 Q1 Q3Q2 Q4 Q5 Q6 Q7
0V
Y1
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materials
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1A
2A
NikiniNikiniNikiniNikiniSilo control system for two bulk
materials Selector switch S2 is used to select between
material A and B.
When a push button S1 is pressed, material A
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should be entered for 13 seconds to the mixing
bin.
Note: What happens if push button S1 is kept
pressed (over 10 or 13 seconds)?
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Areas of System Memory
Input Image Register (I)
Output Image Register (Q)
Bit (M) memory
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Special Memory (SM) bits
Timer (T) memory
Counter (C) memory
Analog Inputs (AI) and Outputs (AQ)
Accumulators (AC)
High Speed Counters (HC)Constant Values: Decimal, Hexadecimal, ASCII
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Instruction types Bit logic Timer Counter Program Control
Logic Operations Logic Stack
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Logic Stack
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Table Conversion High Speed Counter
Interrupt Real Time Clock Math, Increment and Decrement PID Move, Shift, Rotate and Fill
Communication and Networking
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Organizing the User Program
Typical User Program StructureMain Program
MENDMain Program : Executed once per scan
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MEND
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SBR 0RET
SBR 1RET
INT 0RET
INT 1RET
Subroutine : Executed when called
from the main program
Interrupt Routine : Executed on each
occurrence of the interrupt event
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Program Flow
Main Program
CALL 0
SBR 0
RET
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CALL 1
Interrupt Event
MEND
SBR 1
RET
INT 0
RET
NikiniNikiniNikiniNikiniSIMATIC S7-200:
Freeport communication
Option:RS 485 orRS 232 protocol can be us
ed
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Non-Siemens
PLC
Non-Siemensdevice with
RS 485
RS 485
modem
Drive
(e.g. USS protocol)
PLC
ModemPrinter OP
Bar code scanner
RS 485 PPI cable RS 232
NikiniNikiniNikiniNikiniSIMATIC S7-200:
Fieldbus Communication PROFIBUS-DP Slave
AS-I Master
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IT (TCP-IP)
GSM
GPRS
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Selecting a PLC
Understand the process to be controlled
1. list the number and types of inputs andout uts.
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2. determine how the process is to be controlled.
3. determine special needs such as distancebetween parts of the process.
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Selecting a PLC
Consideration Information to record Notes
1. Proposed system
2. Environmental issues
3. Discrete devices
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. na og evices
5.Specialty modules or features
(application-specific)
6. CPU required
7. I/O locations
8.Communications requirements
9.Programming requirements
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Selecting a PLC
Number & types of Inputs and Outputs
Analog Input and Output facility (# and types- V? I?)
Expansion facility (Maximum modules, Module types,..) Function modules available Wei hin Positionin etc.
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Special Functions (HSC, PTO, Real time clock, etc.)
Software
Languages available
Monitoring/ Diagnostic facilities
Other facilities (Wizards, HW Configuration)
Ease of Programming Memory capacity
Speed
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Selecting a PLC
Mathematical Calculations
Types of Operator Interface (Operator panels, etc.)
Communication facilities with other PLCs and Computers
T / H idi / Vib i i
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Temperature/ Humidity/ Vibration resistance
Ease of Maintenance
Spare parts/ After sales service/ Reliability/ Shipping time
Cost $$
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Selecting a PLC Vendor
If not already specified, a single vendor shouldbe selected. Factors that might be considered
are,
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.
2. support while developing programs
3. the range of products available4. support while troubleshooting
5. shipping times for emergency replacements
6. training
7. the track record for the company
8. business practices (billing, upgrades/obsoleteproducts,etc.)
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Review
Introduction to automation technology
Introduction to micro PLC systems
General Structure of PLC System
lli C d fi i h d
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Installing PLC and configuring hardware
CPU memory and data types
Basic programming concepts
Programming languages
Programming instructions
Programming of control systems
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Questions??
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Basics
Number systems
Signal Inputs
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PLC memory
PLC scan cycle
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Number systems
Decimal
5238 = 5x1000 + 2x100 + 3x 10 + 8x1= 3 2 1 0
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Binary
101101112= 1x27 + 0x26 + 1x25 + 1x24 + 0x23
+ 1x22 + 1x21 + 1x20
= 18310
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BCD (Binary Coded Decimal)Decimal number BCD number
010 0000BCD
Number systems
10 BCD
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10 BCD
210 0010BCD
310 0011BCD410 0100BCD
510 0101BCD
610 0110BCD
710 0111BCD
810 1000BCD
910 1001BCD
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Decimal number 3564 in BCD
0011 0101 0110 0100 BCD
Number systems
16 bi i d
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16 bits required
BCD coded numbers are often used forseven segment displays and coding
switches.
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Hexadecimal
A =10, B =11, C =12, D =13, E =14, F =15
Number systems
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87BC16 = 8x163 + 7x162 + 11x161 + 12x160
=3474810
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Types of signals
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Binary signal
Binary signals can take the value of 2 possible states.
Signal state 1 = voltage available = e.g. Switch on
Signal state 0 = voltage not available = e.g. Switch off
In control engineering DC voltage of 24V is used.
+ 24 V = 1 for this input. 0 V = 0
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Types of signals
Analog signal
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a og s g a
Can take many values within a certain range
- Examples Temperature -50 ... +150C
Current flow 0 ... 200 l/min
Number of revolutions 500 ... 1500 r/min
These measurements are converted to currents or resistances. analog information are converted to a voltage, current or resistance
value. (analog to digital conversion -A/D conversion.)
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Input / Output System
Provides the physical connections between the
outside world and CPU
Input Devices
Output Devices
Selector switches Alarms
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Push buttons
Sensors
Circuit breakers
Level sensors
Relay contactors
Motor starter Contacts
Control Relays
Solenoids
Lights
Horns
Valves
Motor Starters
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PLC Operation
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