3PLC 12aug2011

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Nikini Automation Systems (Pvt) Ltd Introduction to PLC 8/5/2011 3:16 PM

Nikini Automation Systems (Pvt.) Ltd.
INTRODUCTION TO
INTRODUCTION TO
PROGRAMMABLE
PROGRAMMABLE
LOGIC CONTROLLERS
LOGIC CONTROLLERS
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Overview
Introduction to automation technology
Introduction to micro PLC systems
General Structure of PLC System
Installing PLC and configuring hardware
CPU memory and data types
Basic programming concepts
Programming languages
Programming instructions
Programming of control systems
Mathematical Operations
Subroutines
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Timing of the workshop
Session 1 09.00 a.m.
Break 10.15 a.m.
Session 2 10.30 a.m.
Lunch 12.15 p.m.
Session 3 01.15 p.m.
Break 03.00 p.m.
Session 4 03.15 p.m.
Conclusion 04.00 p.m.
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Automation Technology
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What is automation?
Automation (ancient Greek: = self dictated)
or industrial automation is the use of
electronic controllers to control industrial
machinery and processes, replacing human
operators.
It is a step beyond mechanization, where
human operators are provided with
machinery to help them in their jobs.
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Machine Machine Interface
(Fieldbus/ Ethernet)
Industrial Automation
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Signal Processors
Programmable Logic
Controller (PLC)
Hard-wired Control
Programmable Control
Electrical
Pneumatics
Hydraulic
Digital
Electronics
Embedded Controller
Micro controller (PIC)
Industrial PC
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Electrical Signal Processing
Signal Input Signal processing Signal output
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Programmable Signal Processing
Programmable
Microprocessor
system
Signal Input Signal processing Signal output
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Hardwired Control &
Programmable Control
Hard-wired control
Wiring of mechanical, electrical, electro-
mechanical or electronic components to obtain
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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What is PLC?
PLC is an abbreviation for Programmable Logic
Controller.
PLC is a small, but powerful Computer which is
designed for industrial Controlling.
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
Signal
Outputs
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What is PLC?
Program loaded into
the memory of PLC..
routed to the
machine
Program with
instructions
PLC
Machine
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Basic Principle of a PLC
Program
(Instructions)
Input Signals Signal Processing Output Signals
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PLCs have inbuilt..
1. Logic controls
2. Timers
3. Counters
4. Analogue Signals
5. Closed loop Control
6. Arithmetic Functionsetc.
What PLC can do?
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Advantages of PLC
Greater Flexibility and reliability
Changes to the design can easily be made on the
program.
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.
Low Cost
Prices of microprocessor-based devices reduced more
than 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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Advantages of PLC
Less project planning work
tested programs and subprograms can be used for a
number of different control setups
but each relay control circuit has to be wired and tested
from scratch
Faster control development
programming and wiring can be carried out in parallel
Simpler monitoring of stations by a higher-level host
computer
a programmable logic controller can easily exchange
data with the host computer
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PLCs Vs Other Microprocessor
Based Devices
Modularity
Expansion possible.
Dedicated Input/Output Units
Inputs & outputs can be easily connected without interfacing.
Programmability
User friendly. No prior computer language required.
IEC 1131-3 Languages
Predictability
Designed to fail predictably. Outputs will turn off when program
fails.
Single-Source Support
Most PLC manufacturers have complete range of input & output
devices.
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Major PLC manufacturers
ABB
Koyo
Honeywell
Siemens
Modicon
Omron
Allen-Bradley
General Electric
Tesco Controls
Panasonic (Matsushita)
Mitsubishi
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SIEMENS SIMATIC S7
SIEMENS SIMATIC S7 consists of 3
families.
S7-200
S7-300
S7-400
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S7-200
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The SIMATIC S7-200 is the CPU for the lower level
performance range.
It is available in various grades.
The CPU is qualified for open and closed loop control tasks in
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 integrated
PID closed loop control functions.
The program software STEP 7 Micro/Win enables a quick
introduction in the programming and configuration.
S7-200
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S7-300
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The SIMATIC S7-300 family offers the automation
solutions for the lower and middle performance range.
Properties of the SIMATIC S7-300
Program memory up to 85 K instructions
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.
S7-300
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S7-400
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The CPUs of the family SIMATIC S7-400 build the
solutions for the middle and higher performance range
(e.g. automobile and machine tool construction or
instrumentation and control).
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 smaller
networks and for configuration with help of the PC/PG.
Quick execution time that the performance capable CPU executes
1024 binary instructions inside of 0.1 s.
Modular configuration and quick enhancements are possible
through interface modules with integrated back plane bus.
S7-400
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Components of a PLC system
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Modular PLC Compact PLC
PLC - Program
Central Processing
Unit
Output Module
Actuators
Input Module
Sensors
PLC Components
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Hardware Components of a PLC
A PLC is made up of two basic sections
Input/Output (I/O) Interface
Central Processing Unit (CPU)
CPU consists of two main parts
Processor
Memory
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Firmware
Firmware is the software part, which is
permanently installed and supplied by the PLC
manufacturer.
This includes fundamental system routines, used
for starting the processor after the power has been
switched on.
Additionally, there is the operating system in the
case of programmable logic controllers, which is
generally stored in a ROM, a read-only memory,
or in the EPROM.
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Software Components
Firmware
Keeps information about hardware
Should be stored in CPU for proper use of
hardware
Operating System
Controls the basic functions of PLC
User Program
Instructions written by the user (programmer)
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Structure of a S7-200 (CPU 222)
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Mode Selector Switch
RUN
TERM
STOP
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Expansion Modules
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Cartridge
Portable EEPROM
Battery
Real Time Clock
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Steps to follow
Steps to follow when using a PLC for the
first time
1. Wire PLC and all the modules
2. Configure Hardware
3. PLC Programming
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Wiring PLC
Follow the instructions/ manual given by
the manufacturer
Correctly connect the power supplies, etc.
Find the required type of inputs (Voltage,
current, etc)
Connect all the modules and wire the
modules as pre given instructions
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Hardware Configuration
Configuring connected hardware units and
downloading the firmware into CPU.
Enables CPU to identify the connected
hardware modules and their capabilities.
This is essential for using the modules.
S7 200 provides facility to read the PLC
rather than manually configuring each
connected unit.
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Hardware Configuration
1. Connect wired PLC to Computer
2. Set PLC & PG (Computer) Interface
(Identify the correct connecting cable)
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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Prepare flow chart or ladder
program
Assign Input/ Output terminal
addresses
Write program into PLC
Simulate operation and
debug program
Correct program
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Connect external devices
Trial Run
Store program
Run
Correct program
Is program correct?
Is program correct?
Yes
Yes
No
No
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Programming Method
Console or
Programming Keypad
PLC
Peripheral Device
Connecting Cable
Link with Console / Programming Keypad
Programming
Software
Computer
Link with Computer
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Programming Languages
IEC 61131-3 Languages
Ladder diagram (LD)
Function block diagram (FBD)
Instruction list (IL)
Structured text (ST)
Sequential function chart (SFC)
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Comparison of Programming
Methods
Graphical Programming (LD, FBD, SFC)
Windows-based graphical programming environment on a
computer, to compose the ladder diagram.
Equipped with good monitoring tools and programming aids.
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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Ladder Diagram Programming
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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
actuated.
B1
S1
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YES Function
Electrical Circuit
+24V
0V
START
Input Output
0 (Off) 0 (Off)
1 (On) 1 (On)
Truth Table
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YES Function
Ladder Diagram
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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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Symbol Table
A window is displayed in which you can edit the symbol
table.
Enter the element that you want to appear as plain text later
on under name.
Under address, enter the operand that you want to have
replaced by a symbolic name.
Under comment, you can enter a text that you find helpful.
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Ladder Diagram
The ladder programs allow the CPU to emulate the flow of
electric current from a power source through a series of
logical input conditions that in turn enable logical output
conditions.
The logic is separated into networks.
The program is executed as dictated by the program, one
network at a time, from left to right and then top to bottom.
Once the CPU has reached the end of the program, it starts
over again at the top of the program.
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Elements of Ladder Diagram
Contacts Represent a switch through which power can flow.
Coils Represent a relay or output that is energized by power flow.
Boxes Represent a function (for instance, a timer, counter, or
mathematical operation) that is executed when power flow reaches the
box.
A network is composed of these elements and represents a complete
circuit.
Power flows from the left power rail (represented in the LAD editor by
a vertical line on the left side of the window) through the closed
contacts to energize the coils or boxes.
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Example of a Ladder Program
Networks
Contact
Coil
Box
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Memory Addressing
Inputs
I0.0
I0.1
.
.
.
.
I0.7
Outputs
Q0.0
Q0.1
.
.
.
.
Q0.5
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Statements
Control Statements
The control statement is the smallest unit of
a PLC user program. A statement consists
of an
operation part
operand part (I0.0, I0.1, Q0.4)
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Ladder Programming Rules
Rules about Placing Contacts
Each network must begin with a contact.
You cannot terminate a network 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.
A single network can have several coils, as long as the
coils exist on parallel branches of that particular
network. 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.
If a box has ENO, you can place further instructions
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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Number of contacts to be connected in series or parallel is
unlimited.
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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.
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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.
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Input/output number, step number, timer/counter values,
etc. can be written with only the significant digits.
Timer & counter data should be entered at the time of
programming.
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
ARROW key on your keyboard, to draw lines
between the elements of your network and the left-
hand power rail when necessary to complete a
network.
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Enter Instructions
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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 the
address area of the instruction. (Use the mouse or the
ENTER key to select the address area for typing.)
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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
buzzer is sounded.
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+24V
0V
START
NOT Function
Electrical Circuit
Input Output
0 (Off) 1 (On)
1 (On) 0 (Off)
Truth Table
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NOT Function
Ladder Diagram
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Press with protective guard
A press stamp 1.0 is to advance
only if a push button S1 is
actuated and a protective guard
is closed.
If one of these conditions is not
met, the press tool is to return
immediately.
The position of the closed
protective guard B1 is monitored
by a proximity switch B1.
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AND Function
+24V
0V
S2
S1
Electrical Circuit
Input 1 Input 2 Output
0 0 0
0 1 0
1 0 0
1 1 1
Truth Table
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AND Function
Ladder Diagram
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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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+24V
0V
S2 S1
OR Function
Electrical Circuit
Input 1 Input 2 Output
0 0 0
0 1 1
1 0 1
1 1 1
Truth Table
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Ladder Diagram
OR Function
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Function Block Diagram
There are no contacts and coils, but there are
equivalent instructions that appear as box
instructions.
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 control
logic.
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Example
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YES Function
Functional Block Diagram
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NOT Function
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AND Function
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OR Function
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Statement List
Statement List (STL) editor allows to create
control programs by entering the instruction
mnemonics.
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
Ladder Diagram
Statement List
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Statement Logic
LD I0.0
= Q0.0
YES Function
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Statement Logic
LDN I0.0
= Q0.0
NOT Function
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Statement Logic
LD I0.0
A I0.1
= Q0.0
AND Function
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Statement Logic
LD I0.0
LD I0.1
ALD
= Q0.0
AND Function
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Statement Logic
LD I0.0
O I0.1
= Q0.0
OR Function
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Statement Logic
LD I0.0
LD I0.1
OLD
= Q0.0
OR Function
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LD Language
Ladder logic is easy for beginning programmers to
use.
Graphical representation is often easy to
understand, and is popular around the world.
The LAD editor can be used with both the
SIMATIC 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
The graphical logic gate style of representation is
good for following program flow.
The FBD editor can be used with both the
SIMATIC and IEC 1131-3 instruction sets.
You can always use the STL editor to display a
program created with the LAD editor.
The expandable AND/OR boxes make it easier to
draw complex input combinations.
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STL Language
STL is most appropriate for experienced programmers.
STL sometimes allows you to solve problems that you
cannot solve easily with the LAD or FBD editor.
While you can always use the STL editor to view or edit a
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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Exercise : X-OR
S1 S2 B1
0 0 0
0 1 1
1 0 1
1 1 0
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LAD Solution
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FBD Solution
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STL solutions
Method 1
Method 2
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Input 1 Input 2 Input 3 Output 1 Output 2
1 1 0 1 0
0 1 1 1 0
1 0 1 0 1
1 1 1 0 1
Exercise -Logic
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Solution
Simplified Solution-Network 1
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Solution
Further Simplified Solution-Network 2
Simplified Solution
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Programming Concept
1. Specification: Description of the task
2. Design: Description of the solution
3. Realisation: Implementation of the
solution
4. Integration/commissioning: Incorporating
into environment and testing the solution
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Exercise
When the Open switch is pressed the motor should rotate
in the forward direction and open the gate
When the Close switch is pressed the motor should rotate
in the reverse direction and the gate should close.
The gate should not try to close and open at the same
time.
If the stop switch is pressed or if the motor gets
overloaded, the motor should stop rotating.
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Heavy Work piece feeding
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Exercise
1. Piston moves forward when
Start button Pressed
2. Return to initial position when
Reset button pressed
Y1
A1
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0V Q0 Q1
24V I0 I1
Q3 Q2 Q4 Q5 Q6 Q7
I3 I2 I4 I5 I6 I7
+24V
0V
Y1
START RESET
1 2 3 4 5
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Solution 1
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Solution 2
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Solution 3
Solution 4
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Exercise
1. Piston moves forward when
Start button Pressed
2. Return to initial position
automatically when piston
moved to Limit Switch LS
1M1
LS
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0V Q0 Q1
24V I0 I1
Q3 Q2 Q4 Q5 Q6 Q7
I3 I2 I4 I5 I6 I7
+24V
0V
Y1
START A2
1 2 3 4 5
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1. Piston moves forward when it
reaches Limit Switch LS1
2. Return to initial position
automatically when piston
moves to Sensor SEN
3. Continuous cycle starts with
S1 (Start) push button
4. Continuous cycle stops with
S2 (Stop) push button
1M1
LS1 SEN
Exercise
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0V Q0 Q1
24V I0 I1
Q3 Q2 Q4 Q5 Q6 Q7
I3 I2 I4 I5 I6 I7
+24V
0V
Y1
START A1 A2 RESET
1 3 4 5 6 7

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Nikini Automation Systems (Pvt) Ltd Introduction to PLC 8/5/2011 3:16 PM

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