Introduction To PLC Presentation

Nikini
INTRODUCTION TO
PROGRAMMABLE
LOGIC CONTROLLERS
Nikini Automation Systems (Pvt.) Ltd.

Introduction to PLC
Nikini Automation Systems (Pvt) Ltd
11/19/2010 8:48 AM
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Overview
Introduction to PLC
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
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Automation Technology
Introduction to PLC
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Introduction to PLC
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What is automation?
Manual Process
Mechanized Process
Automation is aimed at reducing human effort in

performing a task.
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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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Where used?
Introduction to PLC
Production Industry
Offices
Buildings
Construction Industry
Medical field
Household equipment
Aerospace Industry
???
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Example of a Manual process
Drilling machine
Clamping device
Work piece
Manual Process of Drilling a work piece
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Processes carried out
Introduction to PLC
Keeping the work piece

Clamp the work piece
Drill the work piece
Un clamp work piece
Remove the work piece
Sensing each operation
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Elements of the manual system

Actuators
Decision making element
Sensors
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Automating the Process:

Step 1 :Replacement of humans muscles (hands) by some
actuators, e.g. the pneumatic cylinders
Step 2 :Replacement of humans brain by a logic signal
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 element
according to the signal inputs present.
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Automated System
Drill Cylinder
Limit switches/
sensors to detect
end limits of
cylinder movement
Clamp
Cylinder
Operator panel
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Signal Processor
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Industrial Automation
Pentagon of
Automation
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Signal Processors
Hard-wired Control
Electrical
Pneumatics
Hydraulic
Programmable Control
Programmable Logic
Controller (PLC)
Embedded Controller
Digital
Electronics
Micro controller (PIC)

Industrial PC
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Hardwired Control &

Programmable Control
Nikini
Hard-wired control
Wiring of mechanical, electrical, electromechanical 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
Introduction to PLC
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What is PLC?
PLC is an abbreviation for Programmable Logic
Controller.
PLC is a microprocessor-based electronic device.
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 Machine
Controller.
PLC is a small, but powerful Computer which is
designed for industrial Controlling.
To control process/ Machine
Sensors
Signal Inputs
Control switches (Push buttons, Switches)
Signal
Actuators (Solenoid Valves, Motor controllers)
Outputs
should be wired to the PLC
Program with instructions stating how the process/
machine works should be written into the PLC memory
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What is PLC?
Program loaded into
the memory of PLC..
routed to the
machine
Program with
instructions
PLC
Introduction to PLC
Machine
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Basic Principle of a PLC
Program (Instructions)
Input Signals
Introduction to PLC
Signal Processing
Output Signals
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What PLC can do?

PLCs have inbuilt..
1. Logic controls
2. Timers
3. Counters
4. Analogue Signals
5. Closed loop Control
6. Arithmetic Functionsetc.
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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 electromechanical 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
Introduction to PLC
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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S7-200
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.
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S7-300
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S7-300
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.
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S7-400
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S7-400
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.
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Components of a PLC system
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PLC Components
PLC - Program
Input Module
Central Processing
Unit
Sensors
Introduction to PLC
Modular PLC
Compact
PLC
Output Module
Actuators
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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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Introduction to PLC
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Introduction to PLC
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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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Introduction to PLC
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PLC Programming
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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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Programming Concept
1.
Prepare flow chart or Ladder diagram according to the functional

specifications of the machine
2.
Assign Input/ Output terminal addresses to the PLC as per the wiring
diagram and List of symbols
3.
Write program in to the PLC using the software
4.
Simulate operation and debug program (with PLC programming software,
if possible, or with switches and bulbs)
5.
Is Program correct?
<YES>: Go to step 6
<NO>:
Modify program and go to step 4
6.
Connect external devices such as Operator panel switches, sensors of the
machine, relays, solenoids, etc.
7.
Trial Run monitoring the functions closely
8.
Is Program correct?
<YES>: Go to step 9
<NO>:
Modify program and go to step 7
9.
Store Program
10. Run
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Prepare flow chart or ladder
program
Assign Input/ Output terminal

addresses
Write program into PLC
Simulate operation and

debug program
Introduction to PLC
Correct program
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Is program correct?
No
Yes
Connect external devices
Trial Run
Is program correct?
Correct program
No
Yes
Store program
Run
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Programming Method
Console or
Programming Keypad
Peripheral Device
Connecting Cable
PLC
Link with Console / Programming Keypad

Programming
Software
Computer
Link with Computer

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Programming Languages
IEC 61131-3 Languages
Introduction to PLC
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.
S1
B1
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YES Function
+24V
START
Input
Output
0 (Off)
0 (Off)
1 (On)
1 (On)
0V
Truth Table
Electrical Circuit
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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

Coil
Contact
Networks
Box
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Memory Addressing
Introduction to PLC
Inputs
Outputs
I0.0
I0.1
.
.
.
.
I0.7
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
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(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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Introduction to PLC
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Ladder Programming Guide

Number of contacts for I / Os , timers, counters, etc. is
unlimited.
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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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Timer & counter data should be entered at the time of
programming.
Timer call with a pre-set

time of 5.5 seconds
Input/output number, step number, timer/counter values,

etc. can be written with only the significant digits.
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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 lefthand 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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NOT Function
+24V
START
Input
Output
0 (Off)
1 (On)
1 (On)
0 (Off)
0V
Truth Table
Electrical Circuit
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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
S1
Input 1
Input 2
Output
S2
0V
Truth Table
Electrical Circuit
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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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OR Function
+24V
S1
S2
Input 1
Input 2
Output
0V
Truth Table
Electrical Circuit
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OR Function
Ladder Diagram
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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
Statement List
Ladder Diagram
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YES Function
Statement Logic
LD I0.0
=
Q0.0
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NOT Function
Statement Logic
LDN
=
Introduction to PLC
I0.0
Q0.0
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AND Function
Statement Logic
LD I0.0
A I0.1
= Q0.0
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AND Function
Statement Logic
LD I0.0
LD I0.1
ALD
= Q0.0
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OR Function
Statement Logic
LD I0.0
O I0.1
= Q0.0
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OR Function
Statement Logic
LD I0.0
LD I0.1
OLD
= Q0.0
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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 1: NAND
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S1
S2
B1
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Exercise 1: NOR
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S1
S2
B1
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Exercise 1: X-OR
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S1
S2
B1
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Exercise 2-Logic
Introduction to PLC
Input 1
Input 2
Input 3
Output 1
Output 2
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Silo control system for two bulk

materials
2A
1A
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materials
A mixing plant permits a selection between two

bulk materials per selector switch (S2).
In switch position 1 (S2 = 0 signal), bulk material
A reaches a mixing container, if push button S1 is
actuated simultaneously.
If selector switch S2 is in position 2 (S2 = 1
signal) and push button S1 is actuated bulk
material 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
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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Design steps
1.
2.
3.
4.
5.
Sketch the system

Identify the sequence
Design the power circuits
Identify the input signals & Output Signals
Design the control circuit according to the
control requirement
6. If there are signal overlaps, necessary actions
should be taken to overcome signal overlap
problems
Introduction to PLC
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materials
Introduction to PLC
S2
S1
Y1
Y2
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Heavy Work piece feeding
Introduction to PLC
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Exercise 3
A1
1.
Piston moves forward when

Start button Pressed
2.
Return to initial position when

Reset button pressed
Y1
Introduction to PLC
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+24V
3 4
START
Nikini
RESET
24V I0 I1 I2 I3 I4 I5 I6 I7
0V Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Y1
0V
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PLC Hardware Components
Introduction to PLC
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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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Input Modules
Input Modules
Interface for input devices.
CPU works in 5V . Input modules convert 24V
DC (or higher voltage) to 5V DC.
Isolate Signal given to the CPU.
Input delay to screen input signals.
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Introduction to PLC
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Introduction to PLC
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Types of Input modules
Sink-type input module interfaced with dry

contact switches and PNP sensor
Introduction to PLC
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Types of Input modules
Source-type input module interfaced with

dry contact switches and NPN sensor
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Output Modules
Output Modules
The signals coming from CPU are 0V or 5V.
Amplify and condition the output.
Relay/ Transistor/ Triac Output.
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Introduction to PLC
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Types of output modules
Transistor Output (Source Type)

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Transistor Output (Sink Type)

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Relay Output
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Triac Type Output

Introduction to PLC
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Types of Memory
Types of Memory
RAM
ROM
Random Access Memory
Erasing
Programming
When power is
removed,
Memory
contents are:
Electrical
Electrical
Volatile
Not possible
Using masks in
Manufacturing
process
Read Only Memory
PROM
Programmable ROM
EPROM
Erasable PROM
Non volatile
With UV light
RPROM
Reprogrammable PROM
Electrical
EEPROM Electrically Erasable PROM

Electrical
EAPROM Electrically Alterable PROM
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Basic Memory Areas

The Basic memory areas of a PLC :
CPU
Work Memory (RAM)
contains the executable user program
(for example logic and data blocks)
Load Memory
(EEPROM/RAM)
Contains the entire
User Program
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.
The BIT is the smallest binary (bivalent) information
unit.
It can accept a signal status of 1 or 0.
0
BYTE.
A byte has the size of 8 bits.
0 1 0 1 1 0 0 1
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PLC Memory
WORD
The word length corresponds to the number from 16
binary characters.
A word also has the size of 2 bytes or 16
MSB
LSB
1 0 1 0 0 0 0 1 1 0 1 0 0 1 0 0
DOUBLE-WORD
A double-word corresponds to the word length of 32
binary characters.
MSB
LSB
1 0 1 0 0 1 0 1 1 0 1 0 0 1 0 0 1 0 1 1 0 1 0 1 1 0 1 1 0 1 0 0
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PLC Memory
MSB
Bit
20
Byte
27
26
25
24
23
22
21
20
LSB
0 1 0 1 1 0 0 1
MB100
0
MS Byte
Word
MW100
LS Byte
MS Byte
Double Word
MD100
LS Byte
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Memory addressing
MSB
0
LSB
7
Bit
I 0 . 3
0
M
1
0
V
1
0
Area
Identifier
Introduction to PLC
Byte
Bit of
Address Byte
Q
1
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Memory addressing
Byte/ Word/ Double word addressing
<Area><Size> <Starting byte address>
MB0
MB1
VW10
VD100
Timer and Counter addressing are different
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How the Control Program Works

PLC performs the following operations repeatedly:
Read the states of the input devices.

Copy input status into the Process-Image Input
(PII) register.
CPU execute the user program stored in the Load
Memory and stores the results of the program
logic in various memory areas including ProcessImage Output (PIQ) register.
Transfer status from the PIQ to the field outputs.
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Scan Cycle of the PLC

One Scan Cycle
Reading the inputs
Writing to the outputs

Executing the program
Executes the CPU self test diagnostics
Process any communication requests
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Scan Cycle of the PLC

Reading the inputs: The S7-200 copies the state of the physical
inputs to the process-image input register.
Executing the control logic in the program: The S7-200 executes
the instructions of the program and stores the values in the
various memory areas.
Processing any communication requests: The S7-200 performs
any tasks required for point-to-point or network
communications.
Executing the CPU self-test diagnostics: The S7-200 ensures
that 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
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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PLC scan cycle time

The time that the processor requires for this
execution is called a cycle time.
This time is dependent on the number
instructions and types of commands.
Also cycle time is dependent on CPU speed
and I/O conversion time delay
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Exercise 4
1B2
1.
Piston moves forward when

Start button Pressed
2.
Return to initial position

automatically when piston
moved to 1B2
1M1
Introduction to PLC
11/19/2010 8:48 AM
+24V
3 4
START
Nikini
A2
24V I0 I1 I2 I3 I4 I5 I6 I7
0V Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Y1
0V
Introduction to PLC
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Exercise 5
1B1
1B2
1.
Piston moves forward when it

reaches to 1B1
2.
Return to initial position

automatically when piston
moved to 1B2
3.
Continuous cycle starts with

S1 (Start) push button
4.
Continuous cycle stops with

S2 (Stop) push button
1M1
Introduction to PLC
11/19/2010 8:48 AM
+24V
3 4
START
RESET
A1
Nikini
A2
24V I0 I1 I2 I3 I4 I5 I6 I7
0V Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Y1
0V
Introduction to PLC
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Counters
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Counters
Up Counter (CTU)
Down Counter (CTD)
Up-Down Counter (CTUD)
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Up Counter
Counts up from the current value each time the
count-up input CU makes the transition from off to
on.
When the current value (Cxxx) is greater than or
equal to the Preset Value (PV), the counter bit
(Cxxx) turns on.
The counter is reset when the Reset (R) input turns
on, 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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Introduction to PLC
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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 that
counter each time the count down input CD makes
the transition from off to on.
When the current value Cxxx is equal to zero, the
counter bit (Cxxx) turns on.
The counter resets the counter bit (Cxxx) and
loads the current value with the preset value (PV)
when the load input (LD) turns on.
Introduction to PLC
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Example-LAD
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Introduction to PLC
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Example-FBD
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Example-STL
Introduction to PLC
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Up Down Counter
Counts up each time the count-up input CU makes the transition from
off to on.
Counts down each time the count-down input CD makes the transition
from off to on.
The current value Cxx of the counter maintains the current count.
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 value
PV, 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 when
it reaches PV.
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Example-LAD
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Introduction to PLC
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Example-FBD
Introduction to PLC
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Example-STL
Introduction to PLC
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Timers
Introduction to PLC
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Timer Types
Delay On timer (TON)
Delay OFF timer (TOF)
Retentive On Delay timer (TONR)
Introduction to PLC
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Timer Numbers
Timer Type
TONR
TON, TOF
Introduction to PLC
Resolution Maximum Time Timer Number

1 ms
10 ms
100 ms
32.767 s
327.67 s
3276.7 s
T0, T64
T1-T4, T65-T68
T5-T31, T69-T95
1 ms
10 ms
100 ms
32.767 s
327.67 s
3276.7 s
T32, T96
T33-T36, T97-T100
T37-T63, T101-T255
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On Delay Timer
Counts time when the enabling input is ON.
When the current value (Txxx) is greater than or
equal to the preset time (PT), the timer bit is ON.
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.
Introduction to PLC
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Example-LAD
Introduction to PLC
Nikini
11/19/2010 8:48 AM
Nikini
Introduction to PLC
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Example-FBD
Introduction to PLC
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Example- STL
Introduction to PLC
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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
turns ON immediately, and the current value is set
to 0.
When the input turns OFF, the timer counts until
the elapsed time reaches the preset time.
When the preset is reached, the timer bit turns
OFF and the current value stops counting.
Introduction to PLC
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Example-LAD
Introduction to PLC
Nikini
11/19/2010 8:48 AM
Nikini
Introduction to PLC
11/19/2010 8:48 AM
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Example-FBD
Introduction to PLC
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Example-STL
Introduction to PLC
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Retentive On Delay Timer

Counts time when the enabling input is ON.
When the current value (Txxx) is greater than or
equal to the preset time (PT), the timer bit is ON.
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.
Introduction to PLC
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Example-LAD
Introduction to PLC
Nikini
11/19/2010 8:48 AM
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Introduction to PLC
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Example-FBD
Introduction to PLC
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Example-STL
Introduction to PLC
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Exercise 6
1B1
1B2
1. Delay 3s at 1B1 and move

forward
2. Delay 2s at 1B2 and move
backward
1M1
3. Continuous Cycle with S1

(Start) push button
4. Stop when 10 cycles
completed
5. Stop with S2 (Reset) push
button immediately
Introduction to PLC
11/19/2010 8:48 AM
+24V
3 4
START
RESET
A1
Nikini
A2
24V I0 I1 I2 I3 I4 I5 I6 I7
0V Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Y1
0V
Introduction to PLC
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materials
2A
1A
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materials
Selector switch S2 is used to select between
material A and B.
When a push button S1 is pressed, material A
should be entered for 10 seconds or material B
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
Variable (V) memory
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
Introduction to PLC
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Instruction types
Bit logic
Timer
Counter
Program Control
Logic Operations
Logic Stack
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 Structure
Main Program
Main Program : Executed once per scan

MEND
Subroutine : Executed when called

from the main program
Interrupt Routine : Executed on each

occurrence of the interrupt event
Introduction to PLC
SBR 0
RET
SBR 1
RET
INT 0
RET
INT 1
RET
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Program Flow
Main Program
CALL 0
SBR 0
RET
SBR 1
RET
CALL 1
Interrupt Event
INT 0
MEND
Introduction to PLC
RET
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SIMATIC S7-200:
Freeport communication
Option:
RS 485 or
RS 232 protocol can be used
RS 485
RS 485
modem
PPI cable
Drive
(e.g. USS protocol)
Non-Siemens
device with
RS 485
RS 232
Printer
NonSiemens
PLC
OP
Modem
PLC
Bar code scanner
Introduction to PLC
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SIMATIC S7-200:
Fieldbus Communication
Introduction to PLC
PROFIBUS-DP Slave
AS-I Master
Ethernet
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 and
outputs.
2. determine how the process is to be controlled.
3. determine special needs such as distance
between 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
4. Analog devices
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 (Weighing, Positioning, etc.)
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
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 should

be selected. Factors that might be considered
are,
1.
2.
3.
4.
5.
6.
7.
8.
Introduction to PLC
manuals and documentation

support while developing programs
the range of products available
support while troubleshooting
shipping times for emergency replacements
training
the track record for the company
business practices (billing, upgrades/obsolete
products,etc.)
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Review
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
Introduction to PLC
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Questions??
Introduction to PLC
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Introduction to PLC
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Basics
Introduction to PLC
Number systems
Signal Inputs
Signal Outputs
PLC memory
PLC scan cycle
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Number systems
Decimal
5238 = 5x1000 + 2x100 + 3x 10 + 8x1
5238 = 5x103 + 2x102 + 3x 101 + 8x100
Binary
101101112= 1x27 + 0x26 + 1x25 + 1x24 + 0x23
+ 1x22 + 1x21 + 1x20
= 18310
Introduction to PLC
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Number systems
BCD (Binary Coded Decimal)
Introduction to PLC
Decimal number
BCD number
010
0000BCD
110
0001BCD
210
0010BCD
310
0011BCD
410
0100BCD
510
0101BCD
610
0110BCD
710
0111BCD
810
1000BCD
910
1001BCD
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Number systems
Decimal number 3564 in BCD
0011 0101 0110 0100 BCD
16 bits required
BCD coded numbers are often used for
seven segment displays and coding
switches.
Introduction to PLC
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Number systems
Hexadecimal
A =10, B =11, C =12, D =13, E =14, F =15
87BC16 = 8x163 + 7x162 + 11x161 + 12x160
=3474810
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Types of signals
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
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.)
Introduction to PLC
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Input / Output System

Provides the physical connections between the
outside world and CPU
Introduction to PLC
Input Devices
Output Devices
Selector switches
Alarms
Push buttons
Control Relays
Sensors
Solenoids
Circuit breakers
Lights
Level sensors
Horns
Relay contactors
Valves
Motor starter Contacts
Motor Starters
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PLC Operation
Introduction to PLC
11/19/2010 8:48 AM

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Nikini Automation Systems (Pvt.) Ltd.

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Introduction to automation technology

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Automation is aimed at reducing human effort in

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Example of a Manual process

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Processes carried out

Keeping the work piece

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Elements of the manual system

Decision making element

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Automating the Process:

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Micro controller (PIC)

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Hardwired Control &

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This process occurs according to the instructions

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Basic Principle of a PLC

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What PLC can do?

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PLCs Vs Other Microprocessor

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Major PLC manufacturers

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Components of a PLC system

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Hardware Components of a PLC

CPU consists of two main parts

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Structure of a S7-200 (CPU 222)

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Mode Selector Switch

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Steps to follow when using a PLC for the

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