Process Control and Instrumentation Lab.

UNIVERSITI TUNKU ABDUL RAHMAN

Process Control & Instrumentation

Faculty : FES Unit Code : UEEA2413
Course : BEng (Hons) EC, 3E, MM, Unit Title : Process Control amd
MH, ME,BI, ET Instumentation
Year/ : Year 2 / Semester 2 Lecturer : Wong Chee Woon
Semester Year 3 / Semester 1 Wee Sie Toon
Lin Horng Sheng
Session : January 2018
Lab 1: Introduction to Programmable Logic Controller

1 Introduction

Objectives
(i) To understand the functions of the NAiS FP0 C10 PLC.
(ii) To program a NAiS FP0 C10 PLC.
(iii) To design a ladder logic program.

Equipment
(i) NAiS FP0 C10 programmable logic controller training kit.
(ii) FPWin PLC programming software.
(iii) Connecting cables.
(iv) 24V DC power supply.

The FP0-C10 Programmable Logic Controller Training Kit

5 6
3

4
2 1

Figure 1 The NAiS FP0 C10 PLC training kit unit.

No. in Fig. Description Function

1 Status indicator LEDs.
2 Input switches.
3 Tool port (RS232C).
4 Power supply connector.
5 Input terminal (6-pin).
6 Output terminal (6-pin).
Display the status of output channels (Y).
Provide the inputs (X).
Use for connecting to the PC.
Connect to 24 V DC power supply.
[Not use in this exercise.]
[Not use in this exercise.]

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2 Programming Modes

Several programming modes are available for the PLC. You are recommended to use the
LDS mode for this exercise.

Mode Description
1 Ladder Symbol The program will be displayed in ladder diagram and the input
Mode (LDS) method is ladder symbol as shown in Figure 1.2(a).
2 Boolean Ladder The program will be displayed in ladder diagram and the input
Mode (BLD) method is Boolean symbol. Figure 1.2(b) shows the editing
palette.
3 Boolean Non- The program will be displayed in Boolean (text) and input is
Ladder Mode Boolean symbol. The program cannot be complied in this mode.
(BNL)
4 Boolean Text Edit The program is displayed as Boolean (text). Editing is in text,
Mode (TXT) ASCII file.

Figure 2(a): Editing palette in LDS

Figure 2(b): Editing palette in BLD

3 Connecting the PLC

Connecting the FP0-C10 PLC to the computer

RS232C cable

FP0-C10 PLC

Figure 3 Connection of PLC to computer

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In this exercise, the PLC is connected to a computer running Microsoft Windows via a
RS232C cable. Refer to Figure 3.

Procedure for connecting the PLC to the PC

1 Turn OFF the power switch of the FP0-C10 PLC.

2 Connect to the computer via the RS232C conversion adapter at a serial COM port.
3 Connect the FP0-C10 PLC at the interface port (see Figure 1.3).
4 Turn ON the power of the PLC.

Power Supply connection procedure

1 Set the power supply unit to 24V DC.

2 Connect the positive and negative terminal of power supply to the power supply
input of NAIS FP0 CP10 PLC unit.

After the connection to the PC and the power supply is done, switch on the NAIS FP0
CP10 and it is now ready to use.

4 Objective 1: First PLC Ladder Program

4.1 Program specification:

When either of the input switch X0 or X1, or both are closed,

X2 can turn on the output relay Y0.
Opening both X0 and X1 will turn Y0 off.

The ladder diagram is shown in Figure 4.

Y0

Figure 4 Ladder Diagram

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4.2 Creating the Program

1. Execute the FPWIN GR programming software.

2. Click on “Program” “Panasonic MEW Control” “FPWIN GR”.

A dialog box as shown in Figure 5 will appear. At this, select “New Program”.

Figure 5 FPWIN GR Program Selection Manu.

3. Next, you will be required to select the PLC model, highlight FP0-C10 as shown in
Figure 6 and press <ENTER>.

Figure 6 PLC Model type selection menu.

4. The first window will look like Figure 7. You are now in the Ladder Symbol Mode
(LDS).

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Figure 7 The FPSOFT window.

5. Create the ladder diagram

Click on the symbol for the components that you wish to add in to construct the
ladder diagram and insert the name for the components.

Example –

To construct , click on then X 0.

The name for each component consists of an alphabet followed by a number. For
example, X0, X1, R1 and etc.

Once the ladder diagram is complete, compile and convert the program by clicking
on “Edit” “Convert program” on the menu bar at the top of the screen.

6. Checking the program OFFLINE: You can check the program that you are about to
run, regardless of how small and simple they may be. In the OFFLINE mode, you
can check the program displayed in the current edit window by clicking on
“Debug”, then “Totally Check Program”, and “Debug” then “Verify Program” in
the menu bar.

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7. Download Program: Click the ONLINE icon , then the download icon from
the short-cut menu bar. Alternatively, you could select “Download to PLC” at the
Symbol Dialog box. You will be prompted with the following dialog box, dismiss it
with YES.

Figure 8 Download to PLC window.

8. Now, switch the PLC to REM-RUN mode by clicking on the Change PLC mode
icon at the short-cut bar. Make sure that the status indicator of the PLC has the
RUN LED lighted.

9. If you have the circuit properly connect as shown in Figure 1.3, when you close the
input switch X0, you will see that the normally close (NO) contact in the ladder
diagram highlighted, as shown in Figure 9.

Figure 9 Monitoring the PLC status from the ladder diagram.

The highlighted contacts in the diagram reflect the status of each contact, as do the
output LED indicators on the PLC. If you want to stop monitoring the PLC at the
ladder diagram, click on the Stop icon in the short-cut bar and it will change to a
green arrow button. Note that this applies only to monitoring on the computer, the
PLC is still running. To stop running, click on the Change PLC mode icon.

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10. Run your program and check it against the truth table.

X0 X1 X2 Y0
On / Off On / Off Off
On Off On
Off On On
On On On
Off Off On

Table 1 PLC program truth table.

5 Objective 2

Develop a ladder diagram for the following process specified by the narrative
statement below.

Figure 10 Process for objective 2.

Once the Start push button is triggered, the process runs as:
(i) Conveyor moves.
(ii) When a bottle is in position (BP TRUE) –
a. Pause the conveyor (M1OFF),
b. Open the output valve.
(iii) When the bottle is full (BF TRUE) - Close the output valve
(iv) Go to step (i) and repeat the process.
Once the Stop push button is pressed, the process stops.

You are required to design ladder logic program to achieve the sequence stated in
the narrative statement above.

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6 Instructions to students

(i) Verify that your completed program works properly according to the
narrative statement. Please ensure that the program meet the
requirement of on-the-spot evaluation report. It is your
responsibilities to call for on-the-spot evaluation (once you meet
the objective) and submit the hardcopy of on-the-spot evaluation
report to the lecturer in-charge before leaving the lab session.

(ii) Put all input devices in NO state before switching on the PLC. Use the
following I/O ports for the devices.

Inputs Outputs
X0 Start pushbutton Y0 Conveyor M1
X1 Stop pushbutton Y1 Valve
X2 BP sensor
X3 BF sensor

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On-The-Spot Evaluation Report (Lab 1)
Name:________________ ID:______________

Course:__________________ Date:_____________

Group members:_________________________________________________________

Objective 1

1. Truth Table (8 Marks)

X0 X1 X2 Y0
0 0 0
0 0 1
0 1 0
0 1 1
1 0 0
1 0 1
1 1 0
1 1 1

Objective 2
1. IO List (4 Marks)
INPUT OUTPUT
e.g. Start Button (X0)

2. Truth Table (8 Marks)

Truth Table for Conveyer (Y0)
Bottle Position Sensor, BP (X2) Bottle Full Sensor, BF (X3) Conveyor (Y0)
0 0
0 1
1 0
1 1

Truth Table for Output Valve (Y1)

Bottle Position Sensor, BP (X2) Bottle Full Sensor, BF (X3) Output Valve (Y1)
0 0
0 1
1 0
1 1

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3. Ladder Logic Program (20 Marks)
Option 1
You may complete the proposed ladder logic program as below:

Option 2
Design and create the ladder logic diagram as below:

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2. Discussion and Summary (20 Marks)

Objective 1 – Please discuss on:
1. Simplify the truth table to Boolean equation or describe the And/Or logic
relation within the IOs.
2. What is the function of Relay, R1? How it relates to your first ladder logic
diagram?

Objective 2 – Please discuss on:

1. What is the difference of push button and toggle button? How do you
program the push start button?
2. What is the difference between ladder logic program and c++ program (pros
and cons)?

Check by: ________________________

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Marking Criteria Marks

Objective 1 8
Meet the truth table
Objective 2 4
Prepare IO list

State the truth table 8

Ladder logic program 20

Once the Start/stop push button is pressed and released, (5)

the process is started/paused. Note that X0/X1 is
triggered to ON (press) and then to OFF (release) state. -
The push button is converted latching state.

Once the Start push button is pressed and released, the (10)
process is started and resumed at any stage as the truth
table

Once the Stop push button is triggered, at any stage (5)

-The conveyor stops
-The output valve closes
Discussion and Summary 20
The students can critically discuss about the experiments (15-20)
and the discussions show that they can apply the theories
learnt in the classes.
The students can briefly discuss about the experiments (9-14)
and most of the details are correct.
The discussions have many errors. (0-8)
Final Mark (7.5%) Total Mark
* 7.5 / 60

End

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