Bee2931 Basic PLC 2011

17/10/2011
BEE2931 - Basic PLC

Based Model : OMRON CQM1H- CPU51 CQM1HInstructor : syahrulnaim bin mohamad nawi E-Mail : syahrulnaim@ump.edu.my Tel:09-4242129 h.p: 019-9825807 Room no:E10-C25
Universiti Malaysia Pahang
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Course Outcomes
By the end of semester, students should be ab e able to: CO1 Describe the basic principle of PLC and its function. CO2 Implement PLC Hardware configuration. CO3 Identify PLC system wiring and component. CO4 E Execute and practice PLC P d i Programming i for specific tasks. CO5 Practice right attitude and safety procedure.
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Mark distribution
Quizzes Lab Report Assessment 1 Assessment 2 Test Total 5% 10% 25% 30% 30% 100%
References
1 Jon Stenerson Industrial Automation and Process Control,Upper Saddle River, NJ: Prentice Hall,2003 John R Hackworth & Frederick D Hackworth,Jr Programmable Logic Controller:Programming Method and Application,Upper Saddle River,NJ:Prentice Hall,2004 OMRON Sysmac CQM1H Series Operation Manual,Revised August 2005
Frank D. Petruzella, P F kDP t ll Programmable L i C t ll 3 d Editi M bl Logic Controllers, 3rd Edition, McGraw Hill, 2005. Omron, Programming Manual, Revised December 2003, Omron Corporation, 2003.
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1.0 INTRODUCTION
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1.1 What is Control System

In general, a control system is a collection of electronics devices and equipments to ensure the stability ,accuracy and smooth transition of a process or a manufacturing activity.
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1.1 What is Control System

A control system consists of three sections: input processing and output. input, output
Input Sensor
Binary (on/off) Push Button Switch Limit Switch Proximity Continuous Transducer Transmitter
Processing/ Brain Processor

Hard wired System Relay Electronic Logic Pneumatic Logic Software Programmable System Computer Micro-processor PLC System
Output Actuator
Binary Motor Relay Cylinder Continuous Control Valve
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1.2 What is a Programmable Controller

In an automated system, the PLC is commonly regarded as the heart of the control system. The PLC may used to control a simple and repetitive task. Or a few of them may be interconnected together with other controller or host computer through a sort of communication network, in order to integrate the control in a complex process.
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1.2 What is a Programmable Controller

PLC (Programmable Logic Controller) A PLC works by looking at its inputs and depending on their state, and the user entered program, turns on/off outputs. A PLC can be thought of as: p Industrial Computers with specially d i d i ll designed architecture in both their central units (the PLC itself) and their interfacing circuitry to field devices (input / output connections to the real world).
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1.3 PLC Development

Early control systems consisted of huge control boards consisting of hundreds to thousands of electromechanical relays relays. The schematic was commonly called Ladder Schematic The Ladder displayed all switches, sensors, motors, valves, relays etc in the system. Problems: Long commissioning time, Mechanical Reliance, Any system logic design change required the power to the control board to be isolated stopping production.
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1.3 PLC Development

General Motors was among the first to recognize a need to replace the systems wired control board Goal Eliminate the high cost associated with inflexible, relay controlled systems. New Controller Specifications:
Solid State System Computer Flexibility Operate in Industrial Environment (vibrations, heat, dust etc.) O ( ) Capability of being reprogrammed Easily programmed and maintained by electricians and technicians.
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1.3 PLC Development

In 1969 Gould Modicon developed the first PLC. Strength P St th Programmed with Ladder Logic, function d ith L dd L i f ti block, statement list Initially called Programmable Controllers PCs Now - PLCs, Programmable Logic Controllers PLC s PLCs have evolved from simple on/off control to being able to communicate with other control systems, provide production reports, schedule production, diagnose machine and process faults.
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1.3 PLC Development
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Wire Logic Vs PLC

ITEM
Controlled Device ( (Hardware) ) Control Scale Change or addition to specification Delivery period Maintenance (by makers and users) Reliability Economic Efficiency
WIRED LOGIC
Specific Purpose Small and Medium Difficult Several Days Difficult Depends on design and manufacture Advantage on small scale operation
PLC
General Purpose Medium and large Easy Almost immediate Easy Very High Advantage on small medium and large scale operation
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Advantageous of using PLC

Shorter project implementation time Easier modification without cost penalty p y Project cost can be accurately calculated Shorter training time required Design easily changed using software A wide range control application Easy maintenance High reliability Standardization of Controller Hardware
What PLC Can Do?

CONTROL TYPE
Sequences Control
FUNCTIONS
Conventional Relay Control Logic Replacer /P.C.B Card Controller Replacer p Timers/Counters Auto/Semi-auto/Manual Control of machine and Processes Arithmetic Operation Information handling Analog Control (Temperature, Pressure) P.I.D (Proportional-Integral-Derivation) P I D (Proportional Integral Derivation) Servo Motor and Stepper Motor Process Monitoring and Alarm Fault Diagnostic and Monitoring Interfacing with Computer -Printer/ASCII Factory Automation Local Area Network / Wide Area Network
Sophisticated Control / Regulatory Control
Supervisory Control
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PLCs manufacturer
OMRON Allen Bradley Schneider (Modicon, Telemecanique, Square D) GE Fanuc Siemens Automation Direct (Koyo) Toshiba Mitsubishi Hitachi Keyence Honeywell Yokogawa Festo Emerson Eberle Texas Instruments
PLC operation
First the PLC takes a look at each input to determine if it is on or off. In other words, is the sensor connected to the first input on? How about the second input? How about the third... It records this data into its memory to be us
1. CHECK INPUT STATUS
2. EXECUTE PROGRAM
Next the PLC executes your program one instruction at a time. Maybe your program said that if the first input was on then it should turn on the first output output. Since it already knows which inputs are on/off from the previous step it will be able to decide whether the first output should be turned on based on the state of the first input. It will store the execution results for use later during the next step.
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PLC operation
3. UPDATE OUTPUT STATUS
Finally the PLC updates the status of the outputs. It updates the outputs based on which inputs were on during the first step and the results of executing your program during the second step. Based on the example in step 2 it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true.
Check i/p Status
Execute Program
Update o/p Status
2.0 PLC HARDWARE DESIGN
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PLC Configuration
Rack
Mini
Micro Shoe Box
PLC Configuration
The configuration of PLC refers to the packaging of the components. Typical configurations are listed below from largest to smallest.
Rack Type : A rack can often be as large as 18 by 30 by 10 Mini: These are similar in function to PLC racks, but about the half size. Dedicated Backplanes can be used to support the cards OR DIN rail mountable with incorporated I/O bus in module. Shoebox: A compact, all-in-one unit that has limited expansion biliti Lower cost and compactness make these ideal for small t d t k th id l f ll capabilities. L applications. DIN rail mountable. Micro: These units can be as small as a deck of cards. They tend to have fixed quantities of I/O and limited abilities, but costs will be lowest. DIN rail mountable.
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Sizing of PLC
Micro PLC: I/O up to 32 points Small PLC: I/O up to 128 points Medium PLC: I/O up to 1024 points Large PLC: I/O up to 4096 points Very Large: I/O up to 8192 points
Basic PLC Schema

CPU Power Supply Memory Input Blocks Output Blocks Communications Expansion Connections
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CPU Module
The Central Processing Unit (CPU) Module is the brain of the PLC. Primary role to read inputs, execute the control program, update outputs. The CPU consists of the arithmetic logic unit (ALU), timing/control circuitry, accumulator, scratch pad memory, program counter, address stack and instruction register. A PLC works by continually scanning a program
Self Check Scan Inputs
Update Outputs O t t
Execute Code C d
PLC Program SCAN
Memory
The memory includes pre-programmed ROM memory containing the PLCs operating system, driver programs and application programs and the RAM memory. PLC manufacturer offer various types of retentive memory to save user-programs and data while power is removed, so that the PLC can resume execution of the user-written control program as soon as power is restored restored.
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Memory contd
Many PLCs also offer removable memory modules, which are plugged into the CPU module. Memory can be classified into two basic categories: volatile and non-volatile. - Volatile memory is that which loses state (the stored information) when power is removed. - Nonvolatile memory, on the other hand, maintains the information in memory even if the power is interrupted.
Memory contd
Some types of memory used in a PLC include:
ROM (Read-Only Memory) RAM (Random Access Memory) PROM (Programmable Read-Only Memory) EPROM (Erasable Programmable Read-Only Memory) EEPROM (Electronically Erasable Programmable ReadOnly Memory) FLASH Memory Compact Flash Can store complete program information, read & write text files
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I/O Modules
Input and output (I/O) modules connect the PLC to sensors and actuators. Provide isolation for the low-voltage, low-current signals that the PLC uses internally from the higherpower electrical circuits required by most sensors and actuators. d Wide range of I/O modules available including: digital (logical) I/O modules and analog (continuous) I/O modules.
Inputs Modules
Inputs come from sensors that translate physical or chemical phenomena into electrical signals. The simplest form of inputs are digital/discrete in AC/DC. In smaller PLCs the inputs are normally built in and are specified when purchasing the PLC. For l F larger PLCs the inputs are purchased as modules, or PLC h i h d d l cards, with 8,16, 32, 64, 96 inputs of the same type on each card.
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Inputs Modules
The list below shows typical ranges for input voltages voltages.
5 Vdc
12 Vdc 24 Vdc 48 Vdc 12 Vac 24 Vac 120 Vac 240 Vac
Outputs Modules
Output modules rarely supply any power, but instead act as switches. External power supplies are connected to the output card and the card will switch the power on or off for each output. A common choice when purchasing output cards is relays, transistors or triacs. Relay are the most flexible output devices. They are capable of switching both AC and DC outputs. But, they are slower, cost more, and they will wear out after millions of cycles.
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Relays
The most important consideration when selecting g relays, or relay outputs on a PLC, is the rated current and voltage. For transistor outputs or higher density output cards relay terminal blocks are available.
Advantage of individual standard replaceable relays
Output Modules
Typical output voltages are listed below below.
5 Vdc
12 Vdc 24 Vdc 48 Vdc 24 Vac 120 Vac 240 Vac
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Analogue Inputs/Outputs
Analogue input cards convert continuous signals via a A/D converter into discrete values for the PLC Analogue output cards convert digital values in then PLC to continuous signals via a D/A converter. Resolution can be important in choosing an applicable card Example, for a temperature input of 0 to 100 degrees C
For 8 bit resolution the value in the PLC is 0 to 255 For 12 bit resolution the value in the PLC is 0 to 4095 For 12.5 bit resolution the value in the PLC is 0 to 6000 For 13 bit resolution the value in the PLC is 0 to 8192 For 16 bit resolution the value in the PLC is 0 to 32768
Analogue Cards
Typical Analogue Input signals are:
Flow sensors Humidity sensors Load Cells Potentiometers Pressure sensors Temperature sensors Vibration
Analogue Output signals control:

Analogue Valves Analog Actuators Chart Resorders Variable Speed Drives Analogue Meters
Typical Analogue Signal Levels

1-5 Vdc 4-20mA 0-10 Vdc -10 10Vdc
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Special Modules
RF ID Voice Gas Flow C l l i G Fl Calculation Weigh Cell Hydraulic Servo ASCII Fuzzy Logic Temperature Sensor Temperature Control p Heat/Cool Control Field Bus Cards
DeviceNet, Profibus etc Lonworks, BACNet
Fast Response (Interrupt) PID Loop C L Controller ll BASIC Cards RS232 Comms Modbus ASCII/RTU Ethernet Comms High Speed Counters Position Control Cards Per to Per Comms
Controller Link DH+ Modbus Plus
Networks
ASI Devicenet Interbus-S Profibus Interbus Fieldbus Ethernet I/P Smart Distributed System (SDS) Seriplex CANopen Lonworks BACNet
Gateways enable communications between different network topologies
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OMRON PLC CQM1HCQM1H-CPU51
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CQM1H CPU51
Power Supply pp y Unit CPU unit Input p Module Output module
PA206
CQM1H-CPU51
0 CH
OC 221
INNER BOARD SLOT 1

RS-232 PORT
INNER BOARD SLOT 2
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Configuration
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Configuration
I/O point capacity : 512 points. CPU Block
Dedicated I/Os module up to 11 units connectable.
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Configuration
CPU and Expansion I/O Block
CPU: Up to 5 units (exclude I/O Control unit) Expansion: Up to 11 units (exclude I/O Interface Unit)
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Power Consumption
Important to select suitable power supply module. module Requirement to power up each module that attached.
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Power Consumption
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Output unit current consumption
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PLC WIRING SYSTEM
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Incoming Power Supply
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I/Os wiring circuit - input

1 2 3 4 5 6 7 8 9 10 H Input Card: H COM 0000 0001 0002 0003 0004 0005 0006
X2: 11
X2: 12
X2: 13
X2: 14
X2: 15
X2: 16
X2: 17
X2: 18
K6.5
C P24 N24 START STOP SELECTOR SWITCH Remote DCS SENSOR 1

1
/6.6
NAME VERIFY BY A Rev 1 Decription 2 Date CHECK BY DRAW BY 3 <Name> <Name> SNAIM
DATE <date> <date> 05/12/2006 4 5
FKEE Skills Center, Faculty of Electrical & Electronics Engineering, KUKTEM,

Locked Bag 12, 25000 Kuantan, Pahang Phone No: 09-5492318 Fax No: 09-5492377
Title
Drawing Number
Sheet
Input Card
<Drawing No>
File Name ELECTRICAL_DRAWING_MCC2. vsd Rev.
2
A
<Rev.>
10
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I/Os wiring circuit - output
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Inductive device connection
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Point assignment
Rack: 01F Channel: . Card: Digital Input - OCH
Point No. 00 01 02 03 04
Address 0000 0001 0002 0003 0004
Description Start Stop Auto/manual Sensor 1
Name Tag PB1 PB2 SS1 S1

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Lebel/mark 0000
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Address Assignment
Input p 0000
Input slot/channel no Input point no.
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Address Assignment
Output p 10000
Input slot/channel no Input point no.
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Address Assignment
For CQM1H, the address are dedicated by the system (cant setting by user) E.g.
Build in 0CH card is start from 00.00 Next second input card will start at 01.00
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CXCX-POGRAMMING
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Introduction PLC programming

Statement List
If PB1 AND PB2 then set output1 reset output2
Block Diagram
Ladder Diagram
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Basic Element of LD
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Anatomy of a LD
Typically flows from left to right. Divided into sections called rungs, Each i/os instruction is assigned an address indicating the location in the PLC memory where the state of that instruction is stored.
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CXCX-Programmer
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Main windows
Lader Logic
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Lader Logic
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AND Application
IN A 0 0 1 1 IN B 0 1 0 1 OUT
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AND Application - exercise

MAN MODE & PUSH START PB
GREEN LIGHT ON
REMOTE MODE OR RELEASE START PB
GREEN LIGHT OFF
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OR Application
IN A 0 0 1 1 IN B 0 1 0 1 OUT
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OR Application
IN A 0 0 1 1
IN B 0 1 0 1
OUT
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Latching / holding circuit

To hold the output for desire rung. Technique
Or ladder KEEP instruction SET & RSET Instruction
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Latching by using or function
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KEEP Instruction
Purpose:
Defines a bit (B) as a latch, controlled by the set (S) and reset ( ) inputs. ( ) (R) p
Operand Data Areas:

B: Bit IO, AR, HR, LR.
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Flow chart
start
I/O Assignments 000.00 000.01 100.01
Input Devices Start PB Stop PB Green Light
Push Start button
Green Light On Ladder Diagram Push Stop Button Green Light OFF
End
SET & RSET Instruction
Turns ON B for an ON execution condition; does not affect B for an OFF execution condition. Operand Data Areas: B: Bit IO, AR, HR, LR.
Turns OFF B for an ON execution condition; does not affect B for an OFF execution condition. Operand Data Areas: B: Bit IO, AR, HR, LR
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More Exercise.
Timer (TIM)
A timer is activated when its execution condition goes ON and is reset (to S) di i di ( when the execution condition goes OFF. Once activated, TIM measures in units of 0.1 second from the S.
N TC Number S Set value (word, BCD)
000 - 511 IO, AR, DM, HR, #
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Timer (TIM)
ON
ON
If the execution condition remains ON long enough for TIM to time down to zero, the Completion Flag for the TC number used will turn ON and will remain ON until TIM is reset (execution condition goes OFF).
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BASIC TIMER: EXERCISE 1

Start Push Start button No
Timer 5 Sec? Yes Yellow Light ON End
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BASIC TIMER: EXERCISE 2

Start
Select Manual Mode
A Timer 5 Sec? Green Light ON Select Auto Mode Yellow & Green Light OFF End
Timer 5 Sec? Yes Yellow Light ON A
No
FLICKER: EXERCISE 3
Start Push Start button No A Timer 1 Sec? Green Light OFF Push Stop
Timer 1 Sec? Yes Green Light ON A
System RESET End
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FLICKER: EXERCISE 4
Start Push Start button N Timer o 3 Sec? Yes Green Light ON A A N Timer o 1 Sec? Yes Green Light OFF Continuou s Blinking Push Stop System RESET End
TIMER APPLICATION
Lab sheet 2 : Exercise 5
Input Input Devices Assignment A i 0000 0001 0002 Start PB Stop PB Auto/Man Selector
Output Output Devices Assignment 10001 10002 10003 g Green Light Red Light Yellow Light
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Counter (CNT)
CNT is used to count down from SV when the execution condition on the count pulse -CP, goes CP, from OFF to ON. The present value (PV) will be decremented by one whenever CNT is executed with an ON execution condition for CP and the execution condition was OFF for the last execution
N CNT Number 000 - 511 IO, AR, DM, HR, #
SV Set value (word, BCD)

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Counter (CNT)
ON
ON
The Completion Flag for a counter is turned ON when the PV reaches zero and will remain ON until the counter is reset. CNT is reset with a reset input, R. When R goes from OFF to ON, the PV is reset to SV.
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Timer and Counter
Please note that TIM number and CNT number should be unique (NOT SAME) in a same program.
E.g.
CNT000 then use TIM000 in same program.
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BASIC COUNTER: EXERCISE 6

Start Push Start Button No Counter 5X? Yes Green Light ON Push Stop Button Green Light OFF End
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TIME DELAYED 60 SEC: EXERCISE 7

Start Push Start button No Timer 6 Sec? Yes No Counte r 10 X? Yes A Push Stop A
Yellow Light ON
System y RESET End
Extra exercise
MAN MODE NG PART ON & RUN PART OFF
OK PART BLINKING STOP PB AUTO MODE NO RUN PART BLINKING & OK PART OFF IF STOP PB 5x
YES START PB ALL PART OFF OR RESET SYSTEM
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DIFU & DIFD INC & DEC Shift Register Move & Compare p Interlocking
INTERMEDIATE PROGRAM
DIFU instruction
Differential UP (rise edge) DIFU (13) turns ON the designated bit (B) for one scan on reception of the leading (rising) edge of the input signal
Operand Data Areas B Bit IO, AR, HR, LR
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DIFD instruction
Differential Down (fall edge) DIFD(14) turns ON the designated bit (B) for one scan on reception of the trailing (falling) edge of the input signal.
Operand Data Areas B Bit IO, AR, HR, LR
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DIFU vs DIFD
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MOVE instruction
Copies the contents of S to D
Operand Data Areas
S Source Word D Destination

word
IO, AR, DM, HR, LR, # IO, AR, DM, HR, LR
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Compares (CMP) instruction

Compares Cp1 and Cp2 and; Outputs the result to the GR, EQ and LE flags in the SR area
Operand Data Areas
Cp1
1st
compare word
IO, AR, DM, HR, TC, LR, # IO, AR, DM, HR, TC, LR, #
Cp2 2nd compare

word
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Increment (INC) instruction

Increments Wd, without affecting Carry (CY). (CY) For INC(38) and DEC(39) the source and result words are the same. That is, the contents of the source word is overwritten with the instruction result.
Operand Data Areas Wd Increment Words
IO,AR,D M,HR,LR
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Decrement (DEC) instruction

DEC(39) decrements Wd, without affecting CY ff i CY. DEC(39) works the same way as INC(38) except that it decrements the value instead of incrementing it.
Operand Data Areas Wd Decrement Words
IO,AR,D M,HR,LR
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Bee2931 Basic PLC 2011

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17/10/2011

BEE2931 - Basic PLC

Universiti Malaysia Pahang

Universiti Malaysia Pahang

1.1 What is Control System

Universiti Malaysia Pahang

1.1 What is Control System

Processing/ Brain Processor

Universiti Malaysia Pahang

Universiti Malaysia Pahang

1.2 What is a Programmable Controller

1.2 What is a Programmable Controller

1.3 PLC Development

1.3 PLC Development

Universiti Malaysia Pahang

1.3 PLC Development

Universiti Malaysia Pahang

1.3 PLC Development

Universiti Malaysia Pahang

Wire Logic Vs PLC

Advantageous of using PLC

What PLC Can Do?

Sophisticated Control / Regulatory Control

1. CHECK INPUT STATUS

Check i/p Status

Update o/p Status

2.0 PLC HARDWARE DESIGN

Micro Shoe Box

Basic PLC Schema

PLC Program SCAN

Analogue Output signals control:

Typical Analogue Signal Levels

Gateways enable communications between different network topologies

OMRON PLC CQM1HCQM1H-CPU51

Universiti Malaysia Pahang

INNER BOARD SLOT 1

INNER BOARD SLOT 2

Universiti Malaysia Pahang

Universiti Malaysia Pahang

Universiti Malaysia Pahang

Universiti Malaysia Pahang

Universiti Malaysia Pahang

Output unit current consumption

Universiti Malaysia Pahang

PLC WIRING SYSTEM

Universiti Malaysia Pahang

Incoming Power Supply

Universiti Malaysia Pahang

I/Os wiring circuit - input

C P24 N24 START STOP SELECTOR SWITCH Remote DCS SENSOR 1

DATE <date> <date> 05/12/2006 4 5

FKEE Skills Center, Faculty of Electrical & Electronics Engineering, KUKTEM,

Universiti Malaysia Pahang

I/Os wiring circuit - output

Universiti Malaysia Pahang

Inductive device connection

Universiti Malaysia Pahang

Address 0000 0001 0002 0003 0004

Description Start Stop Auto/manual Sensor 1

Name Tag PB1 PB2 SS1 S1

Universiti Malaysia Pahang

Introduction PLC programming