PLC Programming

By: Cabingas, Ben T., ECE

Basic PLC
Objectives: Describe the major components of common PLC Use Automation Studio Simulation Convert conventional relay logic to PLC language Operate and program a PLC (Siemens S7200 PLC) for a given application using Ladder Programming
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Basic PLC
Programmable Logic Controllers (Definition according to NEMA Standard ICS3-1978) A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.
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Basic PLC
PLC other definition: Considered as the Brain of modern industrial control and as the hub for wide varieties of automation and control PLC Utilization in the Industries in Region X A microprocessor based controller specifically designed for industrial control applications

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Basic PLC
Historical Background The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968 Goal: To eliminate the high costs associated with inflexible, relay-controlled systems
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Basic PLC
Historical Background New control system had to meet the following requirements: Survive in an industrial environment Easily programmed and maintained Reusable

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Basic PLC
Other initial specifications: Price competitive with the use of relay systems The controller had to be designed in modular form The input and output had to be easily replaceable The control system needed the capability to pass data collection to a central system

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Basic PLC
Programmable Logic Controller Development 1968 Programmable concept developed 1969 Hardware CPU controller, with logic instructions, 1 K of memory and 128 I/O points 1974 Use of several (multi) processors within a PLC - timers and counters; arithmetic operations; 12 K of memory and 1024 I/O points
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Basic PLC
Programmable Logic Controller Development 1976 Remote input/output systems introduced 1977 Microprocessors - based PLC introduced 1980 Intelligent I/O modules developed Enhanced communications facilities Enhanced software features Use of personal microcomputers as programming aids
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Basic PLC
1983 1985on Low - cost small PLCs introduced Networking of all levels of PLC, computer and machine using SCADA software

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Leading Brands of PLC AMERICAN 1. Allen Bradley 2. Gould Modicon 3. Texas Instruments 4. General Electric 5. Westinghouse 6. Cutter Hammer 7. Square D EUROPEAN 1. Siemens 2. Klockner & Mouller 3. Festo 4. Telemechanique

Basic PLC

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Basic PLC
Leading Brands of PLC Japanese 1. Toshiba 2. Omron 3. Fanuc 4. Mitsubishi

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Basic PLC
Areas of Applications Manufacturing / Machining Food / Beverage Metals Power Mining Petrochemical / Chemical

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Major Components of PLC

POWER SUPPLY

From SENSORS
Pushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

PROCESSOR

O U T P U T

M O D U L E

To OUTPUT
Solenoids, contactors, alarms etc.

PROGRAMMING DEVICE

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Major Components of PLC

1. Power Supply Provides voltage needed to run the primary PLC components 2. I/O Modules Provides signal conversion and isolation between the internal logic- level signals inside the PLC and the fields high level signal (analog or discrete)
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Major Components of PLC

3. Processor Provides intelligence to command and govern the activities of the entire PLC systems 4. Programming device used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine
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Programming Device
Types: Hand held unit with LED / LCD display Desktop type with a CRT display

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Programming Device
Handheld programmers: Industrial terminal (Allen Bradley)

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Programming Device
Handheld programmers: Program Development Terminal (General Electric)

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Programming Device
Handheld programmers: Programming Panel ( Gould Modicon )

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Programming Device
Handheld programmers: Programming Console ( Keyence / Omron )

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Programming Device
Handheld programmers: Siemens

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Discrete Input
Discrete input also referred as digital input (ON or OFF) connected to the PLC digital input. ON condition = logic 1 or a logic high OFF condition= logic o or logic low.
Normally Open Pushbutton Normally Closed Pushbutton Normally Open switch Normally Closed switch Normally Open contact

Normally closed contact

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Basic PLC
IN

OFF Logic 0

PLC Input Module

IN

OFF Logic 1

PLC

Input Module
24 V dc

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Basic PLC
An analog input is an input signal that has a continuous signal. Typical input signals are 0 to 20mA, 4 to 20mA or 0 to10V.
Level Transmitter
IN

Tank

PLC Analog Input Module

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Basic PLC
Digital Output
A discrete output is either in an ON or OFF condition. Examples: Solenoids, contactors coils, and lamps.

OUT

PLC

Lamp
Digital Output Module

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Basic PLC
Analog Output

An analog output is an output signal that has a continuous signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
Electric to pneumatic transducer
OUT

PLC
Analog Output Module

0 to 10V

Supply air

Pneumatic control valve

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PLC Communications
Common Uses of PLC Communications Ports
Changing resident PLC programs - uploading/downloading from a supervisory controller (Laptop or desktop computer). Forcing I/O points and memory elements from a remote terminal.

Linking a PLC into a control hierarchy containing several sizes of PLC and computer

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PLC Communications
Serial Communications PLC communications facilities normally provides serial transmission of information

Common Standards
RS 232 Used in short-distance computer communications, with the majority of computer hardware and peripherals Has a maximum effective distance of approx. 30 m at 9600 baud
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PLC Communications
Local Area Network (LAN) provides a physical link between all devices Provides overall data exchange management or protocol provide the common, high-speed data communications bus which interconnects any or all devices within the local area. RS 422 / RS 485 longer-distance links, often between several PCs in a distributed system maximum distance of about 1000 meters
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PLC Programming
Types of Programming (IEC 1131-3) Ladder Language Instruction List language Sequential Function Chart Language Function Block diagram Language Statement List Language

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Ladder Programming

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Instruction List Programming

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Sequential Function Chart

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Function Block Programming

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Drilling Robot Application

Diagram: yy+ z+ zLIOC2.OUT0 LIOC2.OUT1 LIOC2.OUT2
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DC motor (M) x+ x36

Drilling Robot Application

Problem Statement: Materials from the feeder line is to be pushed by means a solenoid controlled double acting cylinder in horizontal position (x coordinate) refer to set up diagram. After the material is pushed, the solenoid controlled double acting cylinder in vertical position(y coordinate) will be activated allowing the dc motor controlled drilling machine in position. The drilling of the material is for about 5s to ensure that the material is properly bore. After the material is properly bore then the solenoid double acting cylinder in vertical position will return to its original position at the same time deactivating the dc motor. The material that is bore properly will be placed in the storage area by means of solenoid controlled double acting cylinder (z coordinate) placed in adjacent between the two double acting cylinders.
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Motion Sequence Diagram

t=5s z+ xX+ Y+ M+ Y-/M- Z+ Z- X- RST Start/stop y+ yzNote: + = Activation - = Deactivation

x+

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SUGGESTED PATTERN IN PROGRAMMABLE LOGIC CONTROLLER (PLC) SEQUENCE CONTROL by: Ruvel J. Cuasito, PECE
1. A step (rung) is executed and represented by a relay. 2. The first step of the sequence shall be connected in series with the triggering switches and is connected in series with normally closed interlocking contact. Each relay representing a step is self-latched
; X+ Interlocking contact Latching contact
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3.The proceeding steps shall also represented by a relay unique from the other and is connected in series with normally open step marker (relay marker previous rung). The step is also self-latched.

Step Marker

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4. Reset rung shall also be connected in series with the triggering switch and the step marker. No selflatching is required. (This rung is the termination of the control circuit.)
Step marker

5. The relay representing the reset step shall be used and assigned to the interlocking contact of the first step (1st rung). 6. The power circuits shall be represented by the appropriate tag name designated to its output component. (Solenoid Coil, Lamp, Buzzer, and etc.) PLC in Automation Technology

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7. The power circuit rung shall be connected in series with the normally open relay representing step activation of the output component, and then it is connected in series with the normally closed relay representing step deactivation of the concerned output component.

; X+/-

Activation

Deactivation

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8. If the activation and deactivation are repetitive, its relay representation shall be connected in parallel to the previous step activation and deactivation bearing the same output component
First Activation and deactivation ; X+/-

Second Activation and deactivation

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