PLC NOTES COMPLETE 2 Edit 2013 (Penting) PDF

PROGRAMMABLE LOGIC
CONTROLLERS
SARIATI DALIB
[email protected]
PROGRAMMABLE LOGIC CONTROLLERS
CHAPTER 1
UNIT 1: INTRODUCTION TO AUTOMATION SYSTEM
Objectives
1. Understand and learn about automation control systems and types of automation control
systems.
2. Learn about the types of control system pneumatic control systems, hydraulic control systems
and electrical control system.
At the end of this chapter, student should be able to:

1.
2.
3.
4.
5.
Define the Automation Control System

States the need of Automation Control System in the industry
States of the Fixed Automation / Hard-Wire Control System
Differentiate between Fixed Automation with Programmable Automation.
State the basic concepts of pneumatic control systems, hydraulic control systems and electrical
control systems
6. Classification of pneumatic control systems, hydraulic control systems and electrical control
systems.
7. Distinguish between the pneumatic control system, hydraulic control system and electrical
control systems
1.0
Introduction:
In todays fast-moving, highly competitive industrial world, a company must be flexible, cost
effective and efficient if it wishes to survive. In the process and manufacturing industries, this
has resulted in a great demand for industrial control systems/ automation in order to streamline
operations in terms of speed, reliablity and product output. Automation plays an increasingly
important role in the world economy and in daily experience.
Automation is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human
operators with machinery to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental requirements as well.
What is Automation Control System?
Automation Control System - system that is able to control a process with minimal human
assistance or without manual and have the ability to initiate , adjust, acting show or measures
the variables in the process and stop the process in order to obtain the desired output.
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Page 1

The main objective of Automation Control System used in the industry are:
to increase productivity
2. to improve quality of the product
3. to control production cost
1.
1.1 Types of Automation in the industry

1.1.1 Classification of automation
a)
Permanent/Fixed Automation
-
b)
This control system is designed to perform a specific task

Functions of control circuit is fixed and permanent.
It will be complicated if we want to do other task apart from the existing task
Programmable /Flexible Automation

- Programmable automation or felxible automation is a complex control system that can
perform several tasks
- Functions of control circuit programmed by the user and can be modified.
- When the task to be performed by machines changed, changes only need to be done by
making modifications to the machine control program.
1.1.2 Comparison between Fixed and Flexible Automation System

FIXED
AUTOMATION
FLEXIBLE
AUTOMATION
Purpose
Specific
Variety
Ease of making changes /

upgrade
Difficult
Easy
Hard
Easy
Depends on
manufacturing and design
Very high
Slow
Fast
Suitable for small system
Suitable for
all types of systems
Maintenance
Capability
Speed
Economy efficiency
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Example :
Fixed Automation
S1
S2
mentol
VB
bB
Programmed Automation:
S1
S2
0000
0
0000
1
ATURCARA
1000
0
LD
00000
AND
00001
OUT
10000
END (01)
PLC
I
N
P
U
T
O
U
T
P
U
T
mentol
S1
S2
COM
COM
VB
VB
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1.1.3 There are three (3) types of the control system based on supply :
a) Pneumatic Control Systems
b) Hydraulic Control System
c) Electrical Control System
a) Pneumatic Control System

Pneumatic control system is a system that uses compressed air to produce power / energy
to perform any task
Pneumatic systems found in many industrial systems such as food industry,

petrochemical and industrial involves robotics.
Pneumatic systems requires:
i. Compressed air supply
ii. Control valve
iii. Connecting tube
iv. Transducer
Pneumatic control system can be controlled manually and automatically.
Basic Block Diagram of Pneumatic Control System using manual/PLC
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b) Hydraulic Control System
Hydraulic control system is a system that uses fluid to generate power/energy.
The hydraulic system used in the automobile industry such as power systems, braking systems,
cranes, car jack, satellite and others.
The fluid used is oil.

The hydraulic system requires:
a) Hydraulic fluid supply
b) Control Valve
c) Cylinder
Hydraulic control system can be controlled manually and automatically
Basic block diagram of an automatic hydraulic control system by Manual /PLC

c) Electrical Control System
A control system that uses an electric current; either direct current (DC) or current
shuttle (AC) as a source of supply.
Electrical Control Systems Generally requires:
a) Electricity (DC) or (AC)
b) Input elements (switches, sensors, transducer, valves, electronic components,
etc.)
c) Output elements (motor, lights, etc.)
d) Extension cable
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Suis
Lampu
VB
Basic block diagram of a manual electric control system
Suis
Lamp
u
PLC
VB
VB
Basic block diagram of electrical control system using PLC
Comparison between pneumatic control system ,Hydraulic control system and

Electric control system
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a.
PNEUMATIC CONTROL SYSTEM

a) Easy installation
b) Simple design
c) Use compressed air as a supply source to perform task.
b.
HYDRAULIC CONTROL SYSTEM

a) Complex to assemble
b) Use fluid like oil as a supply source to perform task.
c) Potential leakage will lead to pollution.
c.
ELECTRIC CONTROL SYSTEM

a) Simple system
b) Use electricity as a supply source to perform task.
c) Widely use either for home user or in industrial.
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1.1.4 Advantages and disadvantages of automation control in industry
The main advantages of automation are:
Replacing human operators in tasks that involve hard physical work.

Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of size, weight, speed, endurance,
etc.
Economy improvement: Automation may improve in economy of enterprises, society or
most of humanity. For example, when an enterprise invests in automation, technology
recovers its investment; or when a state or country increases its income due to
automation like Germany or Japan in the 20th Century.
Reduces operation time and work handling time significantly.
The main disadvantages of automation are:
Unemployment rate increases due to machines replacing humans and putting those
humans out of their jobs.
Technical Limitation: Current technology is unable to automate all the desired tasks.
Security Threats/Vulnerability: An automated system may have limited level of
intelligence, hence it is most likely susceptible to commit error.
Unpredictable development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
High initial cost: The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product, although the cost of
automation is spread in many product batches of things
TUTORIAL QUESTION:
Give definition of Automation Control System? [3m]
Make a comparison between Fixed Automation and Flexible Automation Control
System.[12m]
State three (3) types of control system which based on supply source and states the
differences between them.[12m]
Sketch an automatic control system diagram for:
a) Hydraulic Control System
b) Electric Control System
c) Pneumatic Control System
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1.2 Explain relays and contactors
1.2.1 Relays
A relay is an electrically operated switch. . Current flowing through the coil of the relay
creates a magnetic field which attracts a lever and changes the switch contacts. The coil current
can be on or off so relays have two switch positions and most have double throw (changeover)
switch contacts as shown in the diagram.
Circuit symbol for a relay
Relays allow one circuit to switch a second circuit which can be completely separate from
the first. For example a low voltage battery circuit can use a relay to switch a 230V AC mains
circuit. There is no electrical connection inside the relay between the two circuits, the link is
magnetic and mechanical.
Relays are usuallly SPDT or DPDT but they can have many more sets of switch contacts,
for example relays with 4 sets of changeover contacts are readily available.
The relay's switch connections are usually labelled COM, NC and NO:
COM = Common, always connect to this, it is the moving part of the switch.
NC = Normally Closed, COM is connected to this when the relay coil is off.
NO = Normally Open, COM is connected to this when the relay coil is on.
Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on.
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off.
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Relay Building Diagram
A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core ,
an iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts (there are two in the relay pictured). The armature is hinged to
the yoke and mechanically linked to one or more sets of moving contacts. It is held in place by a
spring so that when the relay is de-energized there is an air gap in the magnetic circuit.
In this condition, one of the two sets of contacts in the relay pictured is closed, and the
other set is open. Other relays may have more or fewer sets of contacts depending on their
function.
Relays
Relay building diagram
The relay in the picture also has a wire connecting the armature to the yoke. This ensures
continuity of the circuit between the moving contacts on the armature, and the circuit track on
the printed circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic field that
activates the armature, and the consequent movement of the movable contact(s) either makes
or breaks (depending upon construction) a connection with a fixed contact.
If the set of contacts was closed when the relay was de-energized, then the movement
opens the contacts and breaks the connection, and vice versa if the contacts were open.
When the current to the coil is switched off, the armature is returned by a force,
approximately half as strong as the magnetic force, to its relaxed position. Usually this force is
provided by a spring, but gravity is also used commonly in industrial motor starters. Most relays
are manufactured to operate quickly. In a low-voltage application this reduces noise; in a high
voltage or current application it reduces arcing.
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1.2.2 Example of relay use in the traffic light system
1.2.3 Contactors
A relay that can handle the high power required (higher current rating) to directly control
an electric motor or other loads is called a contactor.
A contactor is an electrically controlled switch used for switching a power circuit, similar to
a relay except with higher current ratings.
Contactors come in many forms with varying capacities and features. Contactors range
from those having a breaking current of several amperes and 24 V DC to thousands of amperes
and many kilovolts. The physical size of contactors ranges from a device small enough to pick up
with one hand, to large devices approximately a meter (yard) on a side.
Contactors are used to control electric motors, lighting, heating, capacitor banks, and other
electrical loads.
Basic Component:
A contactor has three components. The contacts are the current carrying part of the
contactor. This includes power contacts, auxiliary contacts, and contact springs. The
electromagnet provides the driving force to close the contacts. The enclosure is a frame housing
the contact and the electromagnet.
Contactor
Contactor building diagram
A basic contactor will have a coil input (which may be driven by either an AC or DC supply
depending on the contactor design). The coil may be energized at the same voltage as the
motor, or may be separately controlled with a lower coil voltage better suited to control by
programmable controllers and lower-voltage pilot devices.
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Operating Principle
Unlike general-purpose relays, contactors are designed to be directly connected to highcurrent load devices. Relays tend to be of lower capacity and are usually designed for
both normally closed and normally open applications. Devices switching more than 15 amperes
or in circuits rated more than a few kilowatts are usually called contactors. Apart from optional
auxiliary low current contacts, contactors are almost exclusively fitted with normally open
contacts. Unlike relays, contactors are designed with features to control and suppress the arc
produced when interrupting heavy motor currents.
When current passes through the electromagnet, a magnetic field is produced, which
attracts the moving core of the contactor. The electromagnet coil draws more current initially,
until its inductance increases when the metal core enters the coil. The moving contact is
propelled by the moving core; the force developed by the electromagnet holds the moving and
fixed contacts together. When the contactor coil is de-energized, gravity or a spring returns the
electromagnet core to its initial position and opens the contacts.
Examples Application of contactor in motor control sytem.
1.2.4 Difference between relay and contactors

A relay is a device that can be classified as electrically operated control switches and
relays are either power relays or control relays depending upon their use. While power relays
are called contactors, control relays are simply called relays.
When a relay is used to switch a large amount of electrical power through its circuits, it is
given a new name, a Contactor. These contactors are very commonly used in industries for
control of electric motors. Thus it is clear that contactor is only a special type of relay. But what
are the differences between a relay and a contactor?
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The Difference :
1. Since a contactor is required for a higher load, a relay is always cheaper than a
contactor.
2. A relay is normally used in appliances below 5KW, while a contactor is preferred when
the appliance is heavier.
3. A relay is used only in control circuit while a contactor can be used in both control and
power circuits.
4. In general contactors are little slower than relays
5. Contactor is so designed that it can be repaired while it is not normally done in the
case of relays.
Conclusion
A contactor is a relay which is capable of switching large electrical loads.

Contactors and relays are operated by applying a voltage to the coil of an Electro-magnet, which
will cause a switch, (or several switches) to close. The circuit that applies the voltage to the coil is
referred to as the control circuit, because it controls the main device that the contactor or relay
is switching.
The coil voltage of a contactor or relay can be installed for virtually any control circuit voltage,
to provide complete flexibility for these devices (both AC and DC), as the control circuit can be
completely independent of the load it is switching.
NOTES:
It should be noted that when installing contactors or relays that you always check the coil
ratings. They often have not got a default rating of 230volts, and only go bang once if they are
connected to the wrong voltage!
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UNIT 2 : TERMINOLOGY
Objectives:
1. Define some terminology in the control system.
2. Describe the open-loop control system, closed-loop control systems and computerized
control systems
SPECIFIC OBJECTIVES
1. Define the terminology of control systems, reference input, control variables,
disturbances and feedback elements
2. Explain the open-loop control system, closed-loop control and computerized controls.
3. Comparing between the open-loop control system with closed-loop control system.
2.0
INTRODUCTION
Planning, design and start-up of process control systems require clear and unambiguous
communication between all parts involved. To ensure this, we need a clear definition of the
terms used and standardized graphical symbols. These symbols help us represent control
systems or measurement and control tasks as well as their device-related solution in a simple
and clear manner.
2.1
CONTROL SYSTEM
A control system is an interconnection of components connected or related in such a manner as

to command, direct, or regulate itself or another system.
There are two common classes of control systems, with many variations and combinations: logic
or sequential controls, and feedback or linear controls. There is also fuzzy logic, which attempts
to combine some of the design simplicity of logic with the utility of linear control. Some devices
or systems are inherently not controllable.
Basic components of control systems can be divided into five sections, namely:
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i.
Reference signal generator
ii.
elements of measurement
iii.
comparator
iv.
controller
v.
Actuator.
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2.2
Reference Input
Reference signal input is provided at the input of a system such as temperature, pressure,
level, etc. Its value is fixed
2.3
Control Variables
Controlled variables are controlled signals or variables in the output such as temperature,
pressure, level and so on. The value can be changed.
2.4
Disturbances
Disturbances is a disturbing element in the control signals of a control system.
Disturbances can result either from within or outside the system itself.
2.5
Feedback
Feedback element is a function to send output signals to be compared with the input
signal by the element Comparator / summer in a closed system
2.6
Open loop system
Open Loop Control System is a type of control system where the output does not affect
the action of the system control functions.
This system can be represented by the block diagram in Figure 2.6 below.
Reference
Input
controller
Actuator
The
Controlle
d system
Output
signal
Figure 2.6 : Block diagram of the open-loop control system
OR
Open loop systems are systems in which the output of a system is not used as a variable
to control the system.
Open loop control systems use the input variables to calculate the output based on the
"open loop transfer function" of the system. The output is not fedback to modify the controlled
output. There are many reasons to use open loop control such as simplifying the control system,
quicker response of the system, to reduce the possiblility of oscillation and sometimes to lower
cost.
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OR
An open-loop system, also known as an open-loop controller or a non-feedback
controller, is a kind of system that bases the input or start of the system without taking into
consideration outside factors directly caused by the system itself. In other words, the feedback
caused by the system does not factor into the decision of whether or not the system runs.
Example 1
One example of an open-loop system is a sprinkler system that turns on every day at a
pre-programmed time. No matter the moisture level of the grass, the sprinkler system
will continue to water it at a prescribed time. (For example, even if there was a heavy rain
and the sprinklers do not need to be turned on, they will still water at their preprogrammed time.) That is an open-loop because the sprinklers will turn on no matter
the feedback (in this case, the grass moisture). However, if someone were to install a
moisture detector where the sprinklers only turn on once it reaches a certain point, then
the entire system turns into a closed-loop system.
Example 2
The system is controlled by a timer (timer) are typically open-loop system, such as street lighting.
These lamps will be lit at a certain time (at night) and then goes off the next day (daytime). The
time between light and time off has been set by the timer (timer)
controller
actuator
Reference input
Fixed time
Timer
Relay
Lampu
The controlled
output/system
Output signal
Lamp ON @ OFF
Block diagram of street lighting (open loop)
Drawbacks
Drawbacks of the open-loop system is the possibility of waste, due to the process running
when it might not have to, and the fact that the process does not learn from feedback
and become more efficient.
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2.7 Close Loop System
Closed-loop control system, also known as feedback control systems. Output of this system will
affect the action of the system control functions.
This is a system where the feedback of the process determines the next part of the process. For
example, if there is a light that turns on in a room if motion is detected in the room, then that is
a closed-loop system since the process of turning on the light entirely depends on feedback, in
this case the introduction of motion.
The system can be represented by the block diagram in Figure 2.7 below
comparator
Reference
input
controller
actuator
The
controlled
system
Output
signal
Measurement devices
Block diagram of the close-loop control system
In a closed-loop control system the controlled variable (actual value) will be measured,
compared with the set point and fed back. So a closed loop arises. The feedback is an essential
attribute of a closed-loop control system. A control system consists of the following components.
Point with your mouse on the blocks in the block diagram and identify the elements in the
scheme below.
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EXAMPLE : STREETT LIGHTING

The system uses sensors (sensor) as input elements are usually closed-loop system. These lamps
will turn on and off automatically when the sensor detects the brightness of light, regardless of
the particular period. At night /dark place, street lights will on. This situation did not occur in
open-loop control system
Reference
Input
The control
system
controller
Light
intensity
controller
Output signal
actuator
relays
lamp
Light
intensity
Measurement devices
Light sensors
Block diagram of closed loop system street lighting

Figure 8 shows basic elements of a feedback control system as represented by a block diagram.
The functional relationships between these elements are easily seen. An important factor to
remember is that the block diagram represents flowpaths of control signals, but does not
represent flow of energy through the system or process.
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Below are several terms associated with the closed-loop block diagram.
The plant is the system or process through which a particular quantity or condition is controlled.
This is also called the controlled system.
The control elements are components needed to generate the appropriate control signal applied
to the plant. These elements are also called the controller.
The feedback elements are components needed to identify the functional relationship between
the feedback signal and the controlled output.
The reference point is an external signal applied to the summing point of the control system to
cause the plant to produce a specified action. This signal represents the desired value of a
controlled variable and is also called the setpoint.
The controlled output is the quantity or condition of the plant which is controlled. This signal
represents the controlled variable.
The feedback signal is a function of the output signal. It is sent to the summing point and
algebraically added to the reference input signal to obtain the actuating signal.
The actuating signal represents the control action of the control loop and is equal to the
algebraic sum of the reference input signal and feedback signal. This is also called the error
signal.
The manipulated variable is the variable of the process acted upon to maintain the plant output
(controlled variable) at the desired value.
The disturbance is an undesirable input signal that upsets the value of the controlled output of
the plant.
2.8
COMPUTERISED CONTROL SYSTEM

Computerized control system is a control system that uses a computer as a controller.
This system can be represented by the block diagram such as Figure 2.8 below
.
Reference
input
COMPUTER
the
controlled
system
controller
actuator
Output
signal
Measurement element
Computerized control system block diagram
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2.9
COMPARISON OPEN LOOP SYSTEM WITH CLOSE LOOP SYSTEM

Open Loop System
The construction is simple.
Accuracy depends on the calibration
elements.
Not so experienced instability problems.
Not able to mitigate the effects of
nonlinearity.
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Closed Loop System

The construction is complicated.
The system is very accurate.
Has the problem of instability.
The effect of nonlinearity can be
reduced
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CHAPTER 2:
INTRODUCTION TO PLC
Objectives:
At the end of this lecture the students should be able to:
1. Describe a PLC and its functions
2. Explain the history of PLC development
3. Identify the mains part of PLC and describe the functions.
4. List the types and advantages of PLC
2.0
INTRODUCTION
In this chapter , we will discussed about PLC in detail:
2.1 Definition of PLC
2.2 Define PLC Terminologies
2.3 Background PLC
2.3 The function of PLC and Types of Construction
2.4 Advantages of PLCs
2.1
Definition of PLC
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.
OR
A device that is pre-programmed to accept relay ladder logic instructions and perform these
instructions to control the equipment operation.
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2.2
PLC Terminologies
Sensors:
switches, flow, level, pressure, temp. transmitters, etc.
Output Devices/Actuators:
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motors, valves, solenoids, lamps, or audible devices
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CPU - Central Processing Unit.
The CPU is a microprocessor that co-ordinates the activities of the PLC system. Its executes the
program, processes I/O signals & communicates with external devices
Ladder Diagram Ladder diagrams are specialized schematics commonly used to document industrial control logic
systems. They are called "ladder" diagrams because they resemble a ladder, with two vertical
rails (supply power) and as many "rungs" (horizontal lines) as there are control circuits to
represent built from relays, is being simulated
2.2
Background of PLC
Among the factors that create the initial design and development of control systems that can be
controlled are as follows:
i.
ii.
iii.
Requirements of a low cost

Intelligent system
The Controller that is easy to control
The first PLC was designed by a team of engineers at the company General Motors (GM), the
United States in 1968 when the company is looking for other methods to replace the complex
system of relays. They also set the specifications of the new control system must meet the
following requirements:
i. Easily programmed
ii. There is no need for rewiring if there are changes on the program
iii. Smaller, cheaper and higher reliability.
iv. Simple building construction and the maintenance cost is cheap.
v. Cost competitive
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2.3 Functions And Type Of Construction
2.3.1
Function of PLC
PLC can perform various functions, such as follows :

Type of control
Sequence Control
Function
1. Successor Control Relay - conventional logic
2. Timer/counter
3. Substitute PCB Control card
4. Machine and Process Controller for Automatic, Semiauto and manual
Advanced Control
1.
2.
3.
4.
5.
6.
Supervision control
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Solve Mathematics of Operations

(+, , , x)
Managing Information
Analog control (temperature, pressure, etc..)
Servo Motor Control
Stepper motor control
control P.I.D (Propotional - Integral - derivation)
1. Process Display and Alarm

2. Diagnosis and Display Fault
3. Interface with Computer
(RS 232C / RS 422)
4. Interface Printer / ASCII
5. Factory Automation Network
6. Local Area Network (LAN)
7. Widespread Area Network (WAN)
8. Factory Automation (FA),Flexible Manufacturing
System (FMS), Computer Integrated Manufacturing
(CIM) etc..
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2.3.2 Type of PLC Construction
PLC types are based on their size and features . The PLC size and feature are depends on
Manufacturer specification. PLC types are:
a)
b)
c)
Compact - Pico or Nano, Micro or Mini

Modular or Rack
Plug In Cards
a) Pico or Nano is the smallest PLC in then world. Example: Omron Zen and Siemens LOGO
b) Micro or Mini PLC- Smaller Size and highly integrated for discrete and analog application in
control. Example: OMRON CP, Mitsubishi FX and Siemen S5 Series
c) Interchangeable modules and highly integrated for discrete and analog application in
control. Can be expanded flexibly at any time via pluggable I/O, functional and
communications modules, providing tailored solutions for our requirements whenever
required. A wide range of performance, scope and interface options depending on our
application.
Figure 2.3.2 shows the types of PLC construction in the market today.
1. Compact Types
Built-in Input/output terminal

Up to 60 I/O point
provide economical solutions to basic control needs for simple machine such as conveyor
automation, security systems, and building and parking lot lighting
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2. Modular Types
Built-in Input/output terminal

and network option
Up to192 I/O point
Modular PLC's are the systems that can be changed easily and simply.
it can be adapted and changed to serve different purposes
Modular PLC's are very practical machines in the fact they can be multi-functional
3. Plug and play/ rack mounted PLC
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The rack mounted PLC is mounted on racks as seen by the diagram.

The most practical of all three as they make the multi-adaptive features
and able to fit out of the way in small places.
This is ideal for industry where space can be vital.
But it is more expensive
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2.4. Advantages of PLC are as follows:
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The implementation of a short control projects.

Program can be change easily.
Accurate calculation of the cost project.
Requires a short training time.
Flexible control system design using the software.
A wide range of control applications.
Easy maintenance.
High reliability
A standard Hardware controller
Resistance to the problems of the environment (temperature, moisture,
voltage instability and noise) is good.
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CHAPTER 3
PLC HARDWARE DESIGN
Objectives:
After completed this chapter, the student will know the major components of a PLC and the
functions of these components.
3.0 Introduction:
The PLC, being a microprocessor based device, has a similar internal structure to many
embedded controllers and computers. A PLC consist of the following components:
i.
ii.
iii.
iv.
v.
CPU,
Memory
Input modules
Output modules
Power supply.
These components are integral to the PLC controller. Additionally the PLC has a connection for
the Programming and Monitoring Unit, Printer and Program Recorder.
3.1 Hardware Design of PLC

DATA BUS
RAM
Microprocessor
ROM
Operation
system
( CPU )
Programming
Data
Input
Unit/
Module
Output
Unit/
Module
Output
Unit
ADDRESS BUS
CONTROLLED BUS
a) Design Of A Basic Microcomputer

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b) PLC Hardware Block Diagram

3.1.1 Explanation of the PLC Block Diagram
The programming terminal in the diagram (b) is not part of the PLC, but it is essential to have a
terminal for programming or monitoring a PLC. In the diagram , the arrows between blocks
indicate the information and power flowing directions.
a) Central Processing Unit - CPU
This unit is the most important unit in the building of a PLC , which is the brain of a PLC.
In this unit lies a chip of microprocessor - intergrated circuit chips which controls the overall
operation of the PLC control system. Microprocessors contain arithmatic unit, control unit and a
number of memory units, known as registrars.
The main function of the microprocessor is to analyze data coming from field sensors through
input modules, make decisions based on the users defined control program and return signal
back through output modules to the field output devices.
In detail, the CPU of a PLC does the following operation:
Updating inputs and outputs. This function allows a OLC to read the status of its input
terminals and energize or deenergize its output terminals.
Performing logic and arithmetic operations. A CPU conducts all the mathematic and logic
operations involved in a PLC.
Communicating with memory. The PLC programs and data are stored in memory. When a
PLC operating, its CPU may read or change the contents of memory locations.
Scanning application programs. An application program , which is called a ladder logic
program , is a set of instructions written by a PLC programmer. The scanning function
allows the PLC to execute the application program as specified by the programmer.
Communicating with a programming terminal. The CPU transfers program and data
between itself and the programming terminal.
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b) Memory Unit
Memory is the component that stores information, programs and data in a PLC. The process
of putting new information into a memory location is called writing. The process of
retrieving information from a memory location is called reading.
Above figure shows the memory unit in the internal design of PLCs. This unit contains two
(2) types of memory:
i.
RAM (Random Access Memory)

RAM is the memory type of read / write and easy to program and repaired.
All users program are stored in this memory. Read indicates that the information
stored in the memory can be retrieved or read, while write indicates that the user can
program or write information into the memory. The data in the RAM would normally
be lost if the power source is removed. This problem is solved by backing up the RAM
with the battery
ii.
ROM (Read Only Memory)

ROM is read-only memory types. Read Only indicates that the information stored in
memory can be read only and cannot be changed. Information in ROM is placed
there by the manufacturer for the internal use and operation of the PLC. The system
program is stored in this memory. This program will not be lost when the power is
disconnected. Special equipment is used to delete the program from this memory
The memory capacities of PLCs vary.

c)
System Busses
The internal paths along which the digital signals flow within the PLC are called
busses. The system has four busses:
- The CPU uses the data bus for sending data between the different elements,
- The address bus to send the addresses of locations for accessing stored data,
- The control bus for signals relating to internal control actions,
- The system bus is used for communications between the I/O ports and the I/O unit.
d)
Display and Indicators Unit
Display and the indicator unit refers to the internal relay PLC status display. This can be seen in
the Console programming if the user using the mnemonic code and programming computer
screen if the user using software programming methods.
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e)
Input And Output Unit /Module
Referring to above figure, the input and output units are the units available in the internal design
of PLCs.
The Input/Output units are the interfaces between the internal PLC systems and the external
processes/ field devices to be monitored and controlled. Input Unit is the unit which input
devices (switches, sensors) are connected to it. While the output unit is a unit which output
devices (Lights, motors) are connected to it.
The main purpose of the I/O interface is to condition the various signals received from or sent
to the external input and output devices. Input modules converts signals from discrete or
analog input devices to logic levels acceptable to PLCs processor. Output modules converts
signal from the processor to levels capable of driving the connected discrete or analog output
devices.
Since the PLC is a logic based device with a typical operating voltage of 5 volts and the external
processes usually demand higher powers and currents, the I/O modules are optically or
otherwise isolated. The typical I/O operating voltages are 5V - 240 V dc (or ac) and currents from
0.1A up to several amperes. The I/O modules are designed in this way to minimize or eliminate
the need for any intermediate circuitry between the PLC and the process to be controlled.
Small PLC units would have around 40 I/O connections with larger ones having more than 128
with either local or remote connections and extensive upgrade capabilities.
3.2
Function And Operation Of The Following Hardware Units
3.2.1 Housing Unit

This unit provides protection to the circuits and components - the internal components of a PLC.
3.2.2 Programming Unit
Programming units are essential components of the PLC systems. Since they are used only in the
development/testing stage of a PLC program, they are not permanently attached to the PLC. The
program in a ladder diagram or other form can be designed and usually tested before
downloading to the PLC. The Programming unit can be a dedicated device or a personal
computer. It allows the graphical display of the program (ladder diagram). The unit, once
connected to the PLC can download the program and allows for the real time monitoring of its
operation to assist debugging. Once the program is found to operate as required the
Programming Unit is disconnected from the PLC which continues the operation
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3.2.3 Program Loader Unit
Is used to enter the desired program into the memory of the processor. Program is entered using
relay ladder logic (most popular programming language used by all major manufacturers of
PLCs). Program loader can be a computer or a console (handheld type). All leading brands of
PLCs have software available so that a PC can be used as the programming device.
3.2.4 Secondary Storage Unit
This unit is related to the Central Processing Unit where all the programs and information stored
3.2.5 VDU (Video Display Unit)
Information processing unit operations and the system status will be displayed by the PLC
3.2.6 Power Supply Unit
This unit provides power to the Central Processing Unit, Input Unit and Output Unit. PLCs are
powered by standard commercial Ac power lines. However , many PLC components such as CPU
and memory, utilize 5 volts or another level of DC power. The PLC power supply converts Ac
power into Dc power to support those components of the PLC.
3.2.7 Printers
This unit is used to print the program a system controlled by a PLC control either graphics or
text.
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Tutorial :
ANSWER ALL THESE QUESTIONS
1.1 State THREE (3) units available in the microprocessor.
1.2 Explain the difference between RAM and ROM memory.
1.3 What do you understand about the Input Unit and Output Unit
1.4 Explain the functions of the printer unit.
QUESTION
a. State TWO (2) information contained in the definition of PLC by NEMA.

b. List Five (5) tasks can be done by the PLC in the control of advanced types.
c. List Five (5) the reason why the factory used the PLC as a controller process automation
control system.
d. Briefly explain any three (3) the units of the PLC hardware
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CHAPTER 4
PROGRAMMING
Main Objective:
Provide an overview of PLC programming method using programming languages commonly
used.
Specific Objectives:
After completed this chapter, student will know the major component
1. Familiarise with the PLC Programming system
2. Able to explain PLC programming method using Ladder Diagram and mnemonic
code., Instruction set and logic function.
3. Understand and use Ladder Diagram and mnemonic code to solve control systems
circuits.
4. Explain the following logic instruction set: Load. Load Not, Out, And, And Not, Or, Or
Not, And Ld and Or Ld.
5. Explain sequential instruction set: No Operation, End, Interlock, Jump, Keep,
Set/Reset and Differential Up/Down.
6. Explain the timer and Counter instruction set and execute timer/counter application
solution methods.
4.0
Introduction
PLC programming process is to plan activities such as design and write a program to perform the
required tasks.Here are the parts that should be there in a PLC program.
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Start
Starting an operation
Operating Mode
Determining the origin of the device input / output and

also the starting point
The Reset
Controlling the operation of start / stop it manually or

automatically in the program
Operations / Ordering
Process
Program design as required by the task
Signal Output
Trigger output devices.
Status Output
Display indicator light or alarm.
End
Stop the process./operation
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4.1
Programming Language
IEC 1131-3 is the international standard for programmable controller programming languages.
The following is a list of programming languages specified by this standard:
i.
Ladder Diagram (LD)
ii.
Instruction List (IL)
iii.
Structured Text (ST)
iv.
Sequential Function Chart (SFC)
v.
Function Block Diagram (FBD)
One of the primary benefits of the standard is that it allows multiple languages to be used within
the same programmable controller. This allows the program developer to select the language
best suited to each particular task.
i.
Ladder Diagram
Ladder Diagram is kind of graphical programming language that changed the relay control wiring
circuit diagram. Ladder Diagram contains tracks from left to right contact diagram (see Figure
below). This platform is connected to contact elements available normally open - NO or available
Normally closed - NC through the current path and loop elements.
Ladder diagram also shows the control circuit and the display function and a combination of the
sequence of operations for each branch of the horizontal lines separately.
+ve
INPUT CONDITION
NO
OUTPUT ACTION
-ve
NC
Ladder Diagram
Mnemonic Instruction
There are other methods to program PLCs. One of the earliest techniques involved mnemonic
instructions. These instructions can be derived directly from the ladder logic diagrams and
entered into the PLC through a simple programming terminal.
ii.
Instruction List
This low-level language is similar to Assembly language and is useful in cases where small
functions are repeated often. Although it is powerful, it is considered to be difficult to learn.
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Example
Calculate new weight by subtracting tare weight from net weight.
LD weigh_command
JMPC WEIGH_NOW
ST ENO
RET
WEIGH_NOW: LD gross_weight
SUB tare_weight
iii.
Structured Text
Structured Text (ST) is a high level textual language that is a Pascal like language. It is very
flexible and intuitive for writing control algorithms.
Structured Text uses operators such as logical branching, multiple branching, and loops. People
trained in computer programming languages often find it the easiest language to use for
programming control logic. When symbolic addressing is used, ST programs resemble sentences,
making it highly intelligible to beginner users as well.
ST is ideal for tasks requiring complex math, algorithms or decision-making. Its concise format
allows a large algorithm to be displayed on a single.
Benefits of Structured Text
People trained in computer languages can easily program control logic
Symbols make the programs easy to understand
Programs can be created in any text editor
Runs as fast as ladder
Example 1
We have Motor that will be controlled manually by 2 push buttons (Start Push Button, and Stop Push Button).
When the Start Push Button is pushed then the Motor will be turned ON. and when the Stop Push Button is
Pushed then we want to stop the Motor. (Security logic has been taken off this logic, for the purpose of
domonstration.)
IF StartPb THEN
Motor := 1;
END_IF;
IF StopPb THEN
Motor := 0;
END_IF;
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iv.
Sequential Function Chart
These are similar to flowcharts, but much more powerful. This method is much different from
flowcharts because it does not have to follow a single path through the flowchart.
SFC programming offers a graphical method of organizing the program. The three main
components of an SFC are steps, actions and transitions. Steps are merely chunks of logic, i.e., a
unit of programming logic that accomplishes a particular control task. Actions are the individual
aspects of that task. Transitions are the mechanisms used to move from one task to another.
Control logic for each Step, Action and Transition is programmed in one of the other languages
such as Ladder Diagram or Structured Text.
Is a kind of graphic language (see Figure 4.1.4). Elements are the steps, transitions, choice and
parallel branch. Each step shows the status of the control program processes the active or
inactive. One step consists of action based on the transition. The action consists of the sequence
structure itself.
MOTOR (Start)
Step 1
Transition 1
Step 2
Action
MOTOR (Stop)
Transition 2
Step 3
Sample Program In Sequencial Function Chart Language
v.
Function Block Diagram
Like SFC, FBD is a graphical language that allows programming in other languages (ladder,
instruction list, or structured text) to be nested within the FBD. In FBD, program elements
appear as blocks which are "wired" together in a manner resembling a circuit diagram. FBD is
most useful in those applications involving a high degree of information/data flow between
control components, such as process control.
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4.1.1 Basic Ladder Diagram
A ladder diagram consists of a vertical line on the left and right are called bus bars and
horizontal lines to the right, called the instruction lines.
Along the lines of command are logical combinations of conditions (conditions) that will
determine when and how the instructions on the right at all to be implemented.
Based on the picture above, one should note that a ladder diagram consists of two basic parts:
left section also called conditional, and a right section which has instructions. When a condition
is fulfilled, instruction is executed.
Example Ladder Diagram as shown in figure below .

00000
00002
00005
00001
00003
00004
instruction
00006
00007
00007
00007
Sample Ladder Diagram
The pairs of vertical lines along the branch line is called the conditions. These conditions consist
of two, namely:
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i. Normally open condition (NO)
ii. Normally closed condition (NC)
The numbers in each case to determine the bit operations per instruction. Each command in
ladder diagram either ON or OFF depending on the status of specified bit operations.
Notes:
Normally open condition is ON if the bit operation is ON and will be OFF if the bit operation is OFF .
Normally closed condition is ON if the bit operation is OFF and will be OFF if bit operation is ON.
00000
Instruction
n
Normally Open
Instruction executed when

the IR bit 00000 is ON
00000
Instruction
n
Normally Closed
Instruction executed when

the IR bit 00000 is OFF
Example of Ladder Diagram
4.2
Basic Terms
4.2.1 Execution Conditions

Logical combination of the ON and OFF states gathered to establish an instruction to be
implemented. This condition is called Execution Condition. Refer to figure below.
0000
0
00001
00002
instruction
Examples of Execution Conditions
Instructions will be in the Execution Conditions ON when IR 00000 is ON, IR 00001 is OFF and IR
00002 is ON.
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4.2.2 Operand Bits
Bit operations for each instruction can consist of any of the bits in the memory area IR, SR, HR,
TC or TR. This means that the conditions in Ladder Diagram can be determined by the bit I / O,
flags , work bits , timer / counters and others.
Table 4.3.2 shows the memory map refers to the PLC type SYSMAC OMRON-CQM1H.
DATA AREA
Input
Area
BIT
IR00000 IR01515
FUNCTION
Used as the input bit
Output
Area
Work
Area
IR10000
IR11515
IR21600
IR21915
used as output bits.
SR Area
SR24400
SR25507
This bit use to do certain

functions, such as flags
(flags) and control bits.
TR Area
TR 0 TR 7
This bit is used to

temporarily store the status
ON / OFF on the branches
of the program
HR Area
HR 0000 HR
9915
This bits used to store data

and maintain the status ON
/ OFF when the power is
off.
IR Area
Bit has no function

specifically. Can be used
freely in the program
Timer/Counter Area TC 000 TC 511 The same number used for

the timer and counter. Use
for TC000 to TC002.
`interval timer '
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4.2.3 Logic Block
The respond to an instruction is determined by the relationship between the conditions on the
instruction line that connects them. Any group of conditions that formed to produce a logical
result is called a logical block. Refer to Figure 4.3.3.
00000
00002
instruction
0000
1
0000
3
Example Logic Block

4.2.4 Instruction Block
A block of instruction is composed of all the instructions contained in a block. Block is obtained
by drawing a horizontal line without cutting a vertical line and vice versa. Refer to Figure 4.3.3.
4.2.5 Mnemonic Code

Ladder diagram can not be read by the Programming Console. Thus the ladder diagram should
be changed to mnemonic code. Mnemonic code provides the same information as ladder
diagram and can be typed directly on Programming Console.
ADDRESS
00000
00001
00002
00003
00004
00005
INSTRUCTION
LD
OR
AND
AND LD
OUT
TIM
00006
CNT
00007
FUN 01
OPERASI / DATA
00000
00001
00003
10000
000
#0050
002
#0010
Example Mnemonic Code
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ANSWER ALL THESE QUESTIONS
1.
2.
What do you understand about Ladder Diagram and draw one (1) example of a
Ladder Diagram.
Explain the purpose of the following terms:
i. The logic blocks
ii. The Instruction block
Reference;
1. http://www.kronotech.com/ST/st.htm
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BASIC INSTRUCTIONS SET

OBJECTIVE:
Describe the set of instructions used in PLC programming
SPECIFIC OBJECTIVES:
At the end of this unit student should be able to:
i.
ii.
iii.
Know the functions of the instruction LOAD, LOAD NOT, OUT, AND, AND NOT,
OR, NOT and OR END
Know the function block instruction AND LD and OR LD.
Convert Ladder diagram to Mnemonic Code.
NOTE: These instructions will be explained later is based on OMRON PLC brands
SYSMAC CQM1H
5.0
Introduction
There are a lot of instructions used to develop the PLC program. Each instruction has a
respective function.
5.1
LD -
LOAD Instruction
These instructions are use to start a line of the program.

It is used in the first contacts in the normally open condition (NO).
Ladder Diagram
Mnemonic Code
00000
instruction
Address
Instruction
Operand/Data
00000
LD
00000
00001
instruction
Explanation:
The Execution Conditions of the instruction on the right will be ON when IR 00000 is ON.
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5.2
LD NOT - LOAD NOT Instruction

These instructions are use to start a line of the program.
It is used in the first contacts in the normally closed condition (NC).
Ladder Diagram
Mnemonic Code
Address Instruction Operand/Data
00000
instruction
n
00000
LD NOT
00001
instruction
00000
Explanation
The Execution Conditions of the instruction on the right will be ON when IR 00000 is OFF
5.3
AND - AND Instruction

These instructions are used in the second contact in a normally open (NO) and a
series with previous contacts
Ladder Diagram
Mnemonic Code
00000
00001
instruction
n
00000
LD
00000
00001
AND
00001
00002
instruction
Explanation
The Execution Conditions of the instruction on the right will be ON when IR 00000 and IR 00001
are ON
5.4
AND NOT - AND NOT Instruction
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These instructions are used in the second contact in a normally closed (NC) and in series
with previous contacts
Ladder Diagram
Mnemonic Code
00000
00001
instruction
n
Address
Instruction
Operand/
Data
00000
LD
00000
00001
AND NOT
00001
00002
instruction
Explanation
The Execution Conditions of the instruction on the right will be ON when IR 00000 ON and IR
00001 are OFF.
5.5
OR - OR Instruction
These instructions are used in the second contact in a normally open (NO) and in
line (parallel) with previous contacts.
.
Ladder Diagram
Mnemonic Code
00000

instruction
n
00001
00000
LD
00000
00001
OR
00001
00002
instruction
Explanation
The Execution Conditions of the instruction on the right will be ON when either IR 00000 or IR
00001 are ON.
5.6
OR NOT - OR NOT Instruction
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These instructions are used in the second contact in a normally closed (NC) and in
line (parallel) with previous contacts
Ladder Diagram
Mnemonic Code
00000
instruction
n
0000
1
00000
LD
00000
00001
OR NOT
00001
00002
instruction
Explanation
The Execution Conditions of the instruction on the right will be ON when either IR 00000 is ON
or IR 00001 is OFF or IR 00000 ON, IR 00001 OFF simultaneously
5.7
OUT - OUTPUT Instruction
These instructions are used for the coil output.

Ladder Diagram
Mnemonic Code
10000
00000
5.8
Address
Instruction
Operand/
Data
00000
LD
00000
00001
OUT
10000
IR 10000 will ON when IR 00000 is ON .
END
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END instruction has no physical contact device.

It is the last instruction required for completion of a program.
If no END instruction, the program cannot be implemented
Mnemonic Code
Ladder Diagram
00000
00001
1000
0
END
Address
Instruction
Operand/
Data
00000
LD
00000
00001
AND NOT
00001
00002
OUT
10000
00003
FUN 01
For PLC type OMRON - SYSMAC CQM1H, the instruction FUN 01 is the END instruction.
5.9
OR LD - BLOCK LOGIC OR Instruction

The OR LD instruction has no physical contact device.
Only a programming tool for solving complex OR function as a series of contacts LD (or LD
NOT), in parallel with a series of other contacts.
Mnemonic Code
Ladder Diagram
00000
00001
00002
00003
1000
0
END
5.10
Address
Instruction
Operand/Data
00000
LD
00000
00001
AND
00001
00002
LD
00002
00003
AND
00003
00004
OR LD
00005
OUT
00006
FUN 01
10000
AND LD - BLOCK LOGIC AND Instruction
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The AND LD no physical contact device.
Only a programming tool for solving complex functions such as AND connects a
number of OR, OR NOT, OR LD in the series.
Ladder Diagram
00000
00001
00002
00001
00003
END
5.11
Mnemonic Code
10000
Address
Instruction
Operand/
Data
00000
LD
00000
00001
OR
00002
00002
LD
00001
00003
OR
00003
00004
AND LD
00005
OUT
00006
FUN 01
10000
OR LD and AND LD
When both logic block instruction is to be used in Ladder Diagram, a program must be
written from the bottom up to merge logic blocks. For example, ladder diagram below:
Logic block of instruction for the last two blocks (blocks b1 and b2 blocks) are written
first and then followed by the first logic block instruction (block a).
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Ladder Diagram
Block b1
00000
00001
00002
00003
00004
00005
1000
0
Block b2
Block a
END
Mnemonic Code
Address
Instruction
Operand/Data
00000
LD NOT
00000
00001
AND
00001
00002
LD
00002
00003
AND NOT
00003
00004
LD NOT
00004
00005
AND
00005
00006
OR LD
00007
AND LD
00008
OUT
00009
FUN 01
Block a
Block b1
Block b2
Block b2 + Block b1 = Block b
Block b, Block a
10000
Example.
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SEQUENTIAL INSTRUCTION SET

Objective
Describe the sequence instruction set NO OPERATION, END, INTERLOCK, JUMP, KEEP, SET /
RESET and DIFFERENTIATE UP / DOWN
Specific Objectives:
At the end of this unit you should be able to understand set of instructions the following
sequence:
NO OPERATION
END
INTERLOCK
6.0
JUMP
KEEP
SET/RESET
DIFFERENTIATE UP / DOWN
Introduction
In this unit you will be exposed to a sequence of instructions which usually acts as the last
instruction in the instruction line.
Instruction sequence SET, RESET, KEEP, DIFFERENTIATE UP, DOWN DIFFERENTIATE, used to ON
and OFF state output bits in the IR. These instructions are used to control the status of the other
bits in the IR or in other areas.
INTERLOCK instruction sequences can overcome the problem of storing execution conditions, in
the branches of the ladder diagram.
JUMP instruction sequence can be used to control devices that require a product that can last a
long time.
6.1
NO OPERATION NOP ( 00 )
These instructions do not have a ladder diagram symbols and will not do any operations.
When you remove the memory in this instruction will be displayed on the console screen PLC
programming.
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6.2
END END(01)
Acting as the last instruction for each program (see figure 6.2)
There is no instruction will be written after the END instruction (01) implemented.
If there is no END instruction (01) in the program, the task would not be implemented
and verse NO END LIST is displayed on the programming PLC console screen.
10000
0000
0
END
Ladder Diagram shows the END instruction
Mnemonic Code
6.3
Address
Instruction
00000
LD NOT
00000
00001
OUT
10000
00002
FUN(01)
Operand/Data
INTERLOCK [ IL ( 02 ) ] DAN INTERLOCK CLEAR [ ILC ( 03 ) ]

IL (02) and ILC (03) must be used together.
These instructions are used to solve the problem of storing execution conditions at
branch points.
When the INTERLOCK instruction is ON as shown in Ladder Diagram 6.3, the
implementation of the INTERLOCK instruction will control all of the instruction execution
until the instruction INTERLOCK CLEAR. When the INTERLOCK instruction is OFF,
INTERLOCK CLEAR instruction will reset the program operation.
To set the INTERLOCK instruction for PLC tpe OMRON - SYSMAC CQM1H is FUN 02 for
INTERLOCK instruction and FUN 03 is INTERLOCK CLEAR instruction.
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00000
IL (02)
00001
10000
ILC (03)
END
Figure 6.3 : Ladder Diagram shows IL ( 02 ) dan ILC ( 03 ) instruction
Mnemonic Code
Address
00000
00001
00002
00003
00004
00005
Instruction
LD
FUN 02
LD
OUT
FUN 03
FUN 01
Operand/Data
00000
00001
10000
-
Referring to Ladder Diagram 6.3,

When the instruction input LD 00 000 is ON, the instruction IL (02) will be ON.
Instruction output OUT 10 000 will depend on the instruction input ON LD 00001 and LD
00000.
If the input instruction LD 00 001 ON, output OUT 10000 will be ON.
If the input instruction LD 00 001 OFF, output OUT 10000 will be OFF.
In the event that the input instructions LD 00 000 OFF, instruction IL (02) is OFF.
Instructions to the output OUT 10 000 will be OFF.
Next program ILC (03) will reset the program.
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Refer the table below:
Instructions
LD 00000
IL(02)
Instructions
LD 00001
Input
Instructions
OUT 10000
Output
ON
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
OFF
6.4
JUMP [ JMP (04) ] DAN JUMP END [ JME (05) ]

Instructions JMP (04) is usually used in pairs with the command JME (05) for the jump.
JMP (04) is a command to determine the starting point of the jump and JME (05) is the
instruction that the direction of the jump.( where to jump).
When the instruction JMP (04) is ON, no jump will occur and the program will be
implemented as written.
When the instruction JMP (04) is OFF, a jump to the instruction JME (05) which has the
same number will be done. Further instructions are the instructions JME (05) will be
implemented.
Instructions JUMP and JUMP END can use the numbers from the range of 00 to 99.
To set the instruction for PLC type OMRON - SYSMAC CQM1H, is FUN 04 for JUMP
instruction and FUN 05 instruction is the JUMP END instruction.
00000
JMP (04)
01
00001
10000
JME (05) 01
END
Figure 6.4 : Ladder Diagram shows JUMP instruction
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Mnemonic Code
Address
00000
00001
00002
00003
00004
00005
Instruction
LD
FUN (04)
LD
OUT
FUN (05)
FUN (01)
Operand/Data
00000
01
00001
10000
01
-

When the input instruction LD 00000 is ON, instruction JMP (04) will be ON. Subsequent
instructions will be implemented as written.
If the input instruction LD 00 001 is ON, output instruction OUT 10000 will be ON.
If the input instruction LD 00 001 is OFF, output instruction OUT 10000 will be OFF.
When the input instruction LD 00 000 is OFF, instruction JMP (04) will be OFF. Next jumps
to Instruction JME (05) will occur. All instruction that is between JMP (04) and JME (05) will
be ignored.
Refer to the table below.
Instruction LD 00000
JMP(04)
Input
Instruction OUT 10000

Output
ON
ON
ON
OFF
OFF
Not
implemented/executed
Not implemented/executed
OFF
SARIATI
Page 53

6.5 KEEP KEEP (11)
KEEP instruction is used to maintain the status bit operation based on two state
execution condition.
KEEP (11) operates like a Latching Relay which is set by S and reset by R.
When S is in the ON state, the operation of a particular product instruction is ON and

remain ON until reset, regardless of whether S is ON or OFF.
When R is in the ON state, the operation of a particular product instruction is OFF and
remain OFF until reset, regardless of whether R is ON or OFF.
For PLC type OMRON - SYSMAC CQM1H, the instruction FUN 11 is KEEP instruction.
00002
KEEP (11)
HR 0000
00003
R
10004
HR0000
END
Figure 6.5 : Ladder Diagram shows KEEP instruction
Mnemonic Code
Address
00000
00001
00002
00003
00004
00005
SARIATI
Instruction
LD
LD
FUN (11)
LD
OUT
FUN (01)
Operand / Data
00002
00003
HR 0000
HR 0000
10004
Page 54

With reference to Figure 6.5,
Instruction LD 00 002 acts as S (Set)-and the LD 00 003 acts as R (Reset).
When the instruction LD 00 002 ON, the output instruction OUT 10004 will be ON and
will remain ON even if the instruction LD 00 002 is OFF.
When the instruction LD 00 003 ON, then the output OUT 10004 instruction OFF and will
remain OFF even though the instruction LD 00 002 in OFF or ON state.
Reset
Set
ON
Instruction OUT 10004

Output
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
ON
6.6
SET and RESET

SET and RESET instruction will change the status of bit operations only when the
implementation is ON.
In the OFF condition, the instructions will not change the bit operation status.
00000
SET 10000
00001
RESET 10000
Figure 6.6 : Ladder Diagram shows the Set and Reset instruction
SARIATI
Page 55

Mnemonic Code
Address
00000
00001
00002
00003
Instruction
LD
SET
LD
RESET
Operand / Data
00000
10000
00001
10000

When the input instruction LD 00 000 is ON, SET instruction command to ON and always
ON regardless of whether the input instruction LD 00 000 is ON or OFF.
When the inputs instruction LD 00 001 is ON, RESET instruction is ON and SET instruction
will be off .
Its operations can be understood clearly in the KEEP instruction.
6.7
DIFFERENTIATE UP [ DIFU (13) ] DAN DIFFERENTIATE DOWN [DIFD (14) ]

DIFU instructions (13) and DIFD (14) will ON the output within a very short time.
Instructions DIFU (13) will turn the output to ON when the input signal changes from OFF
to ON.
Instructions DIFD (14) will turn the output to ON when the input signal changes from ON
to OFF.
For PLC type of OMRON - SYSMAC CQM1H, instruction FUN 13 is instruction
DIFFERENTIATE UP and FUN 14 is instruction DIFFERENTIATE DOWN.
Input
DIF U
DIF D
SARIATI
Page 56
00000
DIFU (13)
01OOO
01000
10000
END
Figure 6.7a : Ladder Diagram shows DIFFERENTIATE UP instruction
Mnemonic Code
Address
00000
00001
00002
00003
Instruction
LD
FUN (13)
LD
OUT
Operand / Data
00000
01000
01000
10000
Referring to Ladder Diagram 6.7a,

When the input instruction LD 00000 is ON (has changes from OFF to ON), operand bit 01
000 will be ON, the output OUT 10000 will be ON within a very short time and then OFF.
We can not see the situation in the products.
After that the operand bit 01 000 will be OFF regardless of the status of the input
instruction LD 00 000.
00000
DIFU (14)
01OOO
01000
10000
END
Figure 6.7b : Ladder Diagram shows the DIFFERENTIATE DOWN instruction
SARIATI
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Mnemonic Code
Address
00000
00001
00002
00003
Instruction
LD
FUN (14)
LD
OUT
Operand / Data
00000
01000
01000
10000
Referring to Ladder Diagram 6.7b,

When the input instruction LD 00 000 is OFF (change from ON to OFF), operand bit 01000
will be ON, the output OUT 10000 will be ON within a very short time and then OFF. We
can not see the situation in the products.
After that the operand bit 01000 will be OFF regardless of the status of the input
instruction LD 00 000.
SARIATI
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TIMER AND COUNTER

OBJECTIVE:
Describe the instruction set of timer and counter.
SPECIFIC OBJECTIVES:
At the end of this unit you should be able to:
1. Describe the instruction timer (TIMER TIM)
2. Describe the instruction counter (COUNTER - CNT).
3. Converts Ladder Diagram to mnemonic code.
7.0
Instruction
TIMER (TIM) and COUNTER (CNT) is the instructions that require numbers TIM / CNT (N) and the
set value(SV). The range of numbers TIM / CNT is from 000 to 511, while the range of set values
for the TIM / CNT is 0000 to 9999
The numbers TIM / CNT can not be used twice. When a number has been used as definer, such
as number 000 for instructions on TIM / CNT, the number can not be used again.
When a number is defined as the number of TIM / CNT, it can be used as often as required as an
operator operand in other instructions from the command TIMER or COUNTER.
7.1
TIMER - TIM
Symbol
TIM
N
SV
SV and 511.
Timer numbers (N) is between 000
The set value (SV) is between 0000 to 9999.
All numbers TIM / CNT can be used as definer in only one TIMER or COUNTER instruction.
SARIATI
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Example 7.1.1
TIMER is enabled/activated when the execution condition is ON and will be reset to set
value (SV) when the execution condition is OFF.
The set value (SV) of TIMER is the BCD between # 0000 to # 9999. For example, if TIMER
be set to 5 seconds, then the set value (SV) is # 0050.
Ladder Diagram
00000
Tim 000
# 0050
(5 saat)
10000
TIM 000
END
Mnemonic Code
Address
Instruction
Operand/Data
00000
LD
00000
00001
TIM
000
# 0050
00002
LD
TIM 000
00003
OUT
10000
00004
FUN 01
Operating Condition:
When the input (LD 00000) is ON, the timer contact will be activated after 5 seconds. Next the
output (OUT 10000) will be ON
SARIATI
Page 60

Example 7.1.2
Ladder Diagram
Tim 000
00000
#0050
TIM 000
10000
(5 saat)
TIM 000
10001
END
Mnemonic Code
Address
Instruction
Operand/Data
00000
LD
00000
00001
TIM
000
# 0050
00002
LD
TIM 000
00003
OUT
10000
00004
LD NOT
TIM 000
00005
OUT
10001
00006
FUN 01
When the input (LD 00000) ON, the timer (TIM 000) will be activated after 5 seconds and the
output (OUT 10000) will be ON. While the output (OUT 10 001) will be ON as soon as the supply
is supplied and will be OFF after 5 seconds. Timer will continue to be active as long as the input
00000 state is ON.
SARIATI
Page 61
Example 7.1.3
Ladder Diagram
Tim 000
00000
# 0050
TIM 000
TIM 001
(5 saat)10000
10000
Tim 001
# 0030
END
(3 saat)
Mnemonic Code
Address
Instruction
Operand/Data
00000
LD
00000
00001
TIM
000
# 0050
00002
LD
TIM 000
00003
AND NOT
TIM 001
00004
OUT
10000
00005
LD
10000
00006
TIM
001
#0030
SARIATI
00007
OUT
00008
FUN 01
10001
Page 62

When the input (LD 00000) ON, the timer (TIM 000) will be activated after 5 seconds. Next the
output (OUT 10000) will be ON.
After 3 seconds the output (OUT 10000) ON, the timer (TIM 001) will be activated the next
output (OUT 10000) will be OFF and the timer (TIM 001) will be OFF.
When the timer TM001 OFF, contact TIM 001 (NC) will be ON and the output (OUT 10000) is ON
state.
Output (OUT 10000) will continue ON and OFF until the input (LD 00000) in the OFF state.
7.2 COUNTER - CNT

Symbol
CP
CNT
SV
Number TIM / CNT can be used as definer for either timer or counter.
Counter numbers are range from 000 to 511.
Counters are used to calculate the count down from the set value (SV) on the execution
condition on the counting pulse (CP) when it is changed from OFF to ON.
The set value (SV) is range 0000 to 9999.
Counters will reset to the reset (R).
Ladder Diagram
0000
0
0000
1
CNT 001
CP
CNT 001
# 0010
(10 kiraan)
10000
END
SARIATI
Page 63
Mnemonic Code
00000
LD
00000
00001
LD
00001
00002
CNT
000
#0010
00003
LD
CNT 001
00004
OUT
10000
00005
FUN 01
Operating Condition
Counter set to count 10. When the input (LD 00,000) is the pulse of ten, a counter will be
activated and thus the output (OUT 10000) will be ON. When reset (LD 00,001) ON, a counter
will be in original condition
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7.3
The Application Of Timer And Counter Instructions
The number of Counter cannot be the same number to the number of timer because both share
the same data in the PLC memory.
0000
0
0000
1
CP
CNT 000
# 0005
CNT 000
(5
10000
kiraan)
1000
0
TIM 001
# 0050
(10001
5 saat )
TIM 001
END
Counter set to count 5. When the input (LD 00,000) is the pulse of five, a counter will be
activated and thus the output (OUT 10000) will be ON.
When the output (OUT 10000) ON, TIM 001 will be activated after 3 seconds and then the
output (OUT 10 001) will be ON.
Both the output (OUT 10000) and (OUT 10 001) will always be ON until reset (LD 00001) in the
ON state.
Reset will return the counter to its original condition.
SARIATI
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CHAPTER 5
APPLICATIONS OF PLC
OBJECTIVE
Understand how to write programs in a PLC.
Write a program based on the correct format
SPECIFIC OBJECTIVES
At the end of this unit you will learn how to:
Write a program for Conveyor Motor Control
Write a program for packaging control.
Write a program for traffic lights control.
5.0
Introduction
This unit will explain samples of writing a PLC program in the applications of automation control
systems. Therefore, understanding the instructions and format shown in the PLC ladder diagram
program, the code mnemonics, and charts the sequence of functions that have been discussed in
unit 4 is needed to help in reviewing and analyze the examples given program.
5.1 CONVEYOR MOTOR CONTROL

Figure 5.1 shows the PLC is used to start and turn off the motor used in conveyor belt. This
section allows any objects such as metal plate is moved from one part to another. Sensor type
limit switch (sensor - proximity switch) installed in each segment of conveyor belt is required to
detect the presence of the plate, which was move by the belt. Conveyor Motor will work (ON) as
long as the plate is in the range of the sensor set. Conveyor motor will stop if the plate moves
beyond the prescribed range, or the timer will be activated when time expired
SARIATI
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INPUT
DEVICE
OUTPUT
DEVICE
00000
Sensor 1 ( S1 )
10000
Motor 1 ( M1 )
00001
Sensor 2 ( S2 )
10001
Motor 2 ( M2 )
00002
Sensor 3 ( S3 )
10002
Motor 3 ( M3 )
Table 5.1 : Input and Output Devices
Figure 5.1 : Conveyor Motor Control
Conveyor Motor Control Operations

i.
Motor 2 will be ON when the sensor 3 detects the presence of objects.
ii.
Motor 2 will be OFF when the motor 1 is ON and the object was outside the
detection
range of sensor 2.
iii.
Motor 1 will be ON when the sensor 2 detects the presence of objects.
iv.
Motor 1 will be OFF when the object was outside the detection range of sensor 1.
SARIATI
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LADDER DIAGRAM
S3 ( 00002 )
TIM 000
M2
Motor 2
10001
M2 (10001)
S2(00001)
TIM 001
M1
10000
Motor 1
M1( 10000)
M1(10000 )
00001
TIM 000
# 0020
S1(00000)
2 sec
TIM 001
04000
04000
04000
00000
TIM 001
# 0020
2 sec
25313 ( Normally closed )

1000
2
Motor 3
FUN (01)
SARIATI
Page 68

5.2 PACKING LINE CONTROL
Referring to Figure 5.2 and Table 5.2, the box is on the conveyor will move when PB1 is pressed.
Box conveyor will stops and the Apple Conveyor will begin to move when the box is detect.
Sensor part will count for 10 apples then Apple Conveyor motor will stops and Box conveyor
motor starts again. Counter will be reset and operation repeats until PB2 is pressed.
Figure 5.3 : Packing Control

Input
Device
00000
Start Push Button ( PB1 )
00001
Stop Push Button ( PB2 )
00002
Sensor - detect Apples( SE1 )
00003
Sensor detect Box ( SE2 )
Output
Device
10000
Apple Conveyor
10001
Box Conveyor
Table 5.3 : Input Output Table
Ladder Diagram
SARIATI
Page 69
PB1 (00000 )
PB2 (00001)
Start -stop
20000
20000
When a box is
detected, a conveyor
with apples start
moving.
20000
10001
10000
SE1 (00002)
Apples Conveyor
SE2 (00003 ) Box Sensor
CNT 010
CNT 010
20000
10001
Box conveyor
SE2 (00003 )
Box sensor
SARIATI
Counter count to 10
apples through a part
Part
Sensor
sensor
.When the
conveyor with boxes
has been activated ,
limit switch resets the
counter.
Counter activate the
box conveyor and the
limit switch resets the
counter.
END(01)
Page 70

Mnemonic Code.
Address
Instruction
Data
0000
LD
00000
0001
OR
20000
0002
AND NOT
00001
0003
OUT
20000
0004
LD
01000
0005
AND NOT
10001
0006
OUT
10000
0007
LD
00002
0008
LD NOT
00003
0009
CNT
010
#0010
SARIATI
0010
LD CNT
010
0011
OR NOT
00003
0012
AND
20000
0013
OUT
10001
0014
FUN 01
Page 71

5.3 TRAFFIC LIGHT CONTROL
Figure 5.4 shows the control of traffic lights installed on a road that is being repaired. A pair of
opposite traffic lights installed in the two road routes to control traffic congestion. Lighting will
be ON alternately. When traffic lights L1 are green , L2 traffic lights will show red and will be
repeated. Each light is controlled by a timer and will be activated for 30 seconds.
Figure 5.4 : Traffic Light Control

Ladder Diagram
TIM 001
TIM
000 # #0030
TIM 000
TIM
001
# 0030
TIM 000
1000
GREEN 1
1000
1001
RED 1
1001
1002
GREEN 2
1003
RED 2
1002
END(01)
SARIATI
Page 72

Mnemonic Code
Address
Instruction
Data
00000
LD NOT TIM
001
00001
TIM
000
#0030
00002
LD TIM
000
00003
TIM
001
#0030
00004
LD NOT TIM
000
00005
OUT
1000
00006
LD NOT
1000
00007
OUT
1001
00008
LD
1001
00009
OUT
1002
00010
LD NOT
1002
00011
OUT
1003
00012
FUN 01
SIMULATION RESULT:
SARIATI
Page 73

5.5 Control Production Filling
MVI
Figure 5.5 : Production Filling

Figure 5.5 shows the operational control of liquid level in the tank. In this process, two sensors
(TLB1 and TLB2) is used to detect the liquid level into the tank. MVI valve functions as a
controller to the input of the liquid through a pipe and valve MV2 will control the output of
liquid
Operations:
1. When the push-button start (PB1) is pressed, MV1 valve opens and the liquid will flow into
the tank. At the same time, the mill motor start functioning.
2. When the liquid passes to reach TLB1 TLB2, MV1 valve will close and start the mill motor
stops.
3. When PB1 is pressed again, the valve opens and liquid MV2 began to flow out of the tank.
MV2 will close when the liquid level was below the TLB2.
4. Once the process repeated four times, the light guidance levels (PL) will be erased. Filling
process and the production of liquid in the tank will be stopped even if PB1 pressed.
Input
Output
00000 Push Button start (PB1)
10000 Water Supply Valve (MV1)
00001 Push Button Stop (PB2)
10001 Drain Valve (MV2)
00005 Top Level Switch (TLB1)
10002 Mill Motor(M)
00006 Bottom Level Switch (TLB2)
10004 Water Level indicator

10005 - Buzzer
Figure 5.5 : Input Output Table

Ladder Diagram
SARIATI
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Start
00000
10005
10004 00005
10000
10000
MV1
MV1
10000
10000
In
10002
MV1
Mill Motor
10000
MV1
00005
00006
10001
10001
MV2
10001
MV2
TLB1
TLB2
ATAS
BAWAH
MV2
Kelua
ran
CNT 047
Count 4
#0004
Counts
00001
CNT 047
Stop
01000
CNT 047
10004
PL
Indicator
TIM 000
Reset
CNT 047
#0020
TIM 000
10005
BZ
Buzzer
01000
Reset
FUN(01)
Mnemonic Code.
SARIATI
Page 75
SARIATI
Address
Instruction
Data
0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012
0013
0014
0015
LD
OR
AND NOT
AND NOT
AND NOT
OUT
LD
OUT
LD
AND NOT
OR
AND NOT
OUT
LD
LD
CNT
0016
0017
0018
0019
LD
OUT
LD
TIM
0020
0021
0022
0023
0024
LD
OR
AND NOT
OUT
FUN 01
00000
10000
10005
10004
00005
10000
10000
10002
10000
00005
10001
00006
10001
10001
00001
047
#0004
CNT 047
10004
01000
000
#0020
CNT 047
01000
TIM 000
10005
Page 76

5.6 Drilling Motor
In the beginning of the drilling cycle the Upper Limit Switch (0001) is closed
The START button (0000) starts the drilling cycle
The drill motor M1 (0500) must start. At the same time, the vertical motor M2 must start
to descend the drill (0501)
The drill will stop at the Lower Limit Switch (0002).
At this time, the vertical motor start to ascend the drill (0502).
The drill motor must stop just at the upper position.
Wait for a new drilling cycle
Timing Diagram
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Ladder Diagram
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5.7 AUTOMATIC ESCALATORS

Automatic escalators are escalators that will automatically ON when there are people who will
ride it. And will be automatically OFF when in a certain period of time the escalators do not detect
any person who will ride it.
Description:
S1 - Sensor passenger arrival
S2 - Sensor passenger departure
MOTOR - Motor driving escalator
Scenario
If S1 is ON, then the MOTOR ON and OFF Timer1
If S2 is ON, then ON Timer1
If Timer1 is ON, then MOTOR is OFF
SARIATI
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Program
Rung 1. If S1 ON and OFF Timer1, the MOTOR ON. The output value of 010.00 bits (MOTOR) is
used as a lock (bit-locking).
Rung 2. If S2 is ON, then OFF for S1, the condition will Timer1_ON ON. Usage instructions DIFU
(13) serves to indicate that a higher priority than the S2 S1. And the Timer1 must be OFF when
S1 ON. This is to anticipate the possibility ON S2 longer than S1.
Rung 3. During the Timer1_ON = ON, then ON Timer1. If the value is met then Timer1 Timer1
MOTOR will disconnect the circuit so that the escalator will stop running.
SARIATI
Page 80
CHAPTER 6
Selection And Maintenance For Plc
1. Selection Specification/Criteria For Plc
(a)
Input and output capacity

Capacity means the number of terminal connections available on Input Unit and Output
Unit. A user must select the input and output capacity appropriately to make sure
terminal connection is enough. Table shows some values of input and output capacity.
INPUT UNIT
TYPES
DC Input
AC Input
MODEL NO
CAPACITY
CQM1-ID211
8 points
CQM1-ID212
16 points
CQM1-ID213
32 points
CQM1- IA121
8 points
CQM1-IA221
8 points
OUTPUT UNIT
TYPES
MODEL NO
CAPACITY
Relay Output
CQM1-OC211
8 points
Units
CQM1-OC222
16 points
Transistor
CQM1-OD211
8 points
Output Units
CQM1-OD212
16 points
CQM1-OD213
32 points
CQM1-OD214
16 points
CQM1-OD215
8 points
CQM1-OD221
8 points
AC Output Unit
(b)
Input /output types

There is several types of Input and Output for PLC. To control the output devices in
common switching, RELAY Types Output can be use. For fast switching TANSISTOR
Output Types can be use, while for high voltage switching, AC Types Output will be used.
The types of input and output have been described above table.
(c)
Memory size
SARIATI
Page 81
A PLC memory size refers to the ability of program storage space in PLC memory system.
Table 10.2 shows the memory size depending on the CPU type.
No. Model
Saiz Ingatan
CQM1-CPU11-E
3.2 K-word Program Memory
CQM1-CPU21-E
1K-word Data Memory
CQM1-CPU41-E
CQM1-CPU42-E
7.2 K-word Program Memory
CQM1-CPU43-E
6K-word Data Memory
CQM1-CPU44-E
(d)
Programming language types

Each PLC has its own programming language. The most popular is Ladder Diagram
(e)
Future system development

Many industries have implemented automation based control systems such as Flexible
Manufacturing System (FMS) and Computer Integrated Manufacturing (CIM). Selection of
the use of PLC should also look to the future needs of industry to avoid the losses.
(f)
Back up and support system

PLC system needs the back up and support unit system to control the existing process if
there is a failure. Delays in replacing the control system will cause the industry have
suffered a losses.
SARIATI
Page 82

2. Types Of PLC Damages/Failure
(a) Input / output equipment failure (censor and actuator)
From the research that has been made about 60% - 80% damages in the automation control
system usually is caused by input and output devices. The possibility of this damage can be
caused by the following:
Sensor in the cylinder changes from the original position.
Sensor burns caused by exceeded current.
Internal Contactor sensor failure.
Motor or solenoid valve coil burns caused by exceeded current.
(b)
Wiring failure
Conductors in the cable disconnected.
Loosen screw at the input and output terminal
Oxidation of the conductor
(c)
Communication connection breakdown

Conductors in communications cables disconnected.
Pin connections on the terminal bend.
Loose pin connection.
There was noise (interference) in the communications cable caused by the
motor, coil, high voltage, soldering is messy and etc
There was a short circuit between conductors in the cable communications
(d)
Power failure
Power failure occurs in the automation control system when the supply voltage drops
below 85% of the rated values. This condition will cause the PLC to stop immediately
(e)
PLC internal damages

Relay or transistor in the Output terminal is on fire.
Opto-coupler in inputs terminal do not work.
Burning fuses.
Storage battery is weak.
Micro-electronic components (microprocessors, RAM, ROM) burning.
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Page 83

3. PLC Wiring And Installation Consideration
To reduce damage to the automation control system, installation and wiring PLC should give
serious consideration to the following matters:
Avoid the installation of a PLC in a place with the characteristics below.
Exposure directly to the sun.
The ambient temperature exceeds the range of 0 C to 55 C.
Relative humidity exceeds the range of 10% to 90% RH.
Condensation occurs due to temperature changes occur suddenly.
Contains flammable gases and toxic.
Contains water, oil, dirt and chemicals.
Vibration areas such as volcano or construction area.
Put the PLC in the panel / cabinet that has the following characteristics:
Enough space for air circulation.

Cooling fan.
Tools that produce heat is placed under PLCs.
No consists of high voltage equipment.
The power line is place approximately 200 mm from the PLC.
SARIATI
Page 84

3 types of Wiring Method.
1. Handing Duct Method
Input / Output
Line
300 mm minimum
Control cable
And supply line
300 mm minimum
Supply cable
2. Floor Duct Method
Input Output Line

Control cable and supply line
Supply cable
200 mm Minimum
SARIATI
Page 85

3. Conduit Method
Input Output Line
Control cable and Supply line

Supply cable
Wiring Guidelines as follows

Use the cable as short as possible.
Use a single line between the equipment and do not connect the cable to make it
run
Avoid making a sharp fold in the cable.
Keep the space of systems and control line from high power line.
Separate the input, output wiring and other wiring types.
Separate ac and dc wiring.
Establish a good grounding for all components
4. Technique to Overcome Grounding Problem
PLC contains many active components (transistors, circuit integrated chip), where it will burn if
surge voltage resulting from lightning occur. It is therefore necessary to overcome this problem
by using the following guidelines:
Ensure that the protective earth terminal and functional earth ground to the PLC
in the maximum value of 100 .
Make sure the cable is used for grounding at least 2 mm2.
Site grounding and green cable must be terminated at the cable lug. Cable lug
must be in screw and solder.
Paint coatings and corrosion must be removed at the grounding connection.
SARIATI
Page 86
5. Preventive Maintenance
Although the PLC is design at a high level of reliability, but it still can have damages. Therefore,
preventive maintenance is needed. Preventive maintenance measures can be made as follows:
Conduct periodic inspections of screw tightness at input and output terminals.
Ensure that all components are free from dust. Cooling system at the PLC can not be
implemented if there is dust in layers.
The possibility of erosion in some condition. Perform periodic inspection of the possible
erosion of the terminal connection. Printed Circuit Boards and eroded the possibility of
internal connectors.
Keep storage of equipment/spare parts with good care easy to use at the time of the
damage to the components. Users will experience losses if there is no storage of
equipment because they have to wait in a long period to obtain parts.
Keep documentation of program operation and circuit wiring neatly. You may need it in
case of emergencies
SARIATI
Page 87

Tutorial Unit 6
(a)
List FIVE (5) types of PLC failure and provide THREE (3) factors that cause
failure.
(b)
the
Draw a diagram of wiring methods:

i)
Floor Ducts
ii)
Conduit
iii)
Handling Ducts
(c)
State FOUR (4) technical guidelines to overcome PLC grounding system problems.
(d)
List FIVE (5) preventive maintenance for the PLC.
(e)
Explain what will happen if preventive maintenance is not done
(f)
What will happen to PLC if we install at the following area:

- Relative humidity exceeds the range of 10% to 90% RH
- Contain flammable gases and toxic
- Contains water, oil, chemical dust
- Vibration area such as construction area and volcano.
(g)
Explain the differences between Output Relay Types and Output Transistor Types
(h)
Why do we need to know the types of Programming language before to use PLC?
(i)
PLC contains many active components (transistors, circuit integrated chip), where it will
burn if surge voltage occur. The surge voltage occurs because of lightning. Therefore it is
necessary to overcome grounding problem to avoid the burning of the component. States
TWO (2) guidelines how to overcome the grounding problem
References:
1.
2.
Modul E4800 . JPP

http://www.kronotech.com/ST/st.htm
SARIATI
Page 88

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What are the main types of automation discussed?

What are the main types of automation discussed?

What are some objectives of using automation control systems in industry?

What are some objectives of using automation control systems in industry?

PROGRAMMABLE LOGIC

PROGRAMMABLE LOGIC CONTROLLERS

At the end of this chapter, student should be able to:

Define the Automation Control System

PROGRAMMABLE LOGIC CONTROLLERS

1.1 Types of Automation in the industry

This control system is designed to perform a specific task

Programmable /Flexible Automation

1.1.2 Comparison between Fixed and Flexible Automation System

Ease of making changes /

Suitable for small system

PROGRAMMABLE LOGIC CONTROLLERS

PROGRAMMABLE LOGIC CONTROLLERS

a) Pneumatic Control System

to perform any task

Pneumatic systems found in many industrial systems such as food industry,

Basic Block Diagram of Pneumatic Control System using manual/PLC

PROGRAMMABLE LOGIC CONTROLLERS

The fluid used is oil.

Basic block diagram of an automatic hydraulic control system by Manual /PLC

PROGRAMMABLE LOGIC CONTROLLERS

Basic block diagram of a manual electric control system

Basic block diagram of electrical control system using PLC

Comparison between pneumatic control system ,Hydraulic control system and

PNEUMATIC CONTROL SYSTEM

HYDRAULIC CONTROL SYSTEM

ELECTRIC CONTROL SYSTEM

PROGRAMMABLE LOGIC CONTROLLERS

Replacing human operators in tasks that involve hard physical work.

The main disadvantages of automation are:

PROGRAMMABLE LOGIC CONTROLLERS

Circuit symbol for a relay

PROGRAMMABLE LOGIC CONTROLLERS

Relay building diagram

PROGRAMMABLE LOGIC CONTROLLERS

Contactor building diagram

PROGRAMMABLE LOGIC CONTROLLERS

1.2.4 Difference between relay and contactors

PROGRAMMABLE LOGIC CONTROLLERS

A contactor is a relay which is capable of switching large electrical loads.

PROGRAMMABLE LOGIC CONTROLLERS

A control system is an interconnection of components connected or related in such a manner as

Reference signal generator

PROGRAMMABLE LOGIC CONTROLLERS

Open loop system

Figure 2.6 : Block diagram of the open-loop control system

PROGRAMMABLE LOGIC CONTROLLERS

Block diagram of street lighting (open loop)

PROGRAMMABLE LOGIC CONTROLLERS

Block diagram of the close-loop control system

PROGRAMMABLE LOGIC CONTROLLERS

EXAMPLE : STREETT LIGHTING

Block diagram of closed loop system street lighting

PROGRAMMABLE LOGIC CONTROLLERS

COMPUTERISED CONTROL SYSTEM