Experiment 6 Instructor’s Manual

American International University- Bangladesh

Department of Electrical and Electronic Engineering
EEE 4101: Modern Control Systems Laboratory

Title: Introduction to Industrial Programmable Logic Controller: Allen Bradley PLC (Part I)

Abstract:

PLC: A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control

system that continuously monitors the state of input devices and makes decisions based upon a
custom program to control the state of output devices. In this experiment, an introduction
program will be designed using timer.

Introduction:

In industry, many manufacturing processes demand a sequence of operations, which are to be

performed repetitively. Early automation systems were mechanical in design, timing, and
sequencing being affected by gears and cams. Slowly these design concepts were replaced by
electrical drives, which were controlled by relays.
Objectives of this experiment are-

1) Familiarization with Programmable Logic Controllers (PLC).

2) Introduction to Ladder Logic Programming.
3) Introduction to basic programming instructions: Examine ON, Examine OFF, Output
energize, Latch, Master control Reset (MCR)
4) To learn the use of different switches and their applications
5) Learning the use of timer

Theory and Methodology:

Basic PLC Operation:

Fig. 1: Basic PLC Operation

The basic operation for programmable logic controllers has been shown in Fig. 1. The input
devices are sensors that monitor the machine or the process being controlled. The status of
these sensors (ON or OFF) is fed to the PLC controller. Depending upon the input status of
these sensors the PLC controller will send signals to switch on (energize) or off (de-energize)
the output devices (motors, relays, valves etc.) in order to control the machine or process.

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The PLC System:

The PLC, like a computer, employ a microprocessor chip to do the processing and memory
chips to store the program.

The PLC consists of three sections:

1. A processor.
2. Input/ Output (I/O).
3. A programming unit

The input and output units are connected via an INTERFACE.

An interface is where two systems come together and interact or communicate, that is,
communication between the plant being controlled the PLC controller.

The basic architecture of a PLC contains a processor (microprocessor chip(s)), memory chips
and an arithmetic logic unit (ALU). It also contains all the input and output interfacing. The
programming devices, either hand-held, dedicated terminal or desktop, are remote from the
PLC controller.

The PLC must be able to perform counting and timing operations. Most PLCs have timers
and counters that can be programmed into a ladder diagram. The timer is essentially an
internal clock that can be set to count in set intervals of seconds or parts of seconds. The
number of intervals counted is called the accumulated value (AC). For example, if each
interval is 0.1 seconds and the AC value is 10, then the time elapsed is 1 second.

Timers are used to insert a delay. Timers are enabled so that an output can be activated after a
certain time. During the time the timer is enabled, it continuously increments its accumulator
value by the timing step, until it reaches the preset value. Counters count events. Every time
it is activated, it increments or decrements the accumulator value by one, unless it reaches the
preset value. When a timer or a counter reaches the preset value a DONE (denoted as DN in
the ladder logic diagrams) signal becomes active. To restart timing or counting, the reset
signals have to be active (denoted as RES in the ladder logic diagrams).

A timer is activated by a latched input. That is why it cannot be simply activated by a switch
or an active sensor. However, a counter is generally activated by a switch or an active sensor.
The following figure illustrates this. Note that the input and output addresses are not the real
addresses of the PLC-they are just used to illustrate the above point.

Timer in Allen Bradley PLC (TON Delay)

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Pre-Lab Homework:
You must solve the following questions and make a short report on that before the start of the
lab. Get all the theoretical basics on timers and counters that will be helpful to implement the
experiment.

Apparatus:
1) Allen-Bradley MicroLogix 1500
Programmable Controller.
2) PC45 Programmable Controller
Trainer.
3) PC45 Accessory kit.
PC49 Hand held compressor
4) pump.
Precautions:
Students should take the following precautions while conducting the experiment –
1. Check the computer if it is working; otherwise inform lab instructor,
2. Be careful while handling the power supply buttons of computers and other accessory
kit and to keep them off when they are not needed,
3. Check if PLC is working correctly and beware of typing mistakes or drawing the
ladder diagram.

Experimental Procedure:
Be familiar with the RSLogix software. All programming will be done using RSLogix
programming software.
Start→Programs→Rockwell Software→ RSLogix 500 Starter.

Implementation of different logics by using ladder logic program:

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Programming Exercise 1
When green push button is pressed green lamp comes on, when red push button is pressed red
lamp comes on.
Ladder Diagram Hardware Wiring
PLC Terminal PC45 Terminal
I/0 SWG
I/1 SWR
DC COM 0 0V(on upper
block)
O/6 LG
O/7 LR
V AC VDC 4 0V(on lower
block)

Programming Exercise 2
A press of green push button starts the conveyor and a press of red push button stops the
conveyor.
Ladder Diagram Hardware Wiring
PLC Terminal PC45 Terminal
I/0 SWG
I/1 SWR
DC COM 0 0V(on upper
block)
O/4 E
V AC VDC 4 0V(on lower
block)

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Programming Exercise 3
When green or red push button is pressed green lamp comes on, when green and red push
button is pressed red lamp comes on.
Ladder Diagram Hardware Wiring
PLC Terminal PC45 Terminal
I/0 SWG
I/1 SWR
DC COM 0 0V(on upper
block)
O/6 LG
O/7 LR
V AC VDC 4 0V(on lower
block)

Programming Exercise 4

A press of green push button starts the conveyor in forward direction (using a self-latch
operation) and a press of red push button stops the conveyor. Green lamp comes on when
conveyor starts and red lamp comes on when conveyor stops. If MCR zone is activated, when
the beam of sensor2 is broken conveyor moves in the reverse direction. It continues in this
reverse direction until the beam of sensor1 is broken and the conveyor moves in the forward
direction again.

Ladder Diagram Hardware Wiring

PLC Terminal PC45 Sequence
Terminal Switch module
terminal
I/0 SWG
I/1 SWR
I/2 S1
I/3 S2
DC COM 0 0V(on upper
block)
O/4 E
O/5 R
O/6 LG
O/7 LR
V AC VDC 0V(on lower
4 block)
+24V(on Vsw
lower back)
I/7 1

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Simulation and Measurement:

Compare the simulation results with your experimental data/ wave shapes and comment on
the differences (if any).

Questions for report writing:

1. Explain how each program works.

2. What is normally open and normally closed relay?
3. What do you understand by the rung of a ladder logic program?
4. Implement various logic gates by using Ladder Diagram?
5. What is the basic difference between normal timer and retentive timer operation?
6. Programming Exercise:
Design a ladder logic program where pressing of green push button will start the
conveyor in forward direction and after 45 second conveyor will stop automatically.

Discussion and Conclusion:

Interpret the data/findings and determine the extent to which the experiment was successful
in complying with the goal that was initially set. Discuss any mistake you might have made
while conducting the investigation and describe ways the study could have been improved.
Reference(s):

[1] Norman S. Nise, “Control Systems Engineering”, available Edition, John Wiley & Sons
Inc.
[2] An Introduction to Industrial Programmable Controllers, PC45/ML Curriculum Manual,
LJ Technical Systems
[2] Control System Laboratory Manual, American International University-Bangladesh
(AIUB), 2013
Appendix
PLC Input Terminal Description
I/0 Green Push Button
I/1 Red Push Button
I/2 Sensor 1
I/3 Sensor 2
I/4 Microswitch 1
I/5 Microswitch 2
I/6 Microswitch 3

PLC Output Terminal Description

O/4 Conveyor (Forwards)
O/5 Conveyor (Reverse)
O/6 Green Lamp
O/7 Red Lamp
O/8 Cylinder 1
O/9 Cylinder 2
O/10 Cylinder 3

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