Workshop on “PLC Basics & Programming ” Prepared by- Rahul N Deshmukh Asst Professor E&TC Dept
Aug 21, 2014
Workshop on
“PLC Basics & Programming”Prepared by- Rahul N Deshmukh Asst Professor E&TC Dept
Content-• History• Basics of Programmable Logic Controller (PLC)• PLC hardware & software• Inputs/Outputs• PLC Programming Languages• What is an Automation?• Supervisory Control & Data Acquisition System (SCADA)
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
History-In 1968, a group of engineers from General Motors developed the
concept of PLC with an initial specification. The PLC must be:
i . Easy to program.ii. Not need rewiring the control system if change the program.iii. Smaller in size, cheaper and high reliability.iv. simple construction and low maintenance v. Cost- competitive
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Development -• Manual• Contactor & relay based• Logic gates• Microcontroller based• Programmable Logic Controllers• Touchscreen & Wireless PLC’s
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Advantages of PLC- • Less wiring. • Wiring between devices and relay contacts are done in the
PLC program. • Easier and faster to make changes. • Trouble shooting aids make programming easier and reduce
downtime. • Reliable components make these likely to operate for years
before failure.
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
PLC Size-• 1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes. - these PLC’s are capable of providing simple to
advance levels or machine controls.• 2. MEDIUM - have up to 2048 I/O’s and memories up to 32
Kbytes.• 3. LARGE - the most sophisticated units of the PLC family.
They have up to 8192 I/O’s and memories up to 750 Kbytes.
- can control individual production processes or entire plant.
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Applications-• Manufacturing / Machining• Food / Beverage• Metals• Power• Mining• Petrochemical / Chemical
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Programmable Logic Controller
CPU
The Basic Block
Inputs Outputs
What is PLC?
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What is PLC?
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PLC Construction-Compact PLC Modular PLC
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Some PLC’s-• 80% market is covered by
Siemens PLC• Modicon is a first PLC
invented in france• Messung & Delta are India
made PLC’s
Allen Bradley Siemens
Modicon Mitsubishi
Schneider Electric Messung
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Block Diagram of PLC-
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PROCESSOR
POWERSUPPLY
I MN O P D U UT L E
O M U OT DP UU LT E
PROGRAMMING DEVICE
From SENSORSPushbuttons,
contacts,limit switches,
etc.
ToOUTPUT
Solenoids, contactors,
alarmsetc.
Functional Interaction of PLC system-
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Rack & Rail System in PLC-
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What is PLC?
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network
digital inputs
digital outputs
analog inputs / outputs
Siemens S7-200 PLC Configuration-
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Siemens S7-200 CPU-
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Siemens PLC expansion Module-
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Siemens PLC Status Indicator-
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Siemens PLC CPU Internal Circuitry-
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Digital Input Circuitry-
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Physical Wiring Input Side-
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AC input module DC input module
DC Inputs (Source/Sink)-
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Sinking input module/sourcing input device Sourcing input module/sinking input device
Digital Outputs-
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Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Digital Output Logic-
Physical wiring Output Side-
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Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Analog Input-
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Physical Wiring PLC analog Input-
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Analog Input example-
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Analog Output-
Physical Wiring PLC analog Output-
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Analog Output example-
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• Switches and Pushbuttons• Sensing Devices
• Limit Switches• Photoelectric Sensors• Proximity Sensors
• Condition Sensors • Pressure Switches• Level Switches• Temperature Switches• Vacuum Switches• Float Switches
• Encoders
What are inputs?
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• Valves• Motor Starters• Solenoids• Actuators• Control Relays• Horns & Alarms• Stack Lights• Fans• Counter/Totalizer• Pumps• Printers
What are outputs?
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Contactor & Relay-
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Contactor Relay
Input Connection-
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Input Connection-
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Output Connection-
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Output Connection-
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PLC Scan Cycle-
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PLC Manufacturers
Allen Bradley PLC (America)
Siemens PLC (Germany)
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Modicon PLC (France)
Crouzet PLCGE Fanuc (Japan & America)
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• Delta PLC (India)
• Messung PLC (India)
• Mitsubishi (Japan)
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PLC Hardwire System
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S1
S2
K1
S1 S2
PLC
K1
Hardwire PLC
0 V
24 VDC
K1
L
N
S7-300 PLC Wiring Diagram
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PLCProgramming Languages
Types of Programming Software Languages
• Ladder Logic (LL)
• IEC Format• Function Block Diagram (FBD)• Structured Text (ST)• Instruction List (IL)• Ladder Diagram (LD)• Sequential Function Chart (SFC) - also known as “Grafcet”
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Ladder Logic
Read / Conditional Instructions
Write / Control Instructions
| | |/|
| | |/|| |
| | |/| ( )
| |
| |
Start (Rung #1)
End (Rung #4)
( )
( )
( )
Inputs Outputs
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Siemens S7-200 I/O Configuration-
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Addressing System Input & Output-
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Input-
Output-
Function Block Diagram (FBD)
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Structured Text (ST)
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Instruction List (IL)
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Ladder Diagram (LD)
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Sequential Function Chart (SFC)
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PLC Software View
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PLC Program example-
eg- Lamp Glows when input switch is activated
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PLC Program example-
eg- Lamp Glows when input switch is activated
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PLC Program example-
eg- to start & stop the motor
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PLC Program example-
eg- to stat the motor
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Latching Condition-
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PLC Programming(Siemens S7-300)
Hardware-Siemens S7-300Software-Simatic Manager
-80% market occupied by Siemens-STEP-5 & STEP-7 available with Siemens-I/O Capacity (S7-200 )-32 analog & 256 digital (S7-300)-256 analog & 1024 digital (S7-400)-1500 analog & 128000 digital
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
Hardware-Siemens S7-300Software-Simatic Manager
Steps for creating programming window (OB-Organization Block)
-Install Simatic Manager V-5.5 Software-for (Simulation) install PLCSim v-5.1
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Addressing System for S7-300
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What is an Automation?
• Automation is a delegation of human control to the machine• For e.g-
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PLC Implementation-
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ANY QUIRY….??
Thank you