PLC Fundamentals. Module 1: Introduction to PLC. Academic Services Unit PREPARED BY. August 2011
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1 PLC Fundamentals PREPARED BY Academic Services Unit August 2011 Applied Technology High Schools, 2011
2 ATE1212 PLC Fundamentals Module Objectives Upon successful completion of this module, students will be able to: 1. Differentiate between manual and automatic control. 2. Define a control system and draw its block diagram. 3. Differentiate between digital and analog control. 4. Mention the different types of controllers and give examples. 5. Differentiate between a microcontroller and a PLC. 6. Mention the main parts of a PLC. 7. Give examples of PLC applications and list the PLC manufacturers. 8. Select the most suitable controller for a given problem. 9. Identify the main parts of the Siemens LOGO! PLC Module. 10. Program the Siemens LOGO! PLC Module through its Basic Control Unit using simple commands. Module Contents: Topic Page No. 1.1 Introduction Types of Controllers PLC Vs. Microcontroller Basic PLC Operation PLC Applications PLC Manufacturers Lab Activity Lab Activity Lab Activity LOGO! Edutrainer Default Input and Output Review Exercise Assignment 27 2
3 ATE1212 PLC Fundamentals 1.1 Introduction In everyday operations or industrial processes, we come across situations where there is a need to control some device or a physical quantity such as time, temperature, sound, light and so on, to get the required result or output. For example, do you think an airplane would be useful to a pilot, if he cannot make it go where he wants it to go? Or would an airconditioner be useful, if the temperature in a room cannot be controlled? In both the examples, there is a need to control a process. Electrical control can be defined as using electrical signals such as current or voltage to enable or disable or direct a certain process. Electrical control can be achieved in different ways, for instance; based on human interaction we can say that the control is either manual or automatic. Manual Control Control is said to be done manually when a user performs an action for the system to function. For example, the user might flip the switch of a manual starter to start and stop a motor (fig 1.1) Fig 1.1: Example of Manual Control 3
4 ATE1212 PLC Fundamentals Automatic Contol Control is said to be automatic when the action is performed automatically in response to a set of conditions. Fig 1.2: Example of Automatic Control Machines can be controlled manually or automatically. Usually, there is a combination of manual and automatic control. For example, a process that is started manually may stop automatically when certain conditions are met. Fig 1.3: Manual & Automatic Control Example A Control System is a system that can sense, switch and/or control an operation. It operates on an input signal and controls the process in order to provide an output signal. This is shown in the block diagram in fig 1.4: Input Process Output Fig 1.4: Elements of a Control System 4
5 ATE1212 PLC Fundamentals In terms of output value, a control system can be classified as either Discrete control (Digital control) or Continuous control (Analog control). Control Discrete control Digital Continuous control Analog Fig 1.5: Types of control based on the output value Discrete (digital) control: The value to be controlled can be either ON or OFF. Example: Turning a light ON and OFF. Continuous (analog) Control: The value to be controlled varies smoothly. Example: Motor speed. In this course we will study discrete control only. 1.2 Types of controllers Different types of controllers could be used based on the requirements of the application. Some examples are included below: 1. Relays and Contactors Simple electromechanical devices like relays and contactors are most widely used for controlling a discrete manufacturing process. Fig 1.6: Relay 5
6 ATE1212 PLC Fundamentals 2. Programmable Logic Controllers (PLCs) A Programmable Logic Controller (or PLC) is a specialised digital controller that can control machines and processes. it monitors inputs, makes decisions, and controls outputs in order to automate machines and processes. Fig 1.8 demonstrates its function. Fig 1.7: PLC Fig 1.8: PLC function 3. Microcontrollers (µcs) Microcontroller is a special purpose computer that can do one job, for example, the one that is used in an automatic washing machine and in a microwave. Fig 1.9: Microcontroller 6
7 ATE1212 PLC Fundamentals 1.3 PLC vs. Microcontroller Usually PLCs are used in an industrial environment, where as the microcontrollers are smaller and well suited for embedded situations. PLCs are programmed with ready made blocks or programming elements, whereas in Microcontrollers a programming language must be used to write a programing code. Fig 1.10 Programming PLC Fig 1.11 Programming a µc The price of the µc could vary from 5 Dirhams to 50 Dirhams. Some of the cheapest PLC's could cost AED 400 for the basic frame (with digital inputs and outputs). PLC Advantages They are highly reliable, fast and flexible. They can handle severe conditions such as dust, humidity etc. They can communicate with other controllers. They are easy to program and troubleshoot. They include display units. 7
8 ATE1212 PLC Fundamentals 1.4 Basic PLC Operation In the example shown in fig 1.12, pushbuttons are connected to the PLC s inputs and a motor is connected to the PLC s output. Here the pushbuttons are used to start and stop the motor. Fig 1.12: Motor control using a PLC PLC Basic Parts A PLC consists of the following basic parts: Inputs Central Processing Unit (CPU) Outputs Inputs CPU Outputs Examples of PLC input devices are sensors,switches,pushbuttons etc Examples of PLC output devices are valves, motors, solenoids etc 8
9 ATE1212 PLC Fundamentals 1.5 PLC Applications A PLC can be used in a wide range of applications, some of which are shown below: Production and assembly lines Automatic Doors Traffic Lights 1.6 PLC Manufacturers The PLC that will be introduced in this course is the LOGO! PLC from Siemens.The table below shows a list of other PLC Manufacturers. 9
10 ATE1212 PLC Fundamentals 1.7 Lab Activity 1 Objective: To familiarise with the Siemens LOGO! PLC Module. Procedure: The following are the 12 main components of the LOGO! Basic PLC module: One LOGO! Basic which operates on 24V dc supply and has: 8 digital inputs 2 analog inputs 4 digital outputs Display unit Control Unit for LOGO! Programming PC Interface Two expansion modules that have: 4 digital inputs 4 digital outputs Status display LEDs that indicate RUN/STOP status Submin D Socket 24VDC safety socket 0V safety socket Control elements Emergency-stop bridge SysLink Interface 1. Identify the LOGO! Basic PLC module components on the EduTrainer that are marked in the figure and write them in the table provided: 10
11 ATE1212 PLC Fundamentals Number Component/Part Table 1.1 Review the parts and mark them in the picture below: 11
12 ATE1212 PLC Fundamentals 2. Identify the three parts on the LOGO! Basic control unit and name them: What is the function of this unit? 3. Measure the output voltage of the power supply unit with the help of a multimeter as shown in figure below: Record the dc output voltage. 12
13 ATE1212 PLC Fundamentals 1.8 Lab Activity 2 Objective: To familiarise with the LOGO! Basic Control unit using simple commands. Procedure: 1. Set the day, time and date Follow the steps below to set the day, time and date. Switch on the power supply. Press the ESC key on the LOGO! Basic module Select Set Select Clock Press the and to change the day and press OK to confirm. Move to date by using the side arrows. Follow the same procedure to set the date and year and press OK to confirm. Press ESC to return to the main screen. 2. Enter your first program on LOGO! using the on-board keys. The digital inputs are denoted by the letter I such as I 1, I 2 and so on, and the digital outputs are denoted as Q 1, Q 2 and so on. Program the PLC to turn on Q1 when I3 is ON. Press ESC to come to the main screen and follow the steps below: Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 13
14 ATE1212 PLC Fundamentals Observation: 1. Press ESC to return to the main screen and press start to run the program. Press the white pushbutton (I3) and observe the result. Can you identify the Q1 output? What do you observe? 2. Stop and clear the program. Repeat the steps by changing the input to I1. What do you observe? 3. Based on your experiment, identify which control element is connected to the following PLC inputs and outputs: PLC input I3 I1 Control Element PLC Output Control Element Q1 Table
15 ATE1212 PLC Fundamentals 1.9 Lab Activity 3 Objective: To perform simple control tasks by entering commands through the BASIC Control Unit. Procedure: A. Write a program to turn on the Green Indicator light when the selector switch is turned on. Refer to table 1.3 to identify the inputs and outputs. Control Elements PLC Input/Output Selector Switch I4 Green Indicator Light Q1 Is it possible to leave the green light in the ON state? What is the difference you observe between the pushbutton and the selector switch? 15
16 ATE1212 PLC Fundamentals B. Write a program to move the table forward when the white pushbutton is pressed. Control Elements PLC Input/Output Table (forward) Q5 Table (backward) Q6 White pushbutton I3 What changes should you make in the program to move the table backward when the white pushbutton is pressed? 16
17 ATE1212 PLC Fundamentals C. Write a program to start the conveyor belt motor when the green pushbutton is pressed. Control Elements PLC Input/Output Conveyor belt motor Q8 Green pushbutton I1 Branching arm Q7 What changes should you make in the program to move the branching arm when the green pushbutton is pressed? 17
18 ATE1212 PLC Fundamentals D. Write a program to turn on the White indicator light when the inductive sensor senses a metal piece. White Indicator Light Control Elements PLC Input/Output White Indicator light Q2 Inductive sensor I12 What changes should you make in the program to move the branching arm when this sensor senses a metal piece? 18
19 ATE1212 PLC Fundamentals 1.10 LOGO Edutrainer Default Input and Output (Note: students are not required to memorise this configuration as it might be changed or modified) Control Elements Green pushbutton (N.O) Red pushbutton (N.C) White pushbutton (N.O) Selector Switch Emergency Jumper Fiber optic barrier Fiber optic barrier Fiber optic sensor Inductive sensor Green Indicator Light White Indicator light Table (forward) Table (backward) Branching arm Conveyor belt motor PLC Input/Output I1 I2 I3 I4 I5 I9 I10 I11 I12 Q1 Q2 Q5 Q6 Q7 Q8 19
20 ATE1212 PLC Fundamentals 1.11 Review Exercise 1. What are the elements of a control system? Include the elements to complete the block diagram given below: 2. Study the following situations and decide which controller is the best for each task. Justify your answers: a) The school management decided to control the main gate automatically, and this includes open and close the gate barrier and count the number of cars that enter the school. (hint : the environment must be taken into consideration ) b) A water tank is required to be filled manually using a small pump and two pushbuttons, one to start filling the tank and one to stop. (hint : cost should be considered) c) You are required to design a portable device that measures human blood pressure. 20
21 ATE1212 PLC Fundamentals 3. What does PLC stand for? 4. Based on what you have studied in this module, what do you think is the difference between a PLC and a microcontroller? Complete the T- chart below to show the difference: PLC Microcontroller 21
22 ATE1212 PLC Fundamentals 5. Mark the parts that are indicated in the table below: Number Component/Part List three advantages of using a PLC: 22
23 ATE1212 PLC Fundamentals 7. What is the difference between Discrete control and Continuous control? Give one example for each type of control. 8. With reference to the table of the default configuration (Page 20) try the following programs and then write down your comments: Program Comments 23
24 ATE1212 PLC Fundamentals 9. The green light of the LOGO! Edutrainer is required to turn ON when the green pushbutton is pressed, while the white light is required to turn ON when the white pushbutton is pressed: a. Draw the LOGO PLC program for this problem. b. How can you implement this task using a relay. Draw the control diagram for this circuit. 24
25 ATE1212 PLC Fundamentals 10. Discuss the following industrial applications and decide which controller is the best to be used for each one. 25
26 ATE1212 PLC Fundamentals 1.12 Assignment Complete any one of the tasks using one of the suitable Microsoft Office tools. Task-1: Use the internet to identify one commercial application and two industrial applications of a PLC other than the ones listed in the module, and prepare a powerpoint presentation or a poster that lists those PLC applications. The powerpoint slides (or the poster) must include the following contents: Assignment Title: PLC Applications Title of application-1, picture and brief description. Title of application-2, picture and brief description. Title of application-3, picture and brief description. Task-2: Prepare a powerpoint presentation or a chart that includes the following: A picture of the LOGO! Basic Control unit with all its parts marked neatly. A list of all the LOGO! Edutrainer control elements that you have used in your lab activities in this module. Include the following details: Control Element Input or Output? PLC Input/Output 26
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