PROGRAMMABLE LOGIC CONTROLLERS

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PROGRAMMABLE LOGIC CONTROLLERS

  1. 1. Workshop on “PLC Basics & Programming” Prepared by- Rahul N Deshmukh Asst Professor E&TC Dept
  2. 2. 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
  3. 3. 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
  4. 4. 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
  5. 5. 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
  6. 6. 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. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  7. 7. Applications- • Manufacturing / Machining • Food / Beverage • Metals • Power • Mining • Petrochemical / Chemical Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  8. 8. Programmable Logic Controller
  9. 9. CPU The Basic Block Inputs Outputs What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  10. 10. What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  11. 11. PLC Construction- Compact PLC Modular PLC Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  12. 12. 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 Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  13. 13. Block Diagram of PLC- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon PROCESSOR POWER SUPPLY I M N O P D U U T L E O M U O T D P U U L T E PROGRAMMING DEVICE From SENSORS Pushbuttons, contacts, limit switches, etc. To OUTPUT Solenoids, contactors, alarms etc.
  14. 14. Functional Interaction of PLC system- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  15. 15. Rack & Rail System in PLC- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  16. 16. What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon network digital inputs digital outputs analog inputs / outputs
  17. 17. Siemens S7-200 PLC Configuration- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  18. 18. Siemens S7-200 CPU- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  19. 19. Siemens PLC expansion Module- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  20. 20. Siemens PLC Status Indicator- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  21. 21. Siemens PLC CPU Internal Circuitry- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  22. 22. Digital Input Circuitry- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  23. 23. Physical Wiring Input Side- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon AC input module DC input module
  24. 24. DC Inputs (Source/Sink)- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Sinking input module/sourcing input device Sourcing input module/sinking input device
  25. 25. Digital Outputs- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  26. 26. Digital Output Logic- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  27. 27. Physical wiring Output Side- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  28. 28. Analog Input- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  29. 29. Physical Wiring PLC analog Input- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  30. 30. Analog Input example- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  31. 31. Analog Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  32. 32. Physical Wiring PLC analog Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  33. 33. Analog Output example- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  34. 34. • 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? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  35. 35. • Valves • Motor Starters • Solenoids • Actuators • Control Relays • Horns & Alarms • Stack Lights • Fans • Counter/Totalizer • Pumps • Printers What are outputs? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  36. 36. Contactor & Relay- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Contactor Relay
  37. 37. Input Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  38. 38. Input Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  39. 39. Output Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  40. 40. Output Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  41. 41. PLC Scan Cycle- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  42. 42. PLC Manufacturers
  43. 43. Allen Bradley PLC (America) Siemens PLC (Germany) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  44. 44. Modicon PLC (France) Crouzet PLC GE Fanuc (Japan & America) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  45. 45. • Delta PLC (India) • Messung PLC (India) • Mitsubishi (Japan) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  46. 46. PLC Hardwire System
  47. 47. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon S1 S2 K1 S1 S2 PLC K1 Hardwire PLC 0 V 24 VDC K1 L N
  48. 48. S7-300 PLC Wiring Diagram Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  49. 49. PLC Programming Languages
  50. 50. 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” Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  51. 51. Ladder Logic Read / Conditional Instructions Write / Control Instructions | | |/| | | |/| | | | | |/| ( ) | | | | Start (Rung #1) End (Rung #4) ( ) ( ) ( ) Inputs Outputs Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  52. 52. Siemens S7-200 I/O Configuration- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  53. 53. Addressing System Input & Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Input- Output-
  54. 54. Function Block Diagram (FBD) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  55. 55. Structured Text (ST) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  56. 56. Instruction List (IL) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  57. 57. Ladder Diagram (LD) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  58. 58. Sequential Function Chart (SFC) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  59. 59. PLC Software View Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  60. 60. PLC Program example- eg- Lamp Glows when input switch is activated Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  61. 61. PLC Program example- eg- Lamp Glows when input switch is activated Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  62. 62. PLC Program example- eg- to start & stop the motor Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  63. 63. PLC Program example- eg- to stat the motor Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  64. 64. Latching Condition- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  65. 65. PLC Programming (Siemens S7-300)
  66. 66. Hardware-Siemens S7-300 Software-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
  67. 67. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  68. 68. Hardware-Siemens S7-300 Software-Simatic Manager Steps for creating programming window (OB-Organization Block) -Install Simatic Manager V-5.5 Software -for (Simulation) install PLCSim v-5.1 Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  69. 69. Addressing System for S7-300 Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  70. 70. What is an Automation?
  71. 71. • Automation is a delegation of human control to the machine • For e.g- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  72. 72. PLC Implementation- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  73. 73. Thank you

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