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Introduction to Basic Programmable Logic Controller Training Presented by Elcomp Trading Sdn Bhd

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Page 1: Basic PLC Training 1 Day

Introduction to

Basic Programmable Logic

Controller TrainingPresented by

Elcomp Trading Sdn Bhd

Page 2: Basic PLC Training 1 Day

Course ContentsCourse Contents

Introduction of Control SystemIntroduction of Control System

~ Control Panel, Input, Output~ Control Panel, Input, Output

Conventional Hardwired LogicConventional Hardwired Logic

Introduction to PLCIntroduction to PLC

What PLC can do?What PLC can do?

The Advantages of using PLCThe Advantages of using PLC

Application of PLCApplication of PLC

Page 3: Basic PLC Training 1 Day

Theory of Operation

Page 4: Basic PLC Training 1 Day

What is a PLC?What is a PLC?

A PLC is a device that was invented to replace A PLC is a device that was invented to replace the necessary sequential relay circuits for the necessary sequential relay circuits for machine control. machine control.

The PLC works by monitor its inputs and The PLC works by monitor its inputs and depending upon their state, turning on/off its depending upon their state, turning on/off its outputs. outputs.

The user enters a program, usually via software, The user enters a program, usually via software, that gives the desired results.that gives the desired results.

Page 5: Basic PLC Training 1 Day

RelayRelay

Page 6: Basic PLC Training 1 Day

Replacing RelaysReplacing Relays

Contact Symbol

Page 7: Basic PLC Training 1 Day

PLC HistoryPLC History

In the late 1960's PLCs were first introduced to In the late 1960's PLCs were first introduced to replace complicated relay based control systems.replace complicated relay based control systems.

In 1970's, the dominant PLC technologies were In 1970's, the dominant PLC technologies were sequencer state-machines. Communications sequencer state-machines. Communications abilities began to introduced for PLCs. abilities began to introduced for PLCs.

In 1980's, an attempt to standardize In 1980's, an attempt to standardize communications with Manufacturing Automation communications with Manufacturing Automation Protocol(MAP). Protocol(MAP).

In 1990’s, an attempt to standardize PLC In 1990’s, an attempt to standardize PLC programming languages under one international programming languages under one international standard: IEC 1131-3.standard: IEC 1131-3.

Page 8: Basic PLC Training 1 Day

Input signals from sensors, switches,etc

Output signals to pump, mixer, etc

VoltageRegulator

PLCHardwire

Logic

Relays

Relays

Redundancy

Isolation

Inside the PLC

Page 9: Basic PLC Training 1 Day

Inside the PLCInside the PLC

Input RelaysInput Relays - (contacts) - (contacts)– connected to the outside worldconnected to the outside world– physically exist and receive signals from physically exist and receive signals from

switches, sensors, etc..switches, sensors, etc.. Internal RelaysInternal Relays - (contacts) - (contacts)

– do not receive signals from the outside world do not receive signals from the outside world nor do they physically existnor do they physically exist

– simulated relays and are what enables a PLC simulated relays and are what enables a PLC to eliminate external relaysto eliminate external relays

– also some special relays that are dedicated to also some special relays that are dedicated to performing only one taskperforming only one task

Page 10: Basic PLC Training 1 Day

Counters Counters – do not physically existdo not physically exist– simulated counters and they can be simulated counters and they can be

programmed to count pulsesprogrammed to count pulses– limited in their counting speedlimited in their counting speed– high-speed counters that are hardware basedhigh-speed counters that are hardware based

Timers Timers – do not physically existdo not physically exist– on-delay and off reseton-delay and off reset

– increments vary from 10ms through 100msincrements vary from 10ms through 100ms

Inside the PLCInside the PLC

Page 11: Basic PLC Training 1 Day

Inside the PLCInside the PLC

Output RelaysOutput Relays (coils) (coils)– connected to the outside worldconnected to the outside world– physically exist and send on/off signals to physically exist and send on/off signals to

solenoids, lights, etcsolenoids, lights, etc– can be transistors, relays, or triacs depending can be transistors, relays, or triacs depending

upon the model chosenupon the model chosen Data MemoryData Memory

– registers assigned to store data for math or registers assigned to store data for math or data manipulationdata manipulation

– can also typically be used to store data when can also typically be used to store data when power is removed from the PLCpower is removed from the PLC

Page 12: Basic PLC Training 1 Day

Types of MemoryTypes of Memory

ROM: Read Only Memory ROM: Read Only Memory

RAM: Temporary storage area, need battery RAM: Temporary storage area, need battery backupbackup

EPROM: Erasable Programmable Read Only EPROM: Erasable Programmable Read Only MemoryMemory

EEPROM: Electrical Erasable Programmable Read EEPROM: Electrical Erasable Programmable Read Only MemoryOnly Memory

Note :Battery is used for backup the data in the RAM in PLC when Power Off

Page 13: Basic PLC Training 1 Day

A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine.

CPU

MemoryInput

Output

ProgrammingDevice

Power Supply

SignalsfromSwitches,Sensors,etc

Signals tosolenoids,motor,lamps,etc.

How PLC Work?

Page 14: Basic PLC Training 1 Day

How PLC Work?How PLC Work?

Page 15: Basic PLC Training 1 Day

Response Time (Scan Time)Response Time (Scan Time)

Page 16: Basic PLC Training 1 Day

Types of PLCTypes of PLC

1. Nano Brick Style1. Nano Brick Style

2. Compact PLC Series2. Compact PLC Series

3. Modular PLC Series3. Modular PLC Series

4. Rack PLC Series4. Rack PLC Series

Page 17: Basic PLC Training 1 Day

Nano Brick StyleNano Brick Style

Expandable to 44 I/O

Low Cost Model 20 I/O max

ZEN

Page 18: Basic PLC Training 1 Day

Compact PLC SeriesCompact PLC Series

CP1H CPM1A CPM2A

CPM2B CPM2C

The all in one PLC Compact & economical The universal small machine controller

Brick Style Micro Controller Board Package

The versatile slim-line controller

Page 19: Basic PLC Training 1 Day

Modular PLC SeriesModular PLC Series

CQM1H

The original backplane-less modular PLC

CJ1

The entry-level modular PLC with a big potential

Page 20: Basic PLC Training 1 Day

Rack PLC SeriesRack PLC Series

CS1

Suitable for any job: the rack-based PLC with over

200 types of I/O units

CS1D

The dual-redundant PLC system for never-fail control

Page 21: Basic PLC Training 1 Day

Numbers of Power Model Inputs Outputs

I/O Terminal Supply

10 AC CPM1A-10CDR-A 6 points 4 points

DC CPM1A-10CDT-D

20 AC CPM1A-20CDR-A 12 points 8 points

DC CPM1A-20CDT-D

30 AC CPM1A-30CDR-A 18 points 12 points

DC CPM1A-30CDT-D

40 AC CPM1A-40CDR-A 24 points 16 points

DC CPM1A-40CDT-D

Omron CPM1A CPU ModelsOmron CPM1A CPU Models

Page 22: Basic PLC Training 1 Day

Expansion Unit Example

• CPM1A-20EDR CPM1A-20EDR 12 Input / 8 Output point12 Input / 8 Output point

• CPM1A-SRT21 CompoBus/S I/O unitCPM1A-SRT21 CompoBus/S I/O unit Connect the I/O in 500m awayConnect the I/O in 500m away

• CPM1A-MAD01 Analog I/O unitCPM1A-MAD01 Analog I/O unit 2 analog Input2 analog Input : 0~10V, 1~5V, 4~20mA. : 0~10V, 1~5V, 4~20mA. 1 analog Output1 analog Output : 0~10V, -10~10V, 4~20mA : 0~10V, -10~10V, 4~20mA

Page 23: Basic PLC Training 1 Day

CPU Status CPU Status IndicatorsIndicators

Indicator Status MeaningPWR (Green) ON Power supply to PLC

OFF Power not supply to PLCRUN (Green) ON RUN or MONITOR mode

OFF PORGRAM mode or Fatal error occurredERR/ALM (Red) ON Fatal error (PLC operation stops)

Flash Non-fatal error (PLC operation continue)COMM (Orange) ON Data being transfer

OFF Data not being transfer

Page 24: Basic PLC Training 1 Day

Data Area Function

IR (Internal Relay)Bits are allocated to external I/Oterminals. Some can be freelyused within program

SRServe for specific function suchas flags & control bits.

TRUsed to temporarily store status atprogram branches.

ARServe for specific function suchas flags & control bits.

LRUsed for data link with anotherPLC

TCSame numbers are used for timers& counters.

DMWord values are retained whenpower off.

Memory Area Memory Area FunctionsFunctions

Page 25: Basic PLC Training 1 Day

Assignment of I/OAssignment of I/O

• I/O NumbersI/O Numbers

- The input and output device (I/O device) are- The input and output device (I/O device) are

managed by number only.managed by number only.

- These numbers are called I/O numbers and are- These numbers are called I/O numbers and are

composed of channel (CH) and bits (bit).composed of channel (CH) and bits (bit).

Page 26: Basic PLC Training 1 Day

PLC Channel RegisterPLC Channel Register

• Storage location in PLCStorage location in PLC

• 16 bits16 bits

• Each bit holds the status of True or False (1 or 0)Each bit holds the status of True or False (1 or 0)

• PLC Address 000.01 = channel 000 bit 01PLC Address 000.01 = channel 000 bit 01

• PLC Address 010.00 = channel 010 bit 00PLC Address 010.00 = channel 010 bit 00

Page 27: Basic PLC Training 1 Day

PLC I/O AddressingPLC I/O AddressingFor CPM1A & CPM2AFor CPM1A & CPM2A

(5 digit)(5 digit)

InputInput

CH 0 : 000.00, 000.01, 000.02, 000.03, …, 000.11CH 0 : 000.00, 000.01, 000.02, 000.03, …, 000.11

(000.12, 000.13, 000.14, 000.15)(000.12, 000.13, 000.14, 000.15)

CH 1 : 001.00, 001.01, 001.02, …, 001.14, 001.15CH 1 : 001.00, 001.01, 001.02, …, 001.14, 001.15

OutputOutput

CH 10 : 010.00, 010.01, 010.02, …, 010.07CH 10 : 010.00, 010.01, 010.02, …, 010.07

(010.08, 010.09, …, 010.14, 010.15)(010.08, 010.09, …, 010.14, 010.15)

CH 11 : 011.00, 011.01, 011.02, …, 011.14, 011.15CH 11 : 011.00, 011.01, 011.02, …, 011.14, 011.15

0 0 0 0 0

Channel Bit

Page 28: Basic PLC Training 1 Day

Introduction to Control System (Control Panel)

Start & StopOperation

Page 29: Basic PLC Training 1 Day

What is inside the control panel?

Contactors, relays, timers & countersin the control panel

Page 30: Basic PLC Training 1 Day

Control SystemControl System(Input)(Input)

Flow Rate

Float Level

Oxygen Level

Page 31: Basic PLC Training 1 Day

Control SystemControl System(Output)(Output)

Motor pump

Valve

Mixer

Page 32: Basic PLC Training 1 Day

Input DeviceInput Device

Proximity Switch

Photoelectric Sensor

Fiber Optic Sensor

EncoderLimit Switches

Page 33: Basic PLC Training 1 Day

Output DeviceOutput Device

Injection Molding Machine Tower Light

Page 34: Basic PLC Training 1 Day

NS Series Touch screenNS Series Touch screen

Page 35: Basic PLC Training 1 Day

NT Series Touch ScreenNT Series Touch Screen

Page 36: Basic PLC Training 1 Day

Positioning Control with PLC

Page 37: Basic PLC Training 1 Day

Conventional

Hardwire Logic

Page 38: Basic PLC Training 1 Day

Hardwire Logic Control Circuit

Relay 1

StartStart StopStop

Relay 1

PumpTimer

TimerRelay 1 Solenoid

Page 39: Basic PLC Training 1 Day

Conventional Relay Control Panel

Page 40: Basic PLC Training 1 Day

What PLC can do?What PLC can do?

Page 41: Basic PLC Training 1 Day

Relays

Timers & Counters

1. Sequence Control1. Sequence Control

Page 42: Basic PLC Training 1 Day

+-x/

2

1

3 4

5

Prod Pass RejectAA 33 4BB 27 3CC 43 8

Arithmetic Operation

Analog ControlInformation Handling

2. Sophisticated Control2. Sophisticated Control

Page 43: Basic PLC Training 1 Day

Computer

Printer

FANetwork

Process Monitoring

3. Supervisory Control3. Supervisory Control

Pager

Page 44: Basic PLC Training 1 Day

The advantages of Using PLCThe advantages of Using PLC Smaller physical size than hard-wire solutions.Smaller physical size than hard-wire solutions.

Easier and faster to make changes.Easier and faster to make changes.

Diagnostics are centrally available.Diagnostics are centrally available.

Applications can be immediately documented.Applications can be immediately documented.

Applications can be duplicated faster and less Applications can be duplicated faster and less expensively.expensively.

Fast project implementation timeFast project implementation time

Low operating costLow operating cost

Increase productivityIncrease productivity

PLC Vs Relay Based Control System

Page 45: Basic PLC Training 1 Day

Control DeviceControl Device

Specific PurposeSpecific PurposeGeneral PurposeGeneral Purpose

Wired LogicWired Logic PLCPLC

Control sequence isfixed for one design

Control sequence can bechanged from time to time

without rewire

Page 46: Basic PLC Training 1 Day

PLCPLC

Control Control ScaleScale

Small & Medium Medium & Large

Wired LogicWired Logic

Page 47: Basic PLC Training 1 Day

LD STARTOR RELAY 1AND NOT STOPOUT RELAY1OUT SOLENOIDLD RELAY 1TIM 000

#0020LD TIM 000OUT PUMP

Modification Modification The same example for PLC control system

Mnemonic CodeMnemonic Code

Relay 1

Relay 1

Pump

Timer

Timer

Relay 1Solenoid

Page 48: Basic PLC Training 1 Day

The same example for PLC control system

Only need to change the ladder program

LD STARTOR RELAY 1AND NOT STOPOUT RELAY1OUT SOLENOIDLD RELAY 1LD STOPCNT 000

#0030LD CNT 000OUT PUMP

Modification Modification

Mnemonic CodeMnemonic Code

Page 49: Basic PLC Training 1 Day

Wired LogicWired Logic PLCPLC

Delivery Period

Several days Almost Immediate

Page 50: Basic PLC Training 1 Day

MaintenanceMaintenance

Difficult

Easy

LED indicator

Wired LogicWired LogicPLCPLC

Input/output connectorcan be remove easily

without using screw driver

ProgrammingConsole

Page 51: Basic PLC Training 1 Day

Economic Efficiency

Advantage onsmall scale

Advantage onsmall, medium

and large

$$$$$$Wired LogicWired Logic PLCPLC

Page 52: Basic PLC Training 1 Day

Power Consumption

High Low

0.2 Amp> 2 Amp

Wired LogicWired Logic PLCPLC

Page 53: Basic PLC Training 1 Day

Applications Of PLC

Material HandlingMaterial Handling Packaging MachinePackaging Machine Pump ControlPump Control Water TreatmentWater Treatment Paper & Pulp Paper & Pulp

IndustriesIndustries Cement Cement

ManufacturingManufacturing Electroplating PlantsElectroplating Plants

Power PlantPower Plant Disk Drive Disk Drive

ManufacturingManufacturing Traffic Light SystemTraffic Light System Car ManufacturingCar Manufacturing Building AutomationBuilding Automation IC ManufacturingIC Manufacturing Amusement Park Amusement Park

ControlControl

Page 54: Basic PLC Training 1 Day

The Programming The Programming ConsoleConsole

Mode of

Operating ModeOperating Mode

PROGRAM - Used for inserting or PROGRAM - Used for inserting or

for modification for modification

existing program.existing program.

MONITOR - Changing the contentsMONITOR - Changing the contents

of the memory whileof the memory while

PLC is operating.PLC is operating.

RUN - To execute program.RUN - To execute program.

No changes can be made. No changes can be made.

Selection

Page 55: Basic PLC Training 1 Day

Start Start ProgrammingProgramming

Page 56: Basic PLC Training 1 Day

Password InputPassword Input

< PROGRAM>< PROGRAM>

PASSWORD!PASSWORD!

CLRCLR CLRCLRMONITORMONITOR 00000000

Page 57: Basic PLC Training 1 Day

Clearing All Clearing All ProgramProgram

< PROGRAM>

* PLC program and memory will be cleared after the following stroke!!!

CLR

CLR 0000

SET NOT

MONTR CLR

RESET

0000 MONITOR CLREND HR CNT DM

Page 58: Basic PLC Training 1 Day

Overview of InstructionOverview of Instruction

FUNFUN

LDLD

ANDAND

OROR

NOTNOT

OUTOUT

TIMTIM

CNTCNT

SHIFTSHIFT

00

CHGCHG

WRITEWRITE

Page 59: Basic PLC Training 1 Day

Basic InstructionBasic Instruction

1. LD / LD NOT1. LD / LD NOT

2. OUT / OUT NOT2. OUT / OUT NOT

3. END3. END

4. AND / AND NOT 4. AND / AND NOT

5. OR / OR NOT5. OR / OR NOT

6. AND LD6. AND LD

7. OR LD7. OR LD

8. TIM8. TIM

9. CNT9. CNT

Page 60: Basic PLC Training 1 Day

LD / LD NOTLD / LD NOT

The The firstfirst condition that starts any logic block condition that starts any logic block within a ladder diagram corresponds to a within a ladder diagram corresponds to a

LD or LD NOT instruction.LD or LD NOT instruction.

LD - Normally Open contact, LD - Normally Open contact,

examine if Onexamine if On

LD NOT - Normally Close contact,LD NOT - Normally Close contact,

examine if Offexamine if Off

Page 61: Basic PLC Training 1 Day

OUT / OUT OUT / OUT NOTNOT

The OUT instruction is like a relay coil.The OUT instruction is like a relay coil. When there is a path of True instruction When there is a path of True instruction

preceding this on the ladder rung, it will also be preceding this on the ladder rung, it will also be True.True.

When the instruction is True it is physically On.When the instruction is True it is physically On. We can think of this instruction as a normally We can think of this instruction as a normally

open output.open output. This instruction can be used for internal coils and This instruction can be used for internal coils and

external outputs.external outputs. The OUT NOT instruction is the reverse logic of The OUT NOT instruction is the reverse logic of

OUT instruction.OUT instruction.

Page 62: Basic PLC Training 1 Day

END (01)END (01)

The last instruction required to complete a The last instruction required to complete a simple program is the END instruction.simple program is the END instruction.

When the CPU scan the program, it executes When the CPU scan the program, it executes all instructions up to the first END instruction all instructions up to the first END instruction before returning to the beginning of the before returning to the beginning of the program and begin the execution again.program and begin the execution again.

END

Page 63: Basic PLC Training 1 Day

AND / AND AND / AND NOTNOT

When 2 or more conditions lie in When 2 or more conditions lie in seriesseries on the on the same instruction line, the first one correspond same instruction line, the first one correspond to a LD or LD NOT instruction, and the rest of to a LD or LD NOT instruction, and the rest of the conditions, to AND or AND NOT the conditions, to AND or AND NOT instructions.instructions.

AND - taking the logical AND of the execution AND - taking the logical AND of the execution conditioncondition

AND NOT - taking the logical AND between its AND NOT - taking the logical AND between its execution condition and the inverse of its execution condition and the inverse of its operand bit.operand bit.

Page 64: Basic PLC Training 1 Day

OR / OR NOTOR / OR NOT

When 2 or more conditions lie on separate When 2 or more conditions lie on separate instruction line running in instruction line running in parallelparallel and joining and joining together, the first one correspond to a LD or together, the first one correspond to a LD or LD NOT instruction, and the rest of the LD NOT instruction, and the rest of the conditions correspond to OR or OR NOT conditions correspond to OR or OR NOT instructions.instructions.

OR - taking the logical OR of the execution OR - taking the logical OR of the execution condition.condition.

OR NOT - taking the logical OR between its OR NOT - taking the logical OR between its execution condition and the inverse of its execution condition and the inverse of its operand bit. operand bit.

Page 65: Basic PLC Training 1 Day

AND LD

The AND LD instruction logically AND the The AND LD instruction logically AND the execution conditions produced by two logic execution conditions produced by two logic blocks.blocks.

The OR LD instruction logically OR the The OR LD instruction logically OR the execution conditions produced by two logic execution conditions produced by two logic blocks.blocks.

OR LD

AND LD & OR LD Instructions

Page 66: Basic PLC Training 1 Day

Timer (TIM)Timer (TIM)

Timer is an instruction normally used for time delay.Timer is an instruction normally used for time delay.It can be ON delay or OFF delay.It can be ON delay or OFF delay.

The timer is based on a decrement method.The timer is based on a decrement method. On-Delay-Timer after our sensor (input) turns on we On-Delay-Timer after our sensor (input) turns on we

wait x-seconds before activating a solenoid valve wait x-seconds before activating a solenoid valve (output).(output).

Timer number 000 to 127 (Must not coincide with Timer number 000 to 127 (Must not coincide with counter)counter)

Set value #0000 to #9999 (0 - 999.9 sec)Set value #0000 to #9999 (0 - 999.9 sec) If the start input becomes OFF or the power is turned If the start input becomes OFF or the power is turned

OFF during operations before time up (current value OFF during operations before time up (current value #0000), the current value will be reset to the value #0000), the current value will be reset to the value set.set.

Page 67: Basic PLC Training 1 Day

TimersTimers

LD 0000TIM 000

#0100LD TIM000OUT 1000END (01)

*#0100 = 10s

Timer present value can be monitored by :

CLRCLR TIMTIM 00 MONTRMONTR

Page 68: Basic PLC Training 1 Day

Counter (CNT)Counter (CNT)

CNT is a preset decrement counter.CNT is a preset decrement counter. It decrements one count every time an input signal It decrements one count every time an input signal

goes from OFF to ON.goes from OFF to ON. The counter must be programmed with a count The counter must be programmed with a count

input, a reset input, a counter number and set value.input, a reset input, a counter number and set value. Set value can range from #0000 - #9999Set value can range from #0000 - #9999 Counter number 000 to 127 (Must not coincide with Counter number 000 to 127 (Must not coincide with

counter)counter) Its current value will not be reset even if the PC Its current value will not be reset even if the PC

power supply is turned OFF. It will preserve the power supply is turned OFF. It will preserve the count until then.count until then.

Page 69: Basic PLC Training 1 Day

COUNTERCOUNTER

LD 0001LD 0002CNT 010

#010LD CNT01OUT 1000END (01)

* Counter present in decrement method. Once reach zero it * Counter present in decrement method. Once reach zero it signal goes from OFF to ON. The Counter & Timer share the signal goes from OFF to ON. The Counter & Timer share the same memory location.same memory location.

Page 70: Basic PLC Training 1 Day

Useful Basic Useful Basic CommandCommand

Page 71: Basic PLC Training 1 Day

Program Program SearchSearch

SHIFTSHIFT CONTCONT ##

CLRCLR

CLRCLR

OUTOUT

SRCHSRCH

SRCHSRCH

00

INSTRUCTION INSTRUCTION SEARCHSEARCH

Page 72: Basic PLC Training 1 Day

Inserting & Deleting Inserting & Deleting InstructionInstruction

BIT SEARCHBIT SEARCH

BIT SEARCHBIT SEARCH

INSINS

DELDEL

<Instruction><Instruction>

<Instruction><Instruction>

Note : Only in PROGRAM mode, instruction that display can be delete or insert.The instruction once deleted, it cannot be recovered !

Page 73: Basic PLC Training 1 Day

Bit MonitorBit Monitor

Word MonitorCHCH

#DM#DM

CONTCONT##SHIFTSHIFT

SHIFTSHIFT

0000000000

010010 MONTRMONTR

SHIFTSHIFT MONTRMONTR

HEXADECIMALHEXADECIMAL

BINARYBINARY

MONTRMONTR

* Monitor the status (ON/OFF) of bit & word in any PLC operating * Monitor the status (ON/OFF) of bit & word in any PLC operating modemode

Bit & Word MonitoringBit & Word Monitoring

Page 74: Basic PLC Training 1 Day

Forced Forced Set/ResetSet/Reset

PLAYPLAYSETSET

ONON

RECRECRESETRESET

OFFOFF

Page 75: Basic PLC Training 1 Day

HEX / BCD DATA HEX / BCD DATA MODIFICATIONMODIFICATION

02000 0100002000 01000

PRESS VAL ?PRESS VAL ?

01000 ???/01000 ???/CHGCHG

WRITEWRITE

* Change the BCD or Hexadecimal value of status being monitor in MONITOR mode or PROGRAM mode.

Page 76: Basic PLC Training 1 Day

Various RelaysVarious Relays

Page 77: Basic PLC Training 1 Day

Internal Relay (IR)Internal Relay (IR)

I/O RelayI/O Relay- Corresponds to input terminals and output- Corresponds to input terminals and output

terminals.terminals.

- 00000 to 00915 (Input relay)- 00000 to 00915 (Input relay)

- 01000 to 01915 (Output relay)- 01000 to 01915 (Output relay)

Internal Auxiliary RelayInternal Auxiliary Relay- Can be used freely on the program- Can be used freely on the program

- 20000 to 23115- 20000 to 23115

Page 78: Basic PLC Training 1 Day

Self-Holding / Latching CircuitSelf-Holding / Latching Circuit

000.00

010.00

010.00000.01

LAMP1SW2SW1

LAMP1000.00

200.00

200.00000.01

LAMP1

SW2SW1END

END

200.00010.00

IR Application ExampleIR Application Example

Page 79: Basic PLC Training 1 Day

Special Relay Special Relay (SR)(SR)

- Special functions are assigned.- Special functions are assigned.

- 23200 to 25515- 23200 to 25515

- Example : - Example : 25313 ----- Always ON25313 ----- Always ON 25314 ----- Always OFF25314 ----- Always OFF 25315 ----- 1 cycle ON when operations start25315 ----- 1 cycle ON when operations start 25500 ----- 0.1 sec. clock pulse25500 ----- 0.1 sec. clock pulse 25501 ----- 0.2 sec. clock pulse25501 ----- 0.2 sec. clock pulse 25502 ----- 1.0 sec. clock pulse25502 ----- 1.0 sec. clock pulse

25500 (0.1 sec. clock pulse)

Page 80: Basic PLC Training 1 Day

SR Application ExampleSR Application Example

000.00

010.00

010.00000.01

LAMP1SW2SW1

LAMP1

END

255.02

1.0 sec clock pulse

* Lamp 1 will starts blinking after SW1 was being trigger.

Page 81: Basic PLC Training 1 Day

Holding Relay (HR)Holding Relay (HR)

- Maintains the ON/OFF state even when the - Maintains the ON/OFF state even when the power is cut off.power is cut off.

- HR0000 to HR01915- HR0000 to HR01915

Page 82: Basic PLC Training 1 Day

HR Application ExampleHR Application Example

Page 83: Basic PLC Training 1 Day

Temporarily Relay Temporarily Relay (TR)(TR)

- Coincidence memory circuits- Coincidence memory circuits

- Temporarily memorizes the ON/OFF states at - Temporarily memorizes the ON/OFF states at the branching of circuits.the branching of circuits.

- Up to 8 (TR0 to TR7) can be used for one - Up to 8 (TR0 to TR7) can be used for one block.block.

Page 84: Basic PLC Training 1 Day

TR Application ExampleTR Application Example

TR0 TR1

Page 85: Basic PLC Training 1 Day

INTERLOCK CIRCUITINTERLOCK CIRCUIT

000.01

010.01

010.01000.03

MOTOR FORWARD

RESETSW 1

000.02

010.02

010.02000.03

MOTOR REVERSE

010.01

010.02

END

MOTOR FORWARD

MOTOR REVERSE

SW 2 RESET

MOTOR REVERSE

MOTOR FORWARD

Page 86: Basic PLC Training 1 Day

Programming InstructionProgramming Instruction

1.1. Latch InstructionLatch Instruction

2.2. DIFU (13) / DIFD (14)DIFU (13) / DIFD (14)

3.3. MOV (21)MOV (21)

4.4. CMP (20)CMP (20)

Page 87: Basic PLC Training 1 Day

Latch Instruction – SET, RSET

Used momentary switches to latch and reset Used momentary switches to latch and reset output.output.

00

01

SET

1000

RSET

1000

Page 88: Basic PLC Training 1 Day

Used momentary switches to latch and reset Used momentary switches to latch and reset output.output.

Operates like a latching relay that is set by S Operates like a latching relay that is set by S and reset by R.and reset by R.

Remains ON or OFF state of a bit until one of Remains ON or OFF state of a bit until one of its two inputs sets or reset.its two inputs sets or reset.

00

01

KEEP (11) S

10.02 R

00 LD00 LD 000.00 000.00

01 LD01 LD 000.01 000.01

02 KEEP (11)02 KEEP (11) 010.02 010.02

03 END (01)03 END (01)

Latch Instruction – KEEP (11)

Page 89: Basic PLC Training 1 Day

Differentiation Up & DownDifferentiation Up & DownDIFU (13) and DIFD (14)DIFU (13) and DIFD (14)

DIFU turns its output ON when it detects an DIFU turns its output ON when it detects an OFF > ON transition in its input signal.OFF > ON transition in its input signal.

DIFD turns its output ON when it detects an DIFD turns its output ON when it detects an ON > OFF transition in its input signal.ON > OFF transition in its input signal.

Page 90: Basic PLC Training 1 Day

One Shot-DIFU (13) and DIFD One Shot-DIFU (13) and DIFD (14)(14)

000.00

DIFU

DIFD

000.00DIFU

200.00

010.00200.00

• DIFU and DIFD only turns an output ON DIFU and DIFD only turns an output ON for only for only one scan/pulseone scan/pulse..

SW1

010.01200.01

000.00DIFD

200.01SW2

Page 91: Basic PLC Training 1 Day

Differentiation MonitorDifferentiation Monitor

SHIFTSHIFTCONTCONT

##

CLRCLR

2000020000 MONTRMONTR

SRCHSRCH

SRCHSRCH

00000000

2000020000

^ OFF^ OFF

2000020000

U@ OFFU@ OFF

2000120001

D@ OFFD@ OFF

2000020000

^ OFF^ OFF

DIFU MonitorDIFU Monitor

DIFD MonitorDIFD Monitor

* Buzzer will sound when the specified bit status * Buzzer will sound when the specified bit status change.change.

Page 92: Basic PLC Training 1 Day

MOV(21MOV(21))

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 00 1 1 1 1 0 1 0 1 0 1 0 1 1 0 0

Channel 100 - Source Word

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 00 1 1 1 1 0 1 0 1 0 1 0 1 1 0 0

Channel 101 - Destination Word

Page 93: Basic PLC Training 1 Day

CMP (20)

CMP is used to compare the data in a specific CMP is used to compare the data in a specific channel, with the data in another channel, or a channel, with the data in another channel, or a

4-digit, hexadecimal constant.4-digit, hexadecimal constant.

00000

First compare wordSecond compare word

25505Greater Than

1000

25506Equal To

1001

25507Less Than

1002

CMP(20)CP1CP2

Page 94: Basic PLC Training 1 Day

ExerciseExerciseUpper Limit Sensor

000.01

Lower Limit Sensor

000.02

Door Close Sensor

000.03

Door Open Sensor

000.00

Truck

Ware House

Door Open Output 010.00

Door Close Output 010.01

How to ensure the truck pass into the ware house How to ensure the truck pass into the ware house correspondent to those input signals? The control circuit will correspondent to those input signals? The control circuit will controls the outputs that drive the motor for open or close controls the outputs that drive the motor for open or close the door. the door.