PROLIFIC SYSTEMS &

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PVT. LTD.,

Overview of Presentation

Introduction to Automation
Introduction to PLC
Introduction to RS Logix PLC programming Software
Communication and Hardware Configuration
Memory Layout and SLC 500 Systems Address
Instruction Set RS Logic 500 Software
Timers
Force I/Os
Compare & Arithmetic Operations
Counters
Logical Operation
Jump & Label Functions

INDUSTRIAL AUTOMATION

What is Automation?
Automation is basically the delegation of human
control function to technical equipment for
Increasing Productivity
Increasing Quality
Reducing Cost
Increasing Safety in working conditions

What does automation facilitate?

Moving heavier loads

Positioning accurately
Moving very fast/slowly
Simultaneous movement of multiple pieces

History of Automation

Manual Control
Pneumatic or Hydraulic Controls
Hardwired Controls
Electronic Control Using Logic Gates
Programmable Logic Control

Manual Control
All the actions related to process control are
taken by the operators

Drawbacks

Likely human errors and consequently its effect

on quality of final product

The production, safety, energy consumption and

usage of raw material are all subject to the
correctness and accuracy of human action.

Pneumatic Control

Industrial automation, with its machine and process

control, had its origin in the 1920s with the advent of
"Pneumatic Controllers".

Actions were controlled by a simple manipulation of

pneumatic valves, which in turn were controlled by
relays and switches.
Drawbacks
Bulky and Complex System
Involves lot of rework to implement control logic
Longer project time

Hard wired logic control

The contactor and Relays together with hardware

timers and counters were used in achieving the
desired level of automation
Drawback
s
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and troubleshooting

Electronic Control using Logic Gates

In 1960s with the advent of electronics, the logic

gates started replacing the relays and auxiliary
contactors in the control circuits.
The hardware timers & counters were replaced by
electronic timers

Advantages
Reduced space requirements
Less maintenance & greater reliability

Drawbacks
Changes in control logic not possible
More project time

Programmable Logic Controller

Programmable Logic Controllers (PLCs), also referred

to as programmable controllers, are in the computer
family.

They are used in commercial and industrial

applications.

A PLC monitors inputs, makes decisions based on its

program, and controls outputs to automate a process
or machine.

Programmable Logic Controller

Bedford Associates, founded by Richard Morley

introduced the first Programmable Logic Controller in
1968

PLC was known as the Modular Digital Controller

from which the MODICON company derived its name

Programmable Logic Controllers were developed to

provide a replacement for large relay based control
panels

Programmable Logic Controller

Definition by NEMA
PLC is a digitally operated electronic
system, designed for use in industrial
environments, which uses a programmable
memory for the internal storage of user
orientated instructions for implementing
specific functions such as logic,
sequencing, timing, counting & arithmetic
to control, through digital or analog input
and output, various types of machines or
process

Components of automation

Hardware
Software
Field Instrumentation

PROGRAMMABLE LOGIC CONTROLLERS (PLC)

PLC ARCHITECTURE
Programmable controllers replace most of the relay
panel wiring by software programming.
Program
Loader

PC
Switches

Printer
Processor

I/O
Modules

Memory

Power
Supply

Machines

Cassette
Loader
EPROM
Loader
Peripherals

External Devices

PLC Hardware
A special computer for logic controls using ladder logic
programming.

Illustration of a PLC in an
Automated system:

PLC SCAN

Time taken to
complete 1 scan
cycle is called scan
time
Typical scan time
<10ms

READ
INPUTS

EXECUTE
LOGICS

HOUSEKEEPING

UPDATE
OUTPUTS

Communication Ports

RS-232
An RS-232 communication channel allows for simple

connectivity to a personal computer for program upload,

download, and
monitoring using multiple protocols,
including DF1 Full-Duplex.

Various makes of PLCs

Siemens
Allen Bradley
GE Fanuc
Modicon
ABB
Omron
Delta
Mitsubishi
Messung

Types of PLC

Integrated type PLC

All modules
are integrated into
single unit.
Rack/ Slot type PLC
All modules
are interconnected
using Racks.

ROCKWELL
Allen Bradley

Introduction to AB PLC Hardware

1.

2.
3.
4.

Allen Bradley makes several PLC product

lines
Logic Family
SLC (Sequential Logic Control)
Micro logix
Compact logix
Control logix

Micro logix 1000

User memory 1k
Max i/o 20 i/p & 12 o/p
Communication options serial, DH
485, Device net
Execution time
1.56microsec/500instructions

SLC 500

User memory 64k

Max i/o 4096 i/p & 4096 o/p
Communication options serial, DH
485, Device net, Ethernet
Execution time
0.45microsec/500instructions

CPU Module Range

5/01

5/02

5/03

5/04

5/05

Configuration of PLC : Allen

Bradley
CPU

Power Supply

I/O Modules

SLC 500 family

5000 - Series PLC

Control Logix

Compact Logix

PLC Programming Language

Ladder Diagram - most commonly used

Functional Block Diagram (FBD)
Instruction list
Structured text
Sequential function chart

Introduction to RS Logic PLC

Programming Software

Using a specialized
Ladder Logic Software
Allen-Bradley uses
RsLogix 500
software to program
SLC, Micrologix and
so on

Instruction sets RS Logix 500

Software

PLC Ladder Diagram Instructions

1) NO & NC
2) Timer
3) Counter
4) Comparator
5) Compute Math
6) Shift Rotate

Input & Output Parameter

Contacts:
a. Normally open -| |b. Normally closed -|/|Coil:
a. Coil

-( )-

b. Set Coil

-(S)-

c. Reset Coil

-(R)-

()

Advantages of PLCs

Easy to program
Easy to maintain
Reliable in industrial environment
Compact

Ladder Logic Diagram

LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize,
etc.
Do not confuse the internal relay and program with the
external switch and relay. Internal symbols are used for
programming. External devices provide actual interface.
(In the notes we use the symbol "~" to represent negation.
AND and OR are logic operators. )

Ladder Logic Diagram

The Ladder Diagram

(LD)
programming
language originated from
the
graphical
representation used to
design
an
electrical
control system
Control
decisions
were
made
using
relays

LADDER LOGIC DIAGRAMS

PLC programming language is called Boolean
instruction language (or mnemonic code
language). This language involves four
standardized
mnemonic
words:
LOAD (yes), AND, OR, NOT

The logical
relationships can be
represented in a
diagram called a logic
network diagram.
The symbols used in
a logic network
diagram
corresponding to the
basic Boolean
operators are shown
in the figure.

AND

OR

NOT

LADDER LOGIC DIAGRAMS

A Boolean statement is like:

If (a conveyor carries a box)
AND (the chute has no box)
THEN (turn the conveyor motor on)
In Boolean logic, terms TRUE or
FALSE are main parameters.

The symbols used in a ladder logic

diagram are as shown:
AND

Input

Output

OR

NOT

AND Operation

AND: Simply represents and

operator in simple logic.
It is put between two statements
when the output is dependent on
whether BOTH of the statements are
true or BOTH of the statements are
false.
It is represented by the symbol:

Ladder Logic using AND Operation

In this AND gate logic, it can be said that only if the switches X1 and
X2 change their states form opened to closed,the current can go to the
lamp.

OR Operation

OR: Simply represents or operator

in simple logic. It is put between two

statements when the output is
dependent on either one statement or
the other. For a number of statements
that are connected in series by or
operator, if one statement required by
the output is true, then output is true.
It is represented by the symbol:

Ladder Logic using OR Operation

In this OR gate logic, it can be said that if either one of the

switches X1 or X2 change its state form opened to closed,the
current can go to the lamp.

COUNTER Operation
COUNTER: It counts the number of times
logical statements go from false or true. It
is used when an application must start or
stop after a number of same task is
performed, or simply when a task is
needed to be counted. It is represented by
the symbol below, with the number
indicating that the following step will be
performed after counter counts that
number of times.

Counter

Up Counter (CTU)
Down Counter (CTD)
Up Down Counter (CUD)

COUNTER UP/DOWN

COUNTER

C5:0

(EN)

PRESET

10

(DN)

ACCUM

Counter Waveform

TIMER Operation

TIMER: It basically counts time units.

It is used for similar purposes like a
counters, and represented by the
symbol below. The number indicated
means that the following task will be
performed after timer counts that
number of time units (usually
seconds).

TIMER ON/OFF/RTO

TIMER

: T4:0

TIMEBASE

: 1 SEC

PRESET

: 100

ACCUM

(EN)
(DN)

ON delay timer
Input

ON
OFF
Time

Output

Time
delay

ON
OFF
Time

OFF delay timer

Input

ON
OFF
Time

Output

Time
delay

ON
OFF
Time

TIMERS AND COUNTERS

Input

Timers:
True

False

True

RTO counting

stop

counting
resume

RTF

counting stop

a. Retentive on delay -(RTO)b. Retentive off delay -(RTF)c. Reset

-(RST)stop

Counter:
a. Counter up

-(CTU)-

b. Counter down

-(CTD)-

c. Counter reset

-(CTR)-

RTO reach PR value, output ON

RTF reach PR value, output OFF
PR value in 0.1 second

AND and OR LOGIC

PB1

PB2

R1
R1 = PB1.AND.PB2

AND

PB3

PB1

PB4

R2

R2 = PB2.AND.~PB4

R1
R1 = PB1 .OR. PB2

OR

PB2

COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

R1

PB1

PB2

pb3

Addressing
Digital Input
Addressing

Digital Output
Addressing

Syntax : Input: Slot No.

word/bit

Syntax : O:Slot No.

Word/bit

Ex

Ex

I:1.0/0 I1

O:2.0/0 O1

I:1.0/1 I2

O:2.0/1 O2

I:1.0/2 I3

O:2.0/2 O3

Downloading Programming software to PLC

Uploading PLC to Programming software

RS 232
Cable
PLC

SWITCHE
S
Non-locking

Normally Open

Loading

Normally Closed

Monitoring Status

Digital Memory
1 Bit 1 Digital information
( 0 or 1 )
1 Byte 8 Bits 1 analog information
( 0 to 255 )
( -128 to +127 )
1 Word 2 Byte 16 Bits 1 analog information
( 0 to 65535 )
( -32768 to +32767 )
1 Double word 2 Word 4 Byte 32 Bits 1 analog information
( 0 4294967295 )
(-2147483648 to +2147483647)

O1

I1

A (NO)
B
B
A (NO)
Press -------------> Energized
Not Press----> Not Energized

DO

DI

O1

I1

A (NO)
B
A (NC)
B
Press --------> Not Energized
Not Press---------> Energized

DI

DO

O1

I1

A
(NO)

B
A (NO)

Press ------------->
Energized
Not Press----> Not
Energized

DI

D
O
O1

I1

A
(NO)

B
A (NC)

Press --------> Not

Energized

DI

Not Press--------->
Energized

D
O

Program 1

There are 2 NO push buttons and 2 digital outputs are

provided
When I press 1st digital input, 2nd digital output
should get energized.
When I press 2nd digital input, both output should
get energized.
When I am not pressing anything, 1st digital output
should get energized

Program 2

There are 2 Digital sensors (Proximity and level) and 2 digital outputs (Motor and
Valve) are provided in Bottle filling process.
Bottle stops moving when proximity sensor detects and open Solenoid valve.
Close solenoid valve when level sensor detects and move the filled bottle.
Assume Proximity sensor gives logic1 when it detects the object
and level sensor gives logic1 when it detects high level.

Valve

Moto
r

PS

LS

Program 3

There are 2 Digital level sensors and 2 digital outputs (Pump and Valve)
are provided in tank level process.
Assume both the sensor detects the water, it gives logic1.
When tank level is low, switch on the pump and close the solenoid
valve.
When tank level is high, switch off the pump and open the solenoid
valve.
Pump
LS
2

TANK
Valv
e
LS
1

Conclusion

PLCs are replacement of Relay based systems

Ladder Logic is developed to program this specialize
devices using graphical symbols
Easy to maintain and program.
Each manufacture has its own custom software to
program PLCs
Inputs are external signal from processes for the PLC to
monitor. Ex: sensors
Outputs are internal signal from PLC to control a
particular process. Ex: motors

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Automation (PGDIA) 3 Months
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Systems (PGDES) 3 Months
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Automation Engineer
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