THEORY

Introduction

A programmable logic controller (PLC) is a special form of microprocessor-based controller

that uses programmable memory to store instructions and to implement function such as logic,
sequencing, timing, counting, and arithmetic in order to control machines and processes.

Program

Inputs Outputs
PLC

Figure 1: A Programmable
Logic Controller

PLC is used as it has great advantage that the same basic controller can be used with
wide range of control systems. To modify a control system and the rules that are to be used, all
that is necessary is for an operator to key-in a different set of instruction to inputs. There is no
need of rewire. The result is a flexible, cost-effective system that can be used with control
systems.

PLC’s is widely used in many operations. Although PLCs is similar to computer, PLCs
are optimized for calculations and display tasks. PLCs are optimized for control tasks and the
industrial environment. Thus, when compared to computer. PLCs:

 Are rugged and designed to withstand vibrations, temperature, humidity, and noise.
 Have interfacing for inputs and outputs already inside the controller. PLCs in a rack
format are easy to expand to tackle a large number of inputs/outputs.
 Easy to be programmed and have easily understood programming language.
 Good with long term data storage and analysis.
Ladder diagram

Ladder logic is a written method to document the design and construction of relay
racks as used in process and manufacturing control. The instructions from a ladder diagram
are translated to machine code that can be stored in the PLC memory. The logic in a ladder
diagram typically flows from left to right. The diagram can be divided into sections called
rungs, which are roughly analogous to the rungs on a ladder. Each rung typically consists of a
combination of input instructions. These instructions lead to a single output instruction;
however, rungs containing function block instructions may be more complicated. Each device
has their own symbol as representation inside the ladder diagram. Below is the main symbol
use in the PLC ladder system.

Symbol Description
NO contact is used to tell the processor to
look at a specific bit in its RAM memory. If
the bit is 1, the instruction is true and if it is
0, the instruction is false.
NC contact plays the same role as the
previous one, except that if the bit addressed
is 1, the instruction is false and if it is 0, the
instruction is true.
Device output is used for outputting to output
module. If the instructions to the left on its
rung have a true path, then the PLC will set
the bit to which it is referenced via the
address to 1. If no complete true path is
available, the bit is set to 0.
The fourth symbol is special instruction
boxes. PLCs are microprocessor-based and
they facilitate a wide area of useful built in
functions like comparators, counters, and
timers comparators with other basic logic
instructions.
PROCEDURE

1. Turn on the PLC CPU (S7-200) and input simulator (Siemens PLC Simulations).
2. By referring to the diagram of PLC input model, select and input each element
accordingly in the simulator.
3. Next, check for error inside the simulator by pressing the “Upload” button.
4. Proceed by uploading the process into PLC CPU and start the process by pressing
“Run” button.
5. Verify the functions of each element below is correct by comparing to the
experimental result obtained with the expected theoretical result from manual.
a. Input
b. Switch
c. Start Push Button
d. Stop Push Button
e. Overload Relay
f. Motor Starter
g. On-Delay Timer
6. Record the result and answer the questions from the manual
7. Modify the arrangement of the elements inside the simulator to obtain different
result as question asked.
8. Discuss and answer the problems by evaluating the result obtained after running
the PLC system.
9. End/Stop the process and clear the sequence in the simulator.
10. Proceed to another question set and repeat steps (2-9).