Industrial Automation - Final PDF

Industrial automation can be defined as the use of set technologies and automatic
control devices that results the automatic operation and control of industrial
processes without significant human intervention and achieving superior
performance than manual control. Industrial automation facilitates to increase the
product quality, reliability and production rate while reducing production and
design cost by adopting new, innovative and integrated technologies and services.
Automation replaces the human involvement with the use of logical programming
commands and powerful machineries. These automation devices include PLCs,
PCs, etc. and technologies include various industrial communication systems.
Advantages of Industrial Automation
 Lower operating cost

 High productivity
 High Quality
 High flexibility
 High Information Accuracy
 High safety
 Reduced Space
 Energy saving
 Easier trouble shooting
Disadvantages of Industrial Automation
 High Initial cost
Applications of Industrial Automation
 Various Machinery
 Various Process Industry
 Food,
 Beverages,
 Refined oil,
 Gasoline,
 Pharmaceuticals,
 Chemicals
 Plastics
 Cement
 Power Generation
 Home Automation
Industrial Automation Overview:
 The Key element in industrial automation system is PLC i.e. Programmable
Logic Controller.
PLC: A programmable logic controller (PLC) is a special form of

microprocessor-based controller that uses a programmable memory to store
instructions and to implement functions such as logic, sequencing, timing,
counting and arithmetic in order to control machines and processes.
The basic units have a CPU (a computer processor) that is dedicated to run one
program that monitors a series of different inputs and logically manipulates the
outputs for the desired control.
The PLC receives information from connected sensors or input devices,

processes the data, and triggers outputs based on pre-programmed parameters.
Depending on the inputs and outputs, a PLC can monitor and record run-time
data such as machine productivity or operating temperature, automatically start
and stop processes, generate alarms if a machine malfunctions, and more.
Programmable Logic Controllers are a flexible and robust control solution,
adaptable to almost any application.
Major Components of a PLC
A programmable logic controller (PLC) is a special form of microprocessor-based

controller that uses a programmable memory to store instructions and to implement
functions such as logic, sequencing, timing, counting and arithmetic in order to
control machines and processes and are designed to be operated by engineers with
perhaps a limited knowledge of computers and computing languages. The term
logic is used because programming is primarily concerned with implementing
logic and switching operations.
Input devices, e.g. sensors such as switches, and output devices in the system being
controlled, e.g. motors, valves, etc., are connected to the PLC. The operator then
enters a sequence of instructions, i.e. a program, into the memory of the PLC. The
controller then monitors the inputs and outputs according to this program and
carries out the control rules for which it has been programmed.
PLCs are similar to computers but whereas computers are optimised for calculation
and display tasks, PLCs are optimised for control tasks and the industrial
environment.
Thus PLCs are:
1. Rugged and designed to withstand vibrations, temperature, humidity and noise.

2. Have interfacing for inputs and outputs already inside the controller.
3. Are easily programmed and have an easily understood programming language
which is primarily concerned with logic and switching operations.
Typically a PLC system has the basic functional components of processor
unit, memory, power supply unit, input/output interface section, communication
interface and the programming device.
1. The processor unit or central processing unit (CPU) is the unit containing the
microprocessor and this interprets the input signals and carries out the control
actions, according to the program stored in its memory, communicating the
decisions as action signals to the outputs.
2. The power supply unit is needed to convert the mains a.c. voltage to the low d.c.
voltage (5 V) necessary for the processor and the circuits in the input and output
interface modules.
3. The programming device is used to enter the required program into the memory
of the processor. The program is developed in the device and then transferred to
the memory unit of the PLC.
4. The memory unit is where the program is stored that is to be used for the control
actions to be exercised by the microprocessor and data stored from the input for
processing and for the output for outputting.
5. The input and output sections are where the processor receives information from
external devices and communicates information to external devices. The inputs
might thus be from switches, other sensors such as photo-electric cells, temperature
sensors, or flow sensors, etc. The outputs might be to motor starter coils, solenoid
valves, etc.
Input and output devices can be classified as giving signals which are discrete,
digital or analogue. Devices giving discrete or digital signals are ones where the
signals are either off or on. Thus a switch is a device giving a discrete signal, either
no voltage or a voltage. Digital devices can be considered to be essentially discrete
devices which give a sequence of on−off signals. Analogue devices give signals
whose size is proportional to the size of the variable being monitored. For example,
a temperature sensor may give a voltage proportional to the temperature.
I/O Configurations:
Fixed I/O: Typical of small PLCs. comes in one package, with no separate units.
The processor and I/O are packaged together.
Modular I/O: Divided by compartments into which separate module into plugged.
6. The communications interface is used to receive and transmit data on
communication networks from or to other remote PLCs & HMI. It is concerned
with such actions as device verification, data acquisition, synchronisation between
user applications and connection management.
Internal architecture
It consists of a central processing unit (CPU) containing the system
microprocessor, memory, and input/output circuitry.
The buses
The buses are the paths used for communication within the PLC. The information
is transmitted in binary form, i.e. as a group of bits with a bit being a binary digit
of 1 or 0, i.e. on/off states. The term word is used for the group of bits constituting
some information. Thus an 8-bit word might be the binary number 00100110. Each
of the bits is communicated simultaneously along its own parallel wire.
The system has four buses:

1. The data bus carries the data used in the processing carried out by the
CPU.
2. The address bus is used to carry the addresses of memory locations. So that each
word can be located in the memory, every memory location is given a unique
address.
3. The control bus carries the signals used by the CPU for control
4. The system bus is used for communications between the input/output
ports and the input/output unit.
Memory
There are several memory elements in a PLC system:
1. System read-only-memory (ROM) to give permanent storage for the operating
system and fixed data used by the CPU.
2. Random-access memory (RAM) for the user’s program.
3. Random-access memory (RAM) for data.
Input/output unit
The input/output unit provides the interface between the system and the outside
world, allowing for connections to be made through input/output channels to input
devices such as sensors and output devices such as motors and solenoids.
It is also through the input/output unit that programs are entered from a program
panel. Every input/output point has a unique address which can be used by the
CPU. It is like a row of houses along a road, number 10 might be the ‘house’ to be
used for an input from a particular sensor while number ‘45’ might be the ‘house’
to be used for the output to a particular motor.
The input/output channels provide isolation and signal conditioning functions so
that sensors and actuators can often be directly connected to them without the need
for other circuitry. Electrical isolation from the external world is usually by means
of optoisolators (the term optocoupler is also often used).
When a digital pulse passes through the light-emitting diode, a pulse of infrared
radiation is produced. This pulse is detected by the phototransistor and gives rise to
a voltage in that circuit. The gap between the light-emitting diode and the
phototransistor gives electrical isolation but the arrangement still allows for a
digital pulse in one circuit to give rise to a digital pulse in another circuit.
The digital signal that is generally compatible with the microprocessor in the PLC
is 5 V D.C. However, signal conditioning in the input channel, with isolation,
enables a wide range of input signals to be supplied to it. A range of inputs might
be available with a larger PLC, e.g. 5 V, 24 V, 110 V and 240 V digital/discrete,
i.e. on−off, signals. A small PLC is likely to have just one form of input, e.g. 24 V.
The output from the input/output unit will be digital with a level of 5 V.
However, after signal conditioning with relays, transistors the output from the
output channel might be a 24 V, 100 mA switching signal, a D.C voltage of 110V,
1 A or perhaps 240 V, 1 A A.C or 240 V, 2 A A.C, from a transistor output
channel. With a small PLC, all the outputs might be of one type, e.g. 240 V A.C, 1
A. With modular PLCs, however, a range of outputs can be accommodated by
selection of the modules to be used.
Outputs are specified as being of relay type, transistor type

1. With the relay type, the signal from the PLC output is used to operate
a relay and is able to switch currents of the order of a few amperes in an external
circuit.
2. The transistor type of output uses a transistor to switch current through the
external circuit. This gives a considerably faster switching action.
Sourcing and sinking
The terms sourcing and sinking are used to describe the way in which D.C devices
are connected to a PLC.
Programming a PLC: In order to create or change a program, the following items
are needed:
 PLC
 Programming Device
 Programming Software
 Connector Cable
Scan time: The scan cycle is the cycle of which the PLC gathers the inputs, runs
PLC program and then updates the outputs. This will take some amount
of time often measured in milliseconds or ms. The amount of time it takes for
the PLC to make one scan cycle is called the scan time of the PLC.
Selection of PLC
 Define capacity input/output

 Define types input/output
 Define memory size
 Describe types of software language
 Number of special I/O modules
 Scan time
 Communications
PLC Programming Language:
 Ladder Diagram (LD)

 Sequential Function Chart (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)
Ladder Diagram:
Ladder diagrams are specialized schematics commonly used to document industrial

control logic systems. They are called "ladder" diagrams because they resemble a
ladder, with two vertical rails (supply power) and as many "rungs" (horizontal
lines) as there are control circuits to represent. If we wanted to draw a simple
ladder diagram showing a lamp that is controlled by a hand switch, it would look
like this:
The "L1" and "L2" designations refer to the two poles of a power supply. L1 is the
"hot" conductor, and L2 is the grounded ("neutral") conductor.
PLC Wiring
PLC Power Connection
PLCs are available that operate on a wide range of power typically 24VDC,
120VAC, 240VAC. Some manufactures produce units that will operate on any
voltage from 120VAC to 240VAC without any modification of unit. Connection of
power to the dc-type units requires that careful attention be paid to ensure that the
positive (+) and negative (-) power wires are correctly connected.
Input Wiring
The inputs of modern PLCs are generally opto-isolators. An opto-isolator is a

device consisting of a light-producing element, such as an LED, and a light sensing
element such as phototransistor. When a voltage is applied to the LED, light is
produced which strikes the photo-detector. The photo-decector then change its
output.
Figure: Typical PLC Input circuit.

Figure: PLC with common inputs.
Figure: PLC input wiring.

Output Wiring
Description of Some Common Input Devices
Switch: A switch is a component which controls the openness or closeness of an

electric circuit. They allow control over current flow in a circuit.
A circuit diagram with an LED, resistor, and a switch. When the switch is closed,
current flows and the LED can illuminate. Otherwise no current flows, and the
LED receives no power.
Commonly used Industrial Switch:
Push-button switch:
A push to make switch allows electricity to flow between its two contacts when
held in. When the button is released, the circuit is broken. This type of switch is
also known as a Normally Open (NO) Switch. (Examples: doorbell, computer
case power switch, calculator buttons, individual keys on a keyboard).
Symbol:
A push to break switch does the opposite, i.e. when the button is not pressed,
electricity can flow, but when it is pressed the circuit is broken. This type of switch
is also known as a Normally Closed (NC) Switch. Example: Alarm Switches in
Fail-Safe circuits.
Selector switch: A switch that is used to select among alternatives.
Symbol:
It is commonly two types two way/three way selector switch.
Key Switch: A key switch is a switch that can be activated only by the use of a
key. They are usually used in situations where access needs to be restricted to the
switch's functions.
Emergency stop switch: A general-purpose push button switch is used for
controls, e.g., to start machine operation or to switch modes. An emergency stop
push button switch is used as a safety measure to stop hazardous parts (loads).
An Emergency Stop Switch must be highly visible in color and shape, and must be
easy to operate in emergency situations. The following requirements are specified
in the European Standard EN 418 (International Standard: ISO13850).
1. A direct opening mechanism must be installed on the NC contact.
2. There must be a self-holding function.
3. The button must be a "mushroom" head design or something equally easy to use.
4. The button must be red and the background must be yellow.
Limit Switch: A switch that operates as an automatic control to prevent a

mechanism or process from going beyond a prescribed limit. Limit switch take the
place of a human operator.
Symbol:
Level Switch: Relay-Based ON/OFF Controller
ON/OFF control is a type of control method commonly applied to process control

applications such as liquid level control. Two level switches are positioned at high
and low level limits. The control circuit maintains the level between the level
limits.
When the level falls below the low level limit, the low level switch send a signal to
the control circuit, causing the control circuit to close to continue rising the level
operated through solenoid valve or motor. The tank level then rises until it reaches
the high level limit. At that point, the high level switch sends a signal to the control
circuit, causing it to open to stop the flow operated through the solenoid valve or
motor. When the level is between the upper and lower level sensors, there is no
change in the control circuit's output. Since there is no change in the output, there
is no change in the position of the final control element (valve). For this reason, the
area between the high level and low level is called the dead band, or neutral zone.
Example: ANLY float less Relay Model: AFR-1
Specification
Operating Voltage : 110, 220, 240 VAC
Rated frequency : 50/60 Hz
Power Consumption : Approx. 3.2 VA

Connection Diagram:
Pressure switch: A pressure switch is a form of switch that close/open an

electrical contact when a certain set fluid pressure has been reached on its input.
The switch may be designed to make contact/break contact either on pressure rise
or on pressure fall. Pressure switch is a device which controls and protects the
system from low pressure and high discharge pressure.
Sensor: A sensor is a device which is capable of converting any physical quantity
to be measured into a signal which can be read, displayed, stored or used to control
some other quantity.
Sensors are used to measure physical quantities such as presence, temperature,

light, pressure, sound, and humidity. They send signals to the processor.
Application of Sensor
Sensor Output type:
Discrete or Digital: 0/1 or On/Off or True/False
Analog: 4-20 mA, 0-20 mA, 0-10 V.
Proximity Sensor: A proximity sensor is a sensor able to detect the presence of

nearby objects without any physical contact. A proximity sensor often emits an
electromagnetic field or a beam of electromagnetic radiation (infrared, for
instance), and looks for changes in the field or return signal.
Inductive Proximity Sensor: An inductive proximity sensor is a type of non-contact

electronic proximity sensor that is used to detect the position of metal objects.
Inductive proximity sensors are used for non-contact detection of metallic objects.
Their operating principle is based on a coil and oscillator that creates an
electromagnetic field in the close surroundings of the sensing surface
Major component: inductive coil, an oscillator, a Schmitt trigger, and an output
amplifier.
It works on the principle of the resonance and eddy currents. This sensor is also
known as an electronic oscillator. These are basically used to detect the metallic
object. It generally consists of an inductive coil made up of very fine copper wire.
A capacitor is used to store the charge and a power supply to produce the electrical
excitation. They are used currents induced by a magnetic field to detect the
metallic objects. In the coil high-frequency magnetic field generated.
Now, If there is any metallic object this inductive magnetic field produces a
current into the metallic object which results to develop a new magnetic field and
this magnetic field opposes the earlier magnetic field. The net effective change in
the magnetic field is to changes in inductance of the inductive sensor.
Output: Most industrial proximity sensors (inductive, capacitive, ultrasonic and

photo electric) are solid state. Solid state electronic components such as transistors
are used to switch the output of the sensor upon detection of an object.
Two specific types of sensors are available; PNP and NPN. The difference is a
result of the internal circuit design and type of transistors used.
Wiring Diagram:
Capacitive Proximity Sensor: Capacitive proximity sensors are similar to inductive
proximity sensors. The main difference between the two types is that capacitive
proximity sensors produce an electrostatic field instead of an electromagnetic field.
Capacitive proximity sensor are suitable for detecting metals, non-metals, solids,
and liquids, although it is best suited for non-metallic targets because of its
characteristics and cost relative to inductive proximity sensors.
The sensor consists of four basic components:
A capacitive probe or plate
An oscillator
A signal level detector
A solid-state output switching device.
The working principle is based on the variation in the capacitance. It consists of

plates, the threshold detector, oscillator and output circuit.
When we put the sensor in working condition an electrostatic field is generated by
the capacitor plate and if there is any object within that field then the capacitance
will change as a result oscillator start oscillating. If the target object is very near to
the sensor then the capacitance will increase and vice versa (As the target moves
away from the sensor the oscillator amplitude decreases).
Photo-electric Sensor: A photoelectric sensor, or photo eye, is an equipment used
to discover the distance, absence, or presence of an object by using a light
transmitter, often infrared, and a photoelectric receiver. It is an electrical device
that responds to a change in the intensity of the light falling upon it.
Photoelectric sensors are made up of a light source (LED), a receiver

(phototransistor), a signal converter, and an amplifier. The phototransistor analyses
incoming light, verifies that it is from the LED, and appropriately triggers an
output.
Types of photoelectric Sensor:
Diffuse: Both the light emitting and light receiving elements are contained in a
single housing. The sensor receives the light reflected from the target.
Reflective: Both the light emitting and light receiving elements are contained in
same housing. The light from the emitting element hits the reflector and returns to
the light receiving element. When a target is present, the light is interrupted.
Through-Beam: The transmitter and receiver are separated. When the target is
between the transmitter and receiver, the light is interrupted.
Temperature Sensor: A temperature sensor is a device, typically, a thermocouple

or RTD, that provides for temperature measurement through an electrical signal.
Temperature sensing is one of the most sensitive properties or parameters for
industries like petrochemical, automotive, aerospace and defense, consumer
electronics, and so on. These sensors are installed into devices with the purpose of
measuring the temperature of a medium accurately and efficiently in a given set of
requirements.
Common Temperature Sensor
 RTD (Resistance Temperature Detector)

 Thermocouple
Resistance Temperature Detector: The main principle of operation of an RTD is
that when the temperature of an object increases or decreases, the resistance also
increases or decreases proportionally. RTD types are broadly classified according
to the different sensing elements used. Platinum, Nickel and Copper are the most
commonly used sensing elements. Platinum is considered the best as it has the
widest temperature range.
PT 100(Platinum Resistance Thermometer): A type of resistance temperature

detector. Pt-100 or pt100 is one of the most used temperature sensor. It is one of
the most used temperature sensor, cheap but robust for use.
PT-100 is named as such because platinum is used as the sensing material and at
with perfect calibration it has 100 ohm resistance at 0°c.
Thermocouple: Thermocouples consist of two wire legs made from different

metals. The wires legs are welded together at one end, creating a junction. This
junction is where the temperature is measured. When the junction experiences a
change in temperature, a voltage is created. The voltage can then be interpreted
using thermocouple reference tables to calculate the temperature range linearly.
Thermocouples are used in many industrial, scientific, and OEM applications.
They can be found in nearly all industrial markets: Power Generation, Oil/Gas,
Pharmaceutical, BioTech, Cement, Paper & Pulp, etc. Thermocouples are also used
in everyday appliances like stoves, furnaces, and toasters.
Types of Thermocouple
Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the

most common type of thermocouple. It’s inexpensive, accurate, reliable, and has a
wide temperature range.
Temperature Range: (–270 to 1260 0 C)
Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a

smaller temperature range and a shorter lifespan at higher temperatures than the
Type K. It is equivalent to the Type K in terms of expense and reliability.
Type T Thermocouple (Copper/Constantan): The Type T is a very stable

thermocouple and is often used in extremely low temperature applications such as
cryogenics or ultra-low freezers.

Pressure Sensor: A pressure sensor is a device for pressure measurement of gases
or liquids. Pressure is an expression of the force required to stop a fluid from
expanding, and is usually stated in terms of force per unit area. A pressure sensor
usually acts as a transducer; it generates a signal as a function of the pressure
imposed. A pressure transducer or pressure transmitter converts pressure into an
analog electrical signal. Although there are various types of pressure transducers,
one of the most common is the strain-gage base transducer.
What is the difference between a pressure sensor, transducer, transmitter,

and switch?
Pressure Sensors
A pressure sensor is any device that measures pressure and converts it to an

electrical signal. It’s an all-encompassing term that includes pressure transducers,
transmitters, and switches (these will be defined below). All transducers,
transmitters, and switches are sensors, but not all sensors are transducers,
transmitters, or switches.
Pressure Transducers and Transmitters
Pressure transducers and pressure transmitters are very similar. A pressure

transducer is an electromechanical device for translating pressure values into
voltages across a high-impedance load (5,000 ohms or greater). A transmitter on
the other hand translates pressure values into currents (generally 4-20 mA) across a
low-impedance load. In general, transmitters are preferred when sending a signal
over relatively long distances (i.e. over thousands of feet). Neither of which,
however, can change or control pressure. These devices are solely for measuring
pressure and communicating the output electronically or visually.
Pressure Switches
Unlike a transducer or transmitter that can translate all of the pressures in its range,
a pressure switch will trigger at a specific set pressure. That set pressure can either
be high or low and can either engage or disengage a circuit. These are commonly
found in vehicles to indicate low engine oil pressure and in gas compressors with
an automatic shut-off mechanism.
Description of Some Common output Devices
Relay: A relay is an electromagnetic switch consisting with a coil and two

terminals called normally open (NO) and normally close (NC). When a small
electric current flows through the coil, the terminals state changes each to another.
It is an electromagnetic switch operated by a relatively small electric current that

can turn on or off a much larger electric current. The heart of a relay is an
electromagnet (a coil of wire that becomes a temporary magnet when electricity
flows through it).
Relay Pin Configuration:

Magnetic Contactor: A magnetic contactor is an electrically controlled switch used
for switching an electrical power circuit, similar to a relay except with higher
current ratings.
A solid-state relay (SSR) is an electronic switching device that switches on or off
when a small external voltage is applied across its control terminals. The relay may
be designed to switch either AC or DC to the load. It serves the same function as
an electromechanical relay, but has no moving parts. Packaged solid-state relays
use power semiconductor devices such as thyristors and transistors, to switch
currents up to around a hundred amperes. Solid-state relays have fast switching
speeds compared with electromechanical relays, and have no physical contacts to
wear out.
Solenoid Valve: A solenoid valve is an electromechanical device in which the

solenoid uses an electric current to generate a magnetic field and thereby operate a
mechanism which regulates the opening of fluid flow in a valve. Solenoid valves
are the most frequently used control elements in fluidics. Their tasks are to shut
off, release, dose, distribute or mix fluids.
A- Input side B- Diaphragm C- Pressure chamber D- Pressure relief passage E-
Electro Mechanical Solenoid F- Output side
Control Valve: A control valve is a valve used to control fluid flow by varying the
size of the flow passage as directed by a signal from a controller. This enables the
direct control of flow rate and the consequential control of process quantities such
as pressure, temperature, and liquid level. A control valve is a valve used to control
fluid flow by varying the size of the flow passage as directed by a signal from a
controller. This enables the direct control of flow rate and the consequential control
of process quantities such as pressure, temperature, and liquid level.
Solid State Relay: A solid-state relay (SSR) is an electronic switching device that
switches on or off when a small external voltage is applied across its control
terminals. SSRs consist of a sensor which responds to an appropriate input (control
signal), a solid-state electronic switching device which switches power to the load
circuitry, and a coupling mechanism to enable the control signal to activate this
switch without mechanical parts. The relay may be designed to switch either AC or
DC to the load. It serves the same function as an electromechanical relay, but has
no moving parts.
The solid state relay being a purely electronic device has no moving parts within
its design as the mechanical contacts have been replaced by power transistors,
thyristors or triac’s. The electrical separation between the input control signal and
the output load voltage is accomplished with the aid of an opto-coupler type Light
Sensor.
Different types of protective devices
 Fuse
 Miniature Circuit Breaker (MCB)
 Molded Case Circuit Breaker (MCCB)
 Earth Leakage Circuit Breaker (ELCB)
 Motor Protection Circuit Breaker (MPCB)
 Air Circuit Breaker (ACB)
 Overload Relay
Electrical Fuse
Fuse is a piece of wire of a material with very low melting point. When a high
current flow through the circuit the wire gets heated and melts. As a result, the
circuit is broken and current stops flowing.
Miniature Circuit Breaker (MCB)
An MCB or miniature circuit breaker is an electromagnetic device that embodies

complete enclosure in a molded insulating material. The main function of an MCB
is to switch the circuit or to open the circuit automatically when the current passing
through it (MCB) exceeds the value for which it is set. It also can be manually
switched ON and OFF as similar to normal switch if necessary.
Molded Case Circuit Breaker
MCCBs are a type of electrical protection device that is commonly used when load
currents exceed the capabilities of MCB. They are also used in applications of any
current rating that require adjustable trip settings, which are not available in
MCBs.
Earth Leakage Circuit Breaker (ELCB)
An earth leakage circuit breaker (ELCB) is a safety device used in electrical

installations with high earth impedance to prevent shock. It detects small stray
voltages on the metal enclosures of electrical equipment, and interrupts the circuit
if a dangerous voltage is detected.
Motor Protection Circuit Breaker
A motor protection circuit breaker is a specialized electromechanical device that

can be used with motor circuits to provide a safe electrical supply for motors and
protection against electrical faults such as short circuits, line to ground faults, line
to line faults, motor overload, phase unbalance and phase loss.
Air Circuit Breaker
Air Circuit Breaker (ACB) is an electrical device used to provide Overcurrent and
short-circuit protection for electric circuits over 800 Amps to 10K Amps. These are
usually used in low voltage applications below 450V. We can find these systems in
Distribution Panels (below 450V).
The main function of air circuit breaker is to:

– Open and close a 3 phase circuit, manually or automatically.
– Open the circuit automatically when a fault occurs. Faults can be of various
types – under or over voltage, under or over frequency, short circuit, reverse
power, earth fault etc.
Overload Relay:
A relay that opens a circuit when the load in the circuit exceeds a pre-set value, in
order to provide overload protection, usually responds to excessive current, but
may respond to excessive values of power, temperature, or other quantities. It also
known as overload release.
Confabulation about motors and motor control
Star-Delta Starter & Working Principle of Induction Motor:
Star or Y-connected system:
When three coils or windings, placed 1200 apart, are connected together at a
common point as shown in below figure, they form star or Y-connected circuit.
The common point is called the Neutral or Star point.
When only three main lines are drawn, it is said to be a 3-phase, 3-wire system.
Often a neutral line is also drawn from the neutral point. In this case the system is
called a 3-phase, 4 wire system.
The current flowing through each coil is called phase current and that flowing
through main line is called line current. It can be seen in figure that each phase or
coil is connected series with its respective main line.
Therefore, in a star connected system line current is equal to phase current i.e. the
same current flows through a phase and main line connected series with it.
In a 3-phase, 4- wire system two different values of voltage are available. Each coil
is connected across a main line and the neutral line as shown in figure. Therefore,
voltage across a coil or phase is equal to voltage between a main line and the
neutral. This voltage is called phase voltage. The voltage between any two main
lines is called line voltage.
Line voltage, VL= √3VP
The power in a 3-phase, star connected system:
Power per phase= VPIPcosϴ
Hence the total power for all the three phase is given by,
P= 3VPIPcosϴ= √3VLILcosϴ
Total apparent power of the three phase= 3VPIP= √3VLIL (VA)
Total reactive power of the three phase= 3VPIPsinϴ= √3VLILsinϴ (VA) or (VAR)
Delta or Mesh Connected Circuit:
In delta connection no neutral point is available. With this connection only three-
phase, three wire system is possible.
In delta or Mesh connection each coil or phase is connected across two main lines.
Therefore in delta connection, line voltage is equal to phase voltage. Two different
values of supply voltage cannot be obtained with this connection. In a delta
connected system line current is equal to √3 times phase current.
Induction Motor
The induction motor has two main parts. The input power is given to stator. When
connected to a three phase power supply the stator of a three phase induction motor
produces a rotating magnetic field. The RMF is the one which makes the rotor
turn. This rotating magnetic field will induce electricity in the rotor bars according
to electromagnetic induction. So the rotor is like current carrying bars immersed in
a magnetic field. This will induce an electromagnetic force according to Lorentz
force law and the rotor will rotate in the same direction as the RMF. This is how
the induction motor works.
Electricity is induced on the rotor bars due to electromagnetic induction rather than
direct connection. When the induction motor starts the rotor speed is zero and
slowly increases. This means the rotating magnetic field will cut the rotor bar at
very high rate. As the rotor gain speed the rate of flux cut will decrease. So a high
current will be induced on the bars at the start. As the rotor speed increases the
current will lower the normal value. At the start stator current also must be high
since the rotor and stator current are coupled due to transformer action. Due to this
the stator coils will draw a huge amount of current when the motor starts.
The main purpose of star-delta starter is to reduce the requirement of high starting
current. Normally the starting current of an induction motor is 6 to 7 times of the
full load current. This will produce a large voltage drop in the line and affect other
devices when a heavy rating induction motor starts. As well as for larger motor the
starting current may be so high that it may damage the stator coil or even the
power cables. When we apply a three phase voltage across a star connection each
coil will receive a much reduced voltage (VP=VL/√3). Reduced input voltage
means reduced current at the starter coil. So to overcome the high starting current
need to connect the coils in star at the starting. After the reaches a considerable
speed, the stator current will be normal so that we can switch to delta
configuration.
0 1 2 3 4 5 6 7 8 9
Some common Wiring Diagram
Relay on and off

1.6 / 220 Vac 220 Vac / 1.3
11
Stop Sw
-S1
12
13 13
Start Sw Relay auxilary
-S2 -K1
14 /1.4 14
A1
-K1
220 Vac A2
1.6 / 0 Vac 0 Vac / 1.3
13 14 /1.4
Relay coil
1.a
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Single relay on and off
Ed. ABDUL AWAL
Appr Project template with identifier structure to IEC 81346 IEC_tpl002 Page 1
Modification Date Name Original Replacement of Replaced by Page 22
0 1 2 3 4 5 6 7 8 9
Relay and indicator on and off
1.a.6 / 220 Vac 220 Vac / 1.a.0
11
Stop Sw
-S3
12
13 13 13
Start Sw Relay auxilary Relay auxilary
-S4 -K2 -K2
14 /1.a.1 14 /1.a.1 14
A1 x1
-K2 -H1
220 Vac A2 220 Vac x2
1.a.6 / 0 Vac 0 Vac / 1.a.0
13 14 /1.a.2
13 14 /1.a.3
13 14 /8.4
Relay coil Indicator
1 2
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Single relay on and off with indicator
Ed. ABDUL AWAL
Appr Project template with identifier structure to IEC 81346 IEC_tpl002 Page 1.a
0 1 2 3 4 5 6 7 8 9
Single relay on- off and indicator on after 5s delay
2.6 / 220 Vac 220 Vac / 2.1
11
Stop Sw
-S5
12
13 13 13 17
Start Sw Relay auxilary
-S6 -K3 -K3 -KT4
14 /2.2 14 /2.2 14
Relay auxilary /2.4 18
A1 A1 x1
-K3 -KT4 -H2
220 Vac A2 220 Vac A2 220 Vac x2
2.6 / 0 Vac 0 Vac / 2.1
13 14 /2.2 17 18 /2.5
13 14 /2.4
Relay coil On delayTimer Indicator

5s
1.a 3
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Indicator on after dealy
Ed. ABDUL AWAL
0 1 2 3 4 5 6 7 8 9
Single phase motor on after 5s delay
-F1
2 1
3.8 / 220 Vac 220 Vac / 3.1
Breaker Single pole
1 11
11 -Q1
-Q1 12
/3.2
/3.8 12 I>
MPCB
2
11
Timer auxilary
-S7 13 17
Stop Sw Control Power
12 -K5 -KT6 1
/3.2 Relay auxilary /3.4 Relay auxilary
14 18 -K100
/3.6 2
13 13
Relay auxilary
-S8 -K5
Start Sw 14 /3.2 14
1
A1 A1
M
-K5 A1 -K100 -M1
220 Vac A2 -KT6 220Vac A2 220 Vac 1~
220 Vac A2 2
3.8 / 0 Vac 0 Vac / 3.1
13 14 /3.3 17 18 /3.6 1 2 /3.8

13 14 /3.4
Control relay On delayTimer Power Relay 1p Motor

5s
2 4
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Single phase motor on and off
Ed. ABDUL AWAL
0 1 2 3 4 5 6 7 8 9
/ R /
400 Vac
3p / S /
/ T /
1
-F3
single phase 2 1 3 5 11
breaker
-Q2
12
MPCB
/4.1
11
-Q2 I>> I>> I>>
OVERLOAD AUX /4.6 12 2 4 6
11
Stop sw
-S9
12
13
control relay
-K7
/4.1 14
auxilary
1 1 1
-k8
Magnetic contactor 2 2 2
13 13
start sw control relay Power auxilary
-S10 -K7
14 /4.1 14
auxilary
U1 V1 W1
A1 A1
M
-K7 -K8 -M2
220 Vac A2 220 Vac A2 400 Vac 3~
PE
4.9 / 0 Vac 0 Vac / 4.0
13 14 /4.2
13 14 /4.3
control relay Magnetic contactor coil Motor
3 5
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Three phase motor on off
Ed. ABDUL AWAL
0 1 2 3 4 5 6 7 8 9
MOTOR FORWARD-REVERSE
/ 220 Vac /
/ /
400 Vac / /
11
overload 3P
-Q3
/5.7 12 / /
Stop sw
11 13 17 17 17 13
-S12 -K9 -KT10 -KT11 -KT12 -K9
12 /5.0 14 /5.1 18 /5.2 18 /5.3 18 /5.0 14
1 3 5 11
-Q3
12
Start sw
/5.0
I> I> I>
13 13 17 17 17 2 4 6
-S11 -K9 -KT13 -KT10 -KT11
14 /5.0 14 /5.4 18 /5.1 18 /5.2 18
17
-KT12
/5.3 18
1 1 1 1 1 1
11 11 -K13 -K14
/5.5 /5.6
-K14 -K13 2 2 2 2 2 2
/5.6 12 /5.5 12
Timer 10 s Timer 3 s Timer 10 s Timer 3 s

U1 V1 W1
A1 A1 A1 A1 A1 A1 A1
M
-K9 -KT10 -KT11 -KT12 -KT13 -K13 -K14 -M3
220 Vac A2 220 Vac A2 220 Vac A2 220 Vac A2 220 Vac A2 220 Vac A2 220 Vac A2 3~
PE
Motor
6.0 / 0 Vac /
Control relay Forward delay Forward reverse reverse delay Reverse- Forward Forward contact Reverse contact Conditions
timer interval delay timer interval delay
Forward time 10s
Forward to Reverse interval 3 s

13 14 /5.1 17 18 /5.2 17 18 /5.3 17 18 /5.4 17 18 /5.1 1 2 /5.7 1 2 /5.8
13 14 /5.1 1 2 /5.8 1 2 /5.8
13 14 /5.5 17 18 /5.5 17 18 /5.6 17 18 /5.6 1 2 /5.8 1 2 /5.9
Reverse Time 10s
11 12 /5.6 11 12 /5.5
Reverse to Forward interval 3s
4 6
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Motor Forward-Reverse
Ed. ABDUL AWAL
0 1 2 3 4 5 6 7 8 9
/ /
400 Vac / /
/ /
MCCB
1 3 5
1 -F5
CONTROL MCB
-F4 2 4 6
/8.0 2
11
OVERLOAD AUX
-F6
/6.7 12
11
STOP SW
-S13
12
MAIN DELTA STAR

1 1 1 1 1 1 1 1 1
START SW
13 13 -KM3 -KM2 -KM1
/6.2 /6.2 /6.1
-S14 -KM3 2 2 2 2 2 2 2 2 2
14 /6.2 14
17 17 13 13
-KT20 -KT20 -KM1 -KM3
/6.0 18 /6.0 18 /6.1 14 /6.2 14
U1 V1 W1
11 11
-KM2 -KM1 1 3 5
/6.2 /6.1 M 1
12 12 -M4 -F6
3~ /6.0 2 4 6
U2 V1 W2
A1 A1 A1 A1
-KT20 -KM1 -KM2 -KM3
5S A2 A2 A2 A2
5.0 / 0 Vac /
17 18 /6.2 1 2 /6.8 1 2 /6.7 1 2 /6.5

1 2 /6.8 1 2 /6.7 1 2 /6.5
17 18 /6.1 1 2 /6.8 1 2 /6.7 1 2 /6.6
11 12 /6.2 11 12 /6.1 13 14 /6.1
13 14 /6.2 13 14 /6.3
STAR-DELTA TIMER STAR DELTA MAIN
5 7
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Star Delta
Ed. ABDUL AWAL
0 1 2 3 4 5 6 7 8 9
/ /
8.1 / N1 N1 / 8.0
8.1 / L1 L1 / 8.0
8.1 / L2 L2 / 8.0
8.1 / L3 L3 / 8.0
8.2
+24V
1 3 5
-F4
/6.0
32A 2 4 6 8.4
MCB +24V I1R1B
13 13
-K6 -K2
14 /1.a.1 14
-W20 -W21 -W22

N24
L21
L22
L23
Altivar 312 R S T
11kW
L1 L2 L3 PE1 R1A R1C R1B R2A R2C P24 STO LI1 LI2 LI3 LI4 LI5 LI6 +24V
Power Supply Common point contact NO contact of R2 External power STO Programable logic inputs Programable Programable Logic input
of programmable relay R1 programmable relay supply for control (Safe Torgue Off) logic input logic input power supply
circuit / Internal safety function or or
power supply input Pulse input Input for PTC
for STO 20 kpps probes
LI6 input Logic input

Filter settings switch switch RJ45
SW2 SW1
Normal PTC Source
IT system LI Sink Ext
Sink Int
Power supply Analog Voltage or current

Output to braking resistor
DC bus (+) DC bus (-) for reference voltage Analog I/O Analog current Analog voltage analog output Analog I/O Analog I/O
Motor (+ polarity) polarity polarity potentiometer input common input input (collector) common common Logic output
T1 T2 T3 PE2 PBe PB PA PC +10V AI1 COM1 AI3 AI2 AO1 COM2 COM3 LO- LO+
U V W + -
W23
U21
V22
A1
-K101
A2
A1 A0
U1 V1 W1 / /
11KW
M
3~
PE
Pump motor 1
7 9
Date 29-7-2017 TEXMATE ENGINEERIG FAKIR KNITWEAR Inverter
Ed. ABDUL AWAL
Induction Motor Starting Method
 Direct online (DoL)

 Star Delta Connection
 Using Soft starter
 Using Inverter/VFD
Soft Starter
Soft starter is a device used with AC electrical motors to temporarily reduce the
load and torque in the power train and electric current surge of the motor during
start-up. It controls the thyristor firing unit to regulate the angle of flow of thyristor
according to the set start-up curve via the thyristor dynamic safety monitoring and
protection unit, so as to control the voltage of motor, slowly increasing the motor
voltage and current and smoothly increasing motor torque until the motor up to full
speed.
VFD (Variable Speed Drive):
A Variable Frequency Drive (VFD) is a type of motor controller that drives an

electric motor by varying the frequency and voltage supplied to the electric motor.
Other names for a VFD are variable speed drive, adjustable speed drive, adjustable
frequency drive, AC drive and inverter.
Frequency (or hertz) is directly related to the motor’s speed (RPMs). In other
words, the faster the frequency, the faster the RPMs go. If an application does not
require an electric motor to run at full speed, the VFD can be used to ramp down
the frequency and voltage to meet the requirements of the electric motor’s load. As
the application’s motor speed requirements change, the VFD can simply turn up or
down the motor speed to meet the speed requirement.
Servo motor: A servomotor is a rotary actuator or linear actuator that allows for
price control of angular or liner position, velocity and acceleration. It consists of a
suitable motor coupled to a sensor for position feedback. Inside there is a small DC
motor, potentiometer, and a control circuit. Servos are controlled by sending an
electrical pulse of variable width, or pulse width modulation (PWM), through the
control wire. The angle of rotation is determined by the width of a pulse that is
applied to the control circuit.
Stepper motor
A stepper motor is a brushless DC electric motor that divides a full rotation into a
number of equal steps. With the help of a stepper motor controller, steps motors
convert electrical energy into precise mechanical motion. The stepper motor rotates
a specific incremental distance per each step. The number of steps that are
executed controls the degree of rotation of the motor’s shaft.
Description of some conventional controller
Counter: A counter is a simple device intended to do one simple thing- count.

These are categorized into 3 types:
Up Counter: When the Input is turned high the count is increased by one (they
only count up 1,2,3...). When the reset is turned high it set the count value back to
zero. If the count value reaches the preset value then it give a high output. The
numerical value of the counter can also be used in real time.
Down Counter: It works similar to the Up Counter just than it decreases the
counter from a preset value (LD) to zero.
Up down Counter: It can perform the functions of both Up Counter and Down
Counter. CU refer to the Up Count and CD refers to the Down Count Pulse. On
input to R the value is reset and when the value reaches PV it generates an output.
Example of Counter
Model Description:
DH48J: can be input by electromagnetic relay, limit switch with reset function.
DH48JA: can be input by proximity sensor, photoelectric sensor etc.
DH48J-11A: can be input by electromagnetic relay, limit switch, proximity sensor,
photoelectric sensor etc. with reset function.
Features:
AC: 110V, 220V, 380V
DC: 12V, 24V
Counting Range: 1-9999*1/*10/*100
Contact Rating: 5A@220 Vac
Circuit Diagram:
2+7: Power
5+6+8: Switch
1+3: Counting Pulse
1+4: Reset
Temperature Controller: The Practical temperature controller controls the
temperature of any device or process according to its requirements for any
industrial application. It also displays the temperature on LCD display at a wide
variety of range.
Importance of Temperature Control:
Safety – Used to prevent overheating that can cause an unsafe work environment.
Troubleshooting – Overheating is often due to loose connections, improper

lubrication, or defective bearings.
Means of processing material – The Correct temperature must be maintained in

order to make a good product.
Example: Brand-SUHED Model:CH102-2k.
Panel Description:
Code Name Description
PV Display: process value
SV Display: setting value
OUT1 Led: light on when out 1 action
OUT2 Led: light on when output 2 action
Code Name Description
ALM1 Led: light on when alarm 1 action
ALM2 Led: light on when alarm 2 action
AT Led: light on when auto-tuning to start
SET Key: change mode or start
↑ Key: changing set value
R/S Key: Shift
Wiring Diagram:
Timer: It is possible to construct a relay with a built in time delay device that
causes the relay contacts to switch ON or switch OFF after a time delay. These
type of relays are called time delay relays or Timer.
There are two basic types of time delay relay-
On delay timer or delay on timer.
Off delay timer or delay off timer.
On delay timer: When an on-timer is installed in a circuit, the user adjusted the
control on the relay for the desired time delay. This time setting is called preset.
When the coil is energized, the internal timer in the relay begins running. When the
time value contained in the timer reaches the preset value, the relay energizes.
When this happen, all normally open (N/O) contacts on the relay close and all
normally closed (N/C) contacts on the relay open.
PLC Programming and Programming Technique
PLC, PLC Module:

 Central Processing Unit (PLC)
 Analog Input Module
 Analog Output Module
 Discrete Input Module
 Discrete Output Module
 BD Board.
PLC Programming Language:
 Ladder diagram (LD)

 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)
Ladder Diagram:
Ladder diagrams are specialized schematics commonly used to document industrial
control logic systems. They are called "ladder" diagrams because they resemble a
ladder, with two vertical rails (supply power) and as many "rungs" (horizontal
lines) as there are control circuits to represent. If we wanted to draw a simple
ladder diagram showing a lamp that is controlled by a hand switch, it would look
like this:
The "L1" and "L2" designations refer to the two poles of a power supply. L1 is the
"hot" conductor, and L2 is the grounded ("neutral") conductor.
Logic Gate
There are many control situations requiring actions to be initiated when a certain
combination of conditions is realized. Thus, for an automatic drilling machine,
there might be the condition that the drill motor is to be activated when the limit
switches are activated that indicate the presence of the work piece and the drill
position as being at the surface of the work piece. Such a situation involves the
AND logic function, condition A and condition B having both to be realized for an
output to occur.
There are many different types of logic gates, the list below include some common
gates.
OR Gate
The OR gate is a logic gate which passes on a signal if one or more of the inputs
are on.
Truth Table:
Input (first) Input (second) Output
off off off
off on on
on off on
on on on
Figure: Electric circuit emulating an OR gate

Figure: Ladder functions of OR gate.
XOR Gate
The XOR gate, sometimes called Exclusive OR, is a logic gate which passes on a
signal if exactly one of the two input is on. This is different to the OR gate, which
will still pass on a signal if both inputs are on.
Truth Table:
off off off
off on on
on off on
on on off
Figure: Electric circuit emulating an XOR gate

Figure: Ladder function of XOR gate.
AND Gate
The AND gate is a logic gate which passes on a signal only when both of the
inputs are on.
Truth Table:
off off off
off on off
on off off
on on on
Figure: Electric circuit emulating an AND gate
Figure: Ladder function of AND gate

NAND Gate
NAND gate passes on a signal always, except in the case where both inputs are on.
Truth Table:
off off on
off on on
on off on
on on off
Figure: Electric circuit emulating an NAND gate
Figure: Ladder function of NAND gate

NOT Gate
NOT gate takes only one input and passes on a signal only when the input is off.
Truth Table:
Input Output
off on
on off
Figure: Electric circuit emulating an NOT gate
Figure: Ladder function of NOT gate
Number System
A numeral system (or system of numeration) is a writing system for expressing
numbers; that is, a mathematical notation for representing numbers of a given set,
using digits or other symbols in a consistent manner.
Computer architecture supports following number systems.
 Binary number system
 Octal number system
 Decimal number system
 Hexadecimal (hex) number system
Binary Number System
A Binary number system has only two digits that are 0 and 1. Every number
(value) represents with 0 and 1 in this number system. The base of binary number
system is 2, because it has only two digits.
Octal number system

Octal number system has only eight (8) digits from 0 to 7. Every number (value)
represents with 0,1,2,3,4,5,6 and 7 in this number system. The base of octal
number system is 8, because it has only 8 digits.
Decimal number system

Decimal number system has only ten (10) digits from 0 to 9. Every number (value)
represents with 0,1,2,3,4,5,6, 7,8 and 9 in this number system. The base of decimal
number system is 10, because it has only 10 digits.
Hexadecimal number system

A Hexadecimal number system has sixteen (16) alphanumeric values from 0 to
9 and A to F. Every number (value) represents with 0,1,2,3,4,5,6, 7,8,9,A,B,C,D,E
and F in this number system. The base of hexadecimal number system is 16,
because it has 16 alphanumeric values. Here A is 10, B is 11, C is 12, D is 13, E is
14and F is 15.
Analog (A/D) input:

Specifying an analog input: There are basically three characteristics that need to be
considered when selecting an analog input.
Uniploar (Positive only) or Bipolar (Plus and minus): This is a simple decision.
If the voltage being measured will never be negative, then a unipolar input is the
best choice. It is not economical to purchase a bipolar input to measure a unipolar
signal. Typical, standard, off the shelf unipolar analog input modules have a ranges
of 0-5 VDC and 0-10 VDC, while standard bipolar units have a range of -5 to +5
VDC and -10 to +10 VDC.
Input Range: For this specification we have need to know the type of output from
the sensor, system or transducer being measured.
Number of Bits of Resolution/ Bit Resolution: For a unipolar converter,
resolution is the full scale divided by 2n, where n is the bit resolution.
Analog (D/A) output: Same as Analog input.

Wiring precautions:
Connect the AC power supply wiring to the dedicated terminal. If an AC power
supply is connected to a DC input/output terminal or DC power supply terminal,
the PLC will burn out.
Wecon PLC Editor Software Overview
PLC is a digital computer used for automation of typically industrial
electromechanical processes; PLCs are used in many machines, in many
industries. It reads external input signals such as: the state of buttons, sensors ,
switches and pulse waves , and then uses a microprocessor to perform logic,
sequence, timing, counting and arithmetic operations, resulting in the
corresponding output signal based on the input signal status or internally stored
value and pre-written program. WECON PLC editor uses ladder and instructions
list as programming language.
1) Ladder Ladder logic is widely used to program PLCs, where sequential control
of a process or manufacturing operation is required. Ladder logic is useful for
simple but critical control systems or for reworking old hardwired relay circuits.
As programmable logic controllers became more sophisticated it has also been
used in very complex automation systems. It is a graphic language evolution came
in relay ladder original relay control system based on the devices used in the
design, such as buttons X, intermediate relay M, time relay T, counter C, and so
on similar properties contact time of electrical device.
2) Instructions list Instruction List (IL) is designed for programmable logic
controllers (PLCs). It is a low level language and resembles assembly. All the
instructions and operands are inputted for PLC programming.
3) Program switch According to their own programming practice, users can
switch ladder and instruction list in order to improve programming efficiency.
Typical PLC Introduction, Example: Wecon PLC

According to the different hardware structure, PLC can be divided into host unit,
expansion module and BD board. WECON PLC has the built-in battery, CPU and
I/O points. The PLC CPU can connect with I/O expansion modules to expend the
I/O point number or connect with some special function expansion modules.
43
① Mounting hole(⌀:4.5) ② Power supply and input signal terminal ③ 24v
output power supply and output terminal ④ Input indicator ⑤ Output indicator
⑥ PLC state indicator: a) PWR: power light b) RUN: running light c) BAT: low
power light d) ERR: blinks when the program is wrong; e) :always on when a
CPU error occurs ⑦ DIN rail mounting clip ⑧ Cover plate ⑨ Com1 port ⑩
RUN/STOP switch ⑪ COM1/COM2 port and rs485 port ⑫ Expansion module
interface ⑬ Micro-USB port ⑭ BD board slot
Expansion module
① Expansion cable ② Com light: always on when digital transmission is normal

③ 24v: always on when connect with external 24v power supply ④ Module
power status light: Always on when normal ⑤ The name of the expansion
module
⑥ Analog signal output terminal ⑦ Expansion interface⑧ DIN rail mounting
clip ⑨ DIN rail hooks ⑩ Mounting hole(⌀:4.5)
44
The PLC CPU and the expansion module are the same size in height and depth,
but different width. So they can connect with each other in a neat form, also the
configuration is flexible.
BD board
Compared with expansion module, BD board is smaller, more flexible (up to 2

BD boards in one PLC) and cheaper, but also with multi-function. Because the
BD board is installed in the host unit, so it will not occupy extra space.
Specification
Input Specification
Input Signal Voltage : DC 24V±10%

Input statues : When input is ON, LED is ON
Input loop Structure : The diagram is NPN connection method, if S/S is
connected to negative pole, X is connected to positive pole that is PNP connection
method.
45
Naming rule of Wecon PLC:
The meaning of ○1 ~○6 is as below.

① Input points ② Output points ③ Output type, R means relay, T means
transistor. Relay can support DC and AC. Transistor can only support DC. ④
High speed output port, 4H means the plc can support 4 channels of high speed
pulse output, the same meaning for 2H. If there are no 2H and 4H, the default is
2H. ⑤ Power supply type: A means AC220V, D means DC24V. ⑥ Instruction
set: 1 means LX1S, 2 means LX2N, the default instruction set is LX2N.
Device Description
X – Input, Y – Output, M – Intermediate, S – State, T – Timer, C – Counter, D –
Data register, P, I – Pointer, K, H – Constant.
Input relay X The input relay X represents the physical inputs to PLC. It can
detect the external signal states. 0 is for open circuit, 1 is for closed circuit.
Devices numbered in: Octal, i.e. X0 to X7, X10 to X17.
Output replay Y The output relay Y represents physical outputs from PLC. 0 is
for open circuit, 1 is for closed circuit. Depending on the output element can be
divided into relay type, transistor type etc. Devices numbered in: Octal, i.e. Y0 to
Y7, Y10 to Y17.
Auxiliary relays M Auxiliary Relay M device is used as an intermediate variable
during the execution of a program, as auxiliary relays in the practical power
control system which is used to transfer the state messages. It can use the word
variable formed by M variables. M variables is not directly linked with any
external ports, but it can contact with the outside world by the manners of copying
X to M or M to Y through the program coding. Devices numbered in: Decimal,
i.e. M0 to M9, M10 to M19. The variables that are more than M8000 are the
system-specific variables, which are used to interact with the PLC user program
with the system states.
46
Auxiliary relay classification
General Stable State Auxiliary Relays
Latched auxiliary relays
System-specific auxiliary relays
Examples: M8000: RUN monitor (ON during run); M8002: Initial pulse (Turned
ON momentarily when PLC starts); M8012: 100 msec clock pulse.
State relays S State relays S is used to design and handle step procedures,
controls transfer of step by STL step instructions to simplify programming
design.
Timer The timer is used to perform the timing function. Each timer contains
coils, contacts, and counting time value register. A driven coil sets internal PLC
contacts. Various timer resolutions are possible, from 1 to 100ms. If the coil
power shuts off (insufficient power), the contacts will restore to their initial states
and the value will automatically be cleared. Some timers have the feature of
accumulation and power-saving. Devices numbered in: Decimal, i.e. T0 to T9,
T10 to T19.
Counter Counter performs counting function, it contains coil, contact and count
value register. The output contact is activated when count value reach to preset
value. Counters which are latched are able to retain their status information, even
after the PLC has been powered down. This means on re-powering up, the latched
counters can immediately resume from where they were at the time of the original
PLC power down. Devices numbered in: Decimal, i.e. C0 to C9, C10 to C19
High Speed Counter
The HSC command is used for counting where timed instances are very short and
a regular CTU or CTD will not do. The counting frequency of an ordinary
PLC’ s software counter can only reach tens of Hz (depending on the scan time).
If the frequency of input signal is higher than that, it is necessary to utilize high-
speed counter (HSC), otherwise loss count or even out of counting may occur.
There are usually two types of HSC implemented for PLC. The hardware high-
speed counter (HHSC) employed special hardware circuit and the software high-
speed counter (SHSC) which when counting signal changes state will interrupt
CPU to perform the increment/decrement counting operation. A good rule of
thumb is simply to always use the normal (software) counters unless the pulses
you are counting will arrive faster than 2X the scan time. (i.e. if the scan time is
2ms and pulses will be arriving for counting every 4ms or longer then use a
47
software counter. If they arrive faster than every 4ms (3ms for example) then use
the hardware (high-speed) counters. (2xscan time = 2x2ms= 4ms)
Data register D Data registers, as the name suggests, store data. The stored data
can be interpreted as a numerical value or as a series of bits, being either ON or
OFF. A single data register contains 16bits or one word. However, two
consecutive data registers can be used to form a 32bit device more commonly
known as a double word. If the contents of the data register are being
considered numerically then the Most Significant Bit (MSB) is used to indicate
if the data has a positive or negative bias. As bit devices can only be ON or
OFF, 1 or 0 the MSB convention used is, 0 is equal to a positive number and 1
is equal to a negative number. Devices numbered in: Decimal, i.e. D0 to D9,
D10 to D19.
Pointers registers P, I Pointers register P is used for entry address of jump

program, and identification of sub-program starting address. Pointer register I is
used for identification of interrupted program starting address. Devices
numbered in: Decimal, i.e. P0 to P9, P10 to P19, I0 to I9, I10 to I19.
Constant K, H, E
Instruction lists
LD Operation contact type NO (normally open), LDI Operation contact type NC
(normally closed), OUT Final logical operation type coil drive, AND Serial
connection of NO (normally open), ANI Serial logical, operation contact type
NC (normally closed) contacts, OR Parallel, connection of NO (normally open)
contacts, ORI Parallel, connection of NC (normally closed) contacts, LDP Initial
logical, operation Rising edge pulse, LDF Initial logical, operation falling/trailing
edge pulse, ANDP Serial connection of Rising edge pulse, ANDF Serial
connection of falling/ trailing edge pulse, ORP Parallel, connection of NO Rising
edge pulse, ORF Parallel connection of Falling/trailing edge pulse, ORB Serial
connection of multiple parallel circuits, ANB Serial connection of multiple
parallel circuits, MPS Stores the current result of the internal PLC operations,
MRD Reads the current result of the internal PLC operations, MPP Pops (recalls
and removes) the currently stored result, MC Denotes the start of a master control
block, MCR Denotes the end of a master control block, INV Invert the current
48
result of the internal PLC operations, PLS-Rising edge pulse, PLF-Falling /
trailing edge pulse, SET-Sets a bit device permanently ON, RST-Resets a bit
device permanently OFF.
Program Flow instruction list

CJ-Conditional jump, CALL-Call Subroutine, EI-Enable Interrupt, DI-Disable
Interrupt, WDT-Watchdog Timer, FOR-Start of a For/Next Loop, NEXT-End a
For/Next Loop,
Move and Compare instruction list
CMP-Compare, ZCP-Zone compare, MOV-Move, SMOV-Shift move, CML-
Compliment, BMOV-Block move, FMOV-Fill move, XCH-Exchange, BCD -
Binary coded decimal, BIN-Binary
Arithmetic and Logical Operations instruction list

ADD Addition, SUB Subtraction, MUL Multiplication, DIV Division, INC
Increment, DEC-Decrement, WAND-Word AND, WOR Word OR, WXOR
Word exclusive OR, NEG Negation
Rotation and Shift instruction list
ROR Rotation right, ROL Rotation left, RCR 16-bit rotation right with carry,
RCL 16-bit rotation left with carry, SFTR (bit) shift right, SFTL (bit) shift left,
WSFR word shift right, WSFL word shift left, SFWR shift register write, SFRD
shift register read
49
Data operation instruction list
ZRST Zone reset, DECO Decode, ENCO Encode, SUM The sum of active bits,
BON Check specified bit status, MEAN Mean, ANS (timed) annunciator set,
ANR Annunciator reset, SQR Square root, FLT Float, SWAP High and low bit
conversion
High-speed Processing Instruction
REF Refresh, REFF Refresh and filter adjust, MTR Input matrix, DHSCR High
speed counter set, DHSCS High speed counter reset, DHSZ High speed counter
zone compare, SPD Speed detect, PLSY 16-bit pulse Y output, PWM Pulse width
modulation, PLSR Ramp pulse output
ECAM instruction list
DECAM-ECAM configuration, DEGEAR-Electronic gear configuration,
ECAMTBX-Create E-CAM datasheet
External I/O Devices instruction list
TKY Ten key input, HKY Hexadecimal input, DSW Digital switch (thumbwheel
input), SEGD Seven segment decoder, SEGL Seven segment with latch, ARWS
Arrow switch, ASC ASCII code, PR “print” to a display, FROM Read from a
special function block, TO Write to a special function block, GRY Converts
binary integer to GRAY code, GBIN Converts GRAY CODE to binary
External Devices instruction list
RS RS communications, RS2 RS2 communications, CPAVL Serial port settings,
CPAVL Ethernet port settings, PRUN Octal bit transmission, ASCI hexadecimal
to ASCII, HEX ASCII to hexadecimal, CCD check code, PID PID control loop
Floating Point instruction list
DECMP Binary floating point data compare, DEZCP Binary floating point zone
compare, DEBCD Binary to BCD floating point data conversion, DEBIN BCD
to Binary floating point data conversion, DEADD Binary floating point addition,
DESUB Binary floating point subtraction, DEMUL Binary floating point
multiplication, DEDIV Binary floating point division, DESQR Binary floating
point square root, INT 16-bit binary floating point to integer, DSIN Sin operation,
DCOS Cosine operation, DTAN Tangent operation, DASIN Calculate radian
value, according to the corresponding value of SIN, DSINH Binary floating point
operation of Hyperbolic Sine function SINH, DACOS Calculate radian value,
according to the corresponding value of COS, DCOSH Binary floating point
operation of Hyperbolic Cosine function COSH, DATAN Calculate radian value,
50
according to the corresponding value of TAN, DTANH Binary floating point
operation of Hyperbolic Tangent function TANH, DEXP Perform exponent
operation of binary floating-point number to base e (2.71828), DLOG10 Perform
common logarithm operation of binary floating-point number to base 10, DLOGE
Perform natural logarithm operation of binary floating-point number to base e
(2.71828)
Positioning Instruction list
DABS Absolute current value read, ZRN Setting of zero return speed, PLSV
Variable speed pulse output, DRVI Relative position control, DRVA Absolute
position control
Real Time Clock Control
TCMP time compare, TZCP time zone compare, TADD time addition, TSUB
time subtraction, TRD read RTC data, TWR set RTC data, HOUR 16-bit
chronograph
Handy Instructions list
IST initial state, SER Search, ABSD Absolute drum, INCD Incremental drum,
TTMR Teaching timer, STMR Special timer – definable, ALT Alternate state,
RAMP Ramp - variable value, ROTC Rotary table control, SORT Sort data
Circular interpolation instruction list
G90G01 Absolute position line interpolation, G91G01 Relative position line
interpolation, G90G02 Absolute position of the clockwise circular interpolation,
G91G02 Relative position clockwise circular interpolation, G90G03 Absolute
position anticlockwise circular interpolation, G91G03 Relative position
anticlockwise circular interpolation
Inline Comparisons Instruction list
LD= Comparison of 16-bit data (==),LD> Comparison of 16-bit data (>), LD<
Comparison of 16-bit data (<), LD<> Comparison of 16-bit data (<>), LD<=
Comparison of 16-bit data (<=), LD>= Comparison of 16-bit data (>=), AND=
Comparison of 16-bit data (==), AND> Comparison of 16-bit data (>), AND<
Comparison of 16-bit data (<), AND<> Comparison of 16-bit data (<>), AND<=
Comparison of 16-bit data (<=), AND>= Comparison of 16-bit data (>=), OR=
Comparison of 16-bit data (==), ORD= Comparison of 32-bit data (==), OR>
Comparison of 16-bit data (>), OR< Comparison of 16-bit data (<), OR<>
Comparison of 16-bit data (<>), OR<= Comparison of 16-bit data (<=), OR>=
Comparison of 16-bit data (>=)
51
52
Example of Analog input/output: PLC Module Wecon LX3V-4DA The LX3V-
4DA analog special function block has four output channels. The output channels
take a digital value and output an equivalent analog signal. This is called a D/A
conversion. The LX3V-4DA has maximum resolution of 12bits.
The selection of voltage or current based input/output is by user wiring. Analog

ranges of -10 to 10V DC (resolution: 5mV), or 0 to 20mA (resolution: 20µA)
maybe selected independently for each channel.
Data transfer between the LX3V-4DA and the LX3V main unit is by buffer
memory exchange. There are 32 buffer memories (each of 16 bits) in the LX3V-
4DA.
The LX3V-4DA consumes 90mA current from the 5V power supply in LX3V
main unit or active expansion unit.
Various special blocks controlled by the FROM/TO commands, such as the analog
input blocks high-speed counter blocks, etc. can be connected to the LX3V
programmable controller (MPU), or connected to the right side of the other
extension blocks or units. Up to 16 special blocks can be connected to a single
MPU in the numeric order of No. 0 to No.15.
Allocation of buffer memories (BFM)
BFM Description
#0(E) Output mode select. Factory setting H0000
#1 Output data Channel CH1
BFM#0 Analog mode Digital mode Resolution
0 -10V ~ 10V -2000 ~2000 5mV
1 4mA ~ 20mA 0 ~ 1000 16uA
2 0 ~ 20mA 0 ~ 1000 20uA
3 Disable -- --
4 -10V ~ 10V -10000 ~ 10000 1mV
5 4mA ~ 20mA 0 ~ 2000 8uA
6 0 ~ 20mA 0 ~ 2000 10uA
Example: H3310
CH1: voltage range (-10V to 10V);
CH2: voltage range (+4mA to +20mA);
CH3CH4: Channel OFF;
Some description of Instruction of Wecon PLC:
CMP instruction
Instruction format CMP: S1S2D
This instruction compares two operational variables and outputs the comparison
result to a specified bit variable. The operands are all algebra compared according
to signed data.
D will occupy 3 continue bit variables address.
Programming Example:
When X0=ON, M0 or M1 or M2 will be ON.

When X0=OFF, CMP will not be executed, M0, M1 and M2 keep the initial state.
By series or parallel M0, M1 and M2 to achieve the results of ≤ or ≥ or ≠.
MOV instruction
Instruction format: MOV S D
The content of the source device (S) is copied to the destination (D) device when
the control input is active. If the MOV instruction is not driven, no operation takes
place.
For 32bit instructions (DMOV), two devices will be copied to the destination
device, for example DMOV D1 D5, the result is D1→D5, D2→D6.
When M0 is on, D2=K4, when M0 becomes off, D2 keeps the initial value. Only
when user copy another value to D2 or power off the plc or set plc off and on
again, the value of D2 will change.
ADD instruction
Instruction format: ADD S1 S2 D
The data contained within the source devices (S1, S2) is combined and the total is
stored at the specified destination device (D).
When M1 is triggered, D100 combines D110 and the total is stored in D120. If
D100=K8, D110=K-12, then D120=K8+K-12=K-4.
SUB instruction
Instruction format: SUB S1 S2 D
The data contained within the source devices, S2 is subtracted from the contents of
S1. The result or remainder is stored at destination device (D). The source devices
are processed by the signed number, the most significant bit is the sign bit, 0 means
positive and 1 means negative.
Programming Example
When M8 is triggered, D100 subtracts D110 and the result is stored in D120. If
D100=K10, D110=K8, then D120=K10-K8=K2.
MUL instruction
Instruction format: MUL S1 S2 D
The contents of the two source devices (S1, S2) are multiplied together and the
result is stored at the destination device (D). The source devices are processed by
the signed number, the most significant bit is the sign bit, 0 means positive and 1
means negative.
When M8 is triggered, contents of D100 and D110 are multiplied together and the
result is stored at D120. If D100=K100, D110=K25, D120=K100*K25=K2500.
DIV instruction
Instruction format: DIV S1 S2 D
The primary source (S1) is divided by the secondary source (S2). The result is
stored in the destination (D). Note the normal rules of algebra apply. The source
devices are processed by the signed number, the most significant bit is the sign bit,
0 means positive and 1 means negative.
Programming example:
When M8 is triggered, D100 is divided by D110. The result is stored in D120. If
D100=200, D110=4, D120=50.
ZCP instruction
Instruction format: ZCP S1 S2 S D
The operation is the same as the CMP instruction, except a single data value (S) is
compared against a data range (S1~S2).
- bit device D is ON
- bit device D +1 is ON
- bit device D +2 is ON
comparison area
variables.
XCH instruction
Instruction format: XCH S D
The contents of the two destination devices S and D are swapped, i.e. the complete
word devices are exchanged.
MEAN instruction
Instruction format: MEAN S D n
The range of source data is defined by operands S and n. S is the head address of
the
source data and n specifies the number of consecutive source devices used.
The value of all the devices within the source range is summed and then divided by
the number of devices summed, i.e. n. This generates an integer mean value which
is
stored in the destination device (D). The remainder of the calculated mean is
ignored.
Program example
(D10+D11+D12+D13)/4=D20
For example, D10=K5，D11=K5，D12=K15，D13=D52 , then D20=K19，the
remainder 1 is ignored.
SQR instruction
Instruction format: SQR S D
This instruction performs a square root operation on source data (S) and stores the
result at destination device (D). The operation is conducted entirely in whole
integers
rendering the square root answer rounded to the lowest whole number. For
example,
if (S) = 154, then (D) is calculated as being 12.
Program example
If D0=K100, then when X2 is ON, D12=K10;

If D0=K110, then when X2 is ON, D12=K10, decimal is ignored.
TCMP instruction
Instruction format: TCMP S1 S2 S3 S D
S1, S2 and S3 represent hours, minutes and seconds respectively. This time is
compared to the time value in the 3 data devices specified by the head address S.
The result is indicated in the 3 bit devices specified by the head address D.
The bit devices in D indicate the following:
0 is set ON, when the time in S is less than the time in S1, S2 and S3.
Program example
When X10 is ON, M0 or M1 or M2 will be ON.
When X10 turns off, TCMP is not executed; M0, M1 and M2 keep the initial
value.
User could use RST or ZRST to reset M0~M2.
User could parallel or cascade M0~M2 to achieve >=, <= or ≠.
TZCP instruction
Instruction format: TZCP S1 S2 S D
S1, S2 and S represent time values. Each specifying the head address of 3 data
devices.
S is compared to the time period defined by S1 and S2. The result is indicated in
the 3
bit devices specified by the head address D.
The bit devices in D indicate the following:
S1 and S2.
Program example
When X10=ON, m0 or m1 or m2 will be ON.

When M12 turns from ON to OFF, TZCP is not executed. M0~M2 keep the initial
value.
User could use RST or ZRST to reset M0~M2.
HOUR instruction
Instruction format: HOUR S D1 D2
S: The value of setting time;
D1: Current value in hours;
D2: Alarm output destination, turns on when D1 exceeds S;
Program example
1 Basic operation and screen introduction
WECON PLC Editor provides full and powerful functions.
1.1 Start and exit software
WECON PLC Editor is a programming tool for

designing, debugging, and maintaining programs on
Windows, please start the software by click icon on
desktop or select [Start]->[WECON PLC Editor]. As
Figure 2-1 shows.
Figure 2-1
Click [WECON logo] ->

[Close] to exit software, if
program is not saved,
software will ask saving, as
Figure 2-2 and Figure 2-3
show.
Figure 2-2
53
Figure 2-3
1.2 Integral structure Introduction

The Figure 2-4 shows WECON PLC Editor Screen, the upper area of main screen is [Menu Toolbar];
the [Project Manager] on the left of screen; the programming area is on the middle of screen. The low part
lists other tools.
Figure 2-4
Users can modify the [Project Manager] and other tools position by themselves.
1.3 QuickAccessBar
Users can do the basic operation via [QuickAccessBar], the [QuickAccessBar] is introduced in front of
content.
54
Figure 2-5
: WECON LOGO,
click it to open the open the
windows, as Figure 2-6
shows.
Figure 2-6
: New, click it to create new program; : Close, click it to exit current program;
: Open, click it to open current program; : Undo;
: Save, click it to save modification; : Redo;
: Save as, click it to save program in other
path;
5
Customize Quick Access Toolbar
Users can more easily customize the functionality as what they need by using the [Customize Quick
Access Toolbar].
1) Access [Customize Quick Access Toolbar]. Please move the mouse cursor to drop-down icon which is
on the right of [QuickAccessBar];
2) Open the [Customize Quick Access Toolbar], and select [More command], as Figure 2-7 shows;
3) After completing Step 2, then open the [custom] window, as Figure 2-8 shows.
4) Add Shortcut: Select any command in the [command] box on the left side. Then click [Add] so that you
will find the selected item moves to the right box. And click [OK] can successfully add a custom tool.
5) Delete Shortcut: Select any command in the [command] box where the right side. Then click [Delete] so
that you can find selected items in the right dialog box disappears .Click [OK] to complete delete the
Figure 2-7
6
Figure 2-8
7
1.4 Menu bar
This sector introduces the software menu bar. The upper area of main screen is [Menu Toolbar]; users
can easily do various operations through it, and then detailed operations, please see following instructions.
Figure 2-9
1.4.1 PLC
1.4.1.1 Project Toolbar
Figure 2-10
User can change the PLC type for program by click [PLC Type] in [Project] toolbar, as Figure 2-11
shows.
Figure 2-11
1.4.1.2 Edit Toolbar

The clipboard toolbar is the basic function commonly used for editing a PLC project. This section will
explain the basic operation of the clipboard.
For example: CUT, COPY, PASTE, UNDO/REDO
1) Cut: The cut command removes the selected data from its original position;
2) Copy: The copy command creates a duplicate;
3) Paste: Transferring text, data, files or objects from a source to a destination;
53
Figure 2-12
4) Undo: It erases the last change done to the document reverting it to an older state;
5) Redo: The redo command reverses the undo or advances the buffer to a more current state;
1.4.1.3 Ladder Symbol Toolbar

The menu in WECON PLC Editor provides the full and powerful functions, which greatly improves
programming efficiency, as Figure 2-13 shows.
Figure 2-13
The Table 2-1 shows a detailed description of the ladder symbol
Table 2-1
Symbol Instruction Function Hotkey
LD, AND Open contact F5
OR Open branch SHIFT+F5
LDI, ANI Close contact F6
ORI Close branch SHIFT+F6
OUT Output coil F7
CJ/CALL Input application instruction F8
Draw horizontal line F9
Draw vertical line F11
Delete horizontal line CTRL+F9
Delete vertical line CTRL+F11
LDP, ANP Rising pulse SHIFT+F7
LDF, ANF Falling pulse SHIFT+F8
ORP Rising pulse open branch CTRL+ALT+F7
ORF Falling pulse close branch CTRL+ALT+F8
54
INV Reverse operation results CTRL+ALT+F11
1.4.1.4 Label Toolbar
In order to increase readability, software allows users to add comments and statement for program.
Click the text to enable this function, the following picture Figure 2-14 shows the state of each text when
function is enabled.
Figure 2-14
Note: Please run the software as Administrator in Windows 7 and later systems
1.4.1.5 Project Toolbar

This section provides a brief description of [Program] menu.
There are two functions in [Program], one is compile program, and the other is switch program.
Figure 2-15
1) Compile: All the program must be compiled before download into PLC device;
2) Switch: It is used for converting program between the ladder format and the IL (Instruction List)
format.
1.4.1.6 Program mode Toolbar

Program mode contains three functions, [Edit Mode], [Monitor Mode (R)] and [Monitor Edit (W)].
Figure 2-16
1) Edit mode: It is for editing program (ladder or IL) for PLC;
2) Monitor Mode(R): It is for monitoring program, which is running in connected PLC;
3) Monitor Edit (W): It is for modifying program when monitoring it;
1.4.1.7 Online Toolbar

The Online toolbar provides nine functions for operating and accessing PLC device, such as
upload/download PLC program.
55
Figure 2-17
Transfer: It is for testing the communication between PC and PLC;
Read from PLC: It is for uploading the program from PLC to PC;
Write to PLC: It is for downloading the program from PC to PLC;
Verify with PLC: It is for verify the project opened by WECON PLC Editor is the same as project that
running in connected PLC.
Device monitor: It is for monitoring and debugging all devices in PLC, when program is executed or
simulated;
Clear PLC Memory

It is for clear PLC memory, the setting window as Figure 2-18 shows;
Clear PLC memory will delete all the data in PLC device, in other word, it will format PLC.
Figure 2-18
Description
1) [Object]: Displays the current PLC information and parameters. They cannot be changed.
2) [Data Object]: Users could select clear content in this area.
 PLC Memory: Clear PLC memory that is format the PLC
 Data Device: Clear all the data blocks settings (device memory area of the D register default
value)
 Bit Device: Clear all data blocks setting (Device Memory) of the bit device values.
Note:
1) This operation only works in PLC stop state.
2) This operation is not reversible.
56
Clock setting
It is for setting real time for PLC device, the setting windows as Figure 2-19 shows;
Users can customize the internal PLC time by clock setting to achieve accurate calculation.
Description
1) Connection: Displays the current PLC information and parameters. They cannot be changed;
2) Time and Calendar: Users can easily select the time information and free to match time;
3) Read PC Time: Automatically read PC time without manual calibration;
4) Set Time: After completing the settings, click the button, then PLC will save the current settings;
5) Cancel: Don't save the current operating data. Exit and close the window;
Figure 2-19
Setting time
1) Connect PLC to PC, and run WECON PLC Editor;

2) Switch the PLC to stop state;
3) Click [Online]-> [Clock setting];
4) Set the clock and time. The range of year is 1980~2079, the range of month is 1~12, the range of
hour is 0~23, the range of minute is 0~59, the range of second is 0~59;
5) Users can click [Get PC time] for quickly setting;
6) Click [Set Clock] to save the date and time, it will pop-up tip message as following figure shows;
57
Figure 2-20
Remote Operation
Remote operation can change the PLC states when PLC is running; it has the same functionality as
PLC DIP switch.
Figure 2-21
Description
1) [Object]: Displays the current PLC information and parameters. They cannot be changed;
2) [Operation]: Displays the current status of the PLC, RUN or STOP;
 [RUN]: PLC into RUN state;
 [STOP]: PLC into the STOP state;
 [CLOSE]: Close the window;
Note:
The device monitor requires a good communication between PLC and PC.
Diagnostics:
This function contains most online functions; users can view the diagnostic data in this window, and
can quickly perform the operations.
1.4.1.8 Tool Toolbar

Tool toolbar provides five tools for users, such as check program, auto-saving as so on; it brings more
58
convenience for programming.
Figure 2-22
Check Program
The function of [Check Program] is that checking the program error, and modified them timely, at the
same time can quickly locate to the error. The Check Program Figure 2-23 shows.
Figure 2-23
Simulator (Not recommended)

The function of simulator is checking the running result of program. But most instructions can be
executed in simulator mode, so this function is not recommended.
The operation steps for simulator
1) Run WECON PLC Editor Software;
2) Create a PLC program and compile it;
3) Click [Simulator] for offline simulation, it will pop-up simulator window as Figure 2-24 shows;
Figure 2-24
 There are two debug modes, one is Single instruction, and the other is Breakpoint.
 Single Instruction: Execute program statements one by one; interrupt occurs after executing
59
each program statement or a process.
 Breakpoint: Users set a breakpoint in PLC program, interrupt occurs when PLC execute to this
low.
Figure 2-25 Figure 2-26
Figure 2-27
4) Click the register that needs to be modified, and right click it, it wills pop-up a menu window.
5) Select [Debug]->[Modify the current value], as Figure 2-27 shows;
6) Users can set the value for registers as Figure 2-28 shows;
7) After setting the value, users can view the program running result, as Figure 2-29 shows.
60
Figure 2-28
Figure 2-29
Auto-save setting
It provides auto-save program function to avoid losing data. The default saving time is 5 seconds. The
auto-save setting window as Figure 2-30 shows.
61
Figure 2-30
Encryption tools for PLC and program

WECON PLC Editor provides encryption tools for users to set all kinds of password for programs.
Those passwords can prevent program from being uploaded from PLC by ending users.
Generate download file

This is for generating download file, its format is .swcp, which can’t be viewed and modified by
WECON PLC Editor, and so that programmer can send it to ending users directly.
2.4.2 View
This section introduces the [View] menu function.
Figure 2-31
2.4.2.1 Folding Window toolbar
It is similar with other software; the Folding Window toolbar is used for setting the display of WECON
PLC Editor, when check the option, the corresponding window will be available in software screen.
2.4.2.2 Show toolbar

Every devices addresses in program can be commented and aliased, check the options to show the
comments are alias in programming area.
2.4.2.3 Zoom toolbar

The zoom only works in programming area; there are six modes as Figure 2-32 shows, users can select
the display mode according to requirements.
62
Figure 2-32
2.4.3 Help
This section introduces the [Help] menu function.
Figure 2-33
2.4.3.1 Language toolbar
Language toolbar is used for setting software displaying language. Simplified Chinese, Traditional
Chinese and English are supported in software.
Note: Please run the software as Administrator in Windows 7 and later systems for language switching.
2.4.3.2 Website toolbar

It is linked to WECON official webpage.
2.4.3.3 Info toolbar

Please click the [Help] in info toolbar for opening the helping document.
2.4.3.4 Version toolbar

Please click it to check the software version, the software version information as Figure 2-34 shows.
Figure 2-34
63
2.5 Project manager
This sector introduces the [Project manager].

The left side of main screen is [Project Manager]. It shows
the entire project by tree. The project includes organization
structure, project name, program, device comment, parameter,
device memory, extended function, all kinds of instruction table
and so on.
Users can control the whole project by [Project Manager].
And [Project Manager] supports the use of right button function.
As Figure 2-35 shows.
Figure 2-35
2.6 Programming area
Programming area is a main screen used for operations such as programming (ladder or instruction list),
parameter setting, and monitoring in WECON PLC Editor.
On the top left, it shows current states and programming information.
64
Figure 2-36
Figure 2-37
2.7 Folding windows

This sector main introduces the fives windows in folding windows. Such as [Information Output],
[Search/Replace], [PLC Verify], [Cross Reference list] and [Devices List]
2.7.1 Information output

Information output displays compilation, communication and check results (errors and warnings).
Figure 2-38
65
The detailed errors will be displayed in information output windows, user can select the message and
the software will automatically locate the corresponding area.
2.7.2 PLC Verify

PLC Verify window displays the verifying result, users can check the difference between displaying
program and running program.
Figure 2-39
2.7.3 Cross reference list

Cross reference list is used for displaying specified device usage in the program, and it can also display
all the devices that used in current program.
Figure 2-40
Description
1) [Device]: Users can enter the specified device in bar, and press [Enter] in keyboard, or click
[Search] to display the device information. For example, enter the D2, it will display all the devices
that contains D2, such as D2, D24, D203 and so on;
2) [Search]: Click it to execute the searching operation;
3) [Show All]: Click it to display all devices in current program, as Figure 2-40 shows
66
2.7.4 Device list
Device list is used for checking the used devices information in current program, such as Device, Contact,
Coil (Count), Comment and Alias, and users can modify the devices in [Device list].
Figure 2-41
Description
1) [Device]: it is drop down list menu, users can select the device type from it, such as D, C and so on,
and window will display the corresponding device information.
Figure 2-42
2) [Start Device]: It is used for setting displaying device start address; the default is from 0, such M0,
C0, D0 and so on. The drop down list displays the search records.
Figure 2-43
3) [Search]: Click it to execute search operation, it [Start Device] is empty, it will pop-up tip message.
4) [Range]: The searching range is displayed in this area, and it isn’t editable.
Figure 2-44
67
5) [+]: Click it to view the detailed information of selected device, such as instructions, steps, and
data type, double-click the item, it can jump to corresponding location.
Figure 2-45
6) [Comment & Alias]: The area which background is in white is used for displaying device comment
and alias, uses can edit the comment and alias by double-click white area.
Figure 2-46
7) [Display Option]
 [All]: Check it to display all the device of selected type;

 [Used Devices]: Check it to only display the devices that used in current program;
[Contact]: Only display contact that used in current program;
[Coil]: Only display coil that used in current program;
Note: if users didn’t check anyone, it will display both contact and coil;
 [Unused Device]: Check it to only display the unused device in current program;
2.7.5 Search/ Replace

Search/replace feature is similar to the MS OFFICE search replace function, it can locate a user-specified
data block in large amounts of data, or botchily modify data, and it can greatly improve the efficiency of
programming. The window as Figure 2-47 shows, there are five sub-windows.
Press [Ctrl] + [F] key in keyboard can open the window, or click [Search/Replace] in software, as Figure
2-48 shows.
68
Figure 2-47
Figure 2-48
2.8 State bar

It display some information of software and current program, such as language, caps, state of number
keyboard, communication port, PLC model, and steps information.
69
Figure 2-49
 Language: The language of software interface;
 CAP: It is for caps lock;
 NUM: It used for indicating whether the numeric keyboard is available;
 OVR: Ladder diagram edit mode.
 COM port: Software communication COM port. Click it will popup window of Communication
Settings;
 LX3V: It is used for display PLC model;
 The steps of current program/Total steps of program: It used for displaying steps information of
current program;
70
3 Project management
This chapter explains basic operations and management of projects
3.1 Project operations

This section explains basic operations of WECON PLC Editor such as creating, opening, and saving
projects.
3.1.1 Create new project

Create a new project after starting software, user need to set following parameters for new project.
 PLC Series
 PLC type
 Programming language
Operating procedure
1) Click the WECON icon on the top left corner of software interface, the menu will pop up
automatically;
2) Select the [New];
Figure 3-1
3) Set the parameters for new project as the Figure 3-2 shows, using LX3V as an example, and please
click [OK] to open the main screen.
71
Figure 3-2
3.1.2 Saving project

Save a project in a hard disk or other memory media of a PC.
Operating procedure
1) Click [Save] or [Save As] in quick access bar;
2) Enter/ Select the folder (drive/path);
3) Enter project name;
4) Click [Save];
Figure 3-3
3.1.3 Closing project

Close an open project.
72
Operating procedure
Click [Close] in quick access bar or click close button on the top right of the software main screen.
3.1.4 Opening existing projects

Read a project saved in a hard disk or other memory media of a PC.
Operating procedure
1) Select [Open (Ctrol+O)] in quick access bar;
2) Enter/ Select the folder (drive/path);
3) Enter/Select project name;
4) Click [Open];
Figure 3-4
3.1.5 Deleting projects

Delete a project saved in a hard disk or other memory media of a PC.
Operating procedure
1) Open project saving folder;
2) Select projects;
3) Right-click and select [Delete];
73
3.1.6 Changing PLC type of project
Change the PLC type of a project being edited
Operating procedure
1) Select [Project] -> [PLC Type]
2) Select PLC Type
Figure 3-5
3) Click [Execute]
4) The following confirmation message is displayed. Click the [Yes] button to execute the function.
Figure 3-6
3.1.7 Switching programming language of project

Switch programming language of a project being edited.
Operating procedure
Click [Program] -> [Switch]
74
3.2 Project property
This section explains project property of WECON PLC Editor for a project.
3.2.1 Program
MAIN is the name of PLC program; one project only contains one program, and double click MAIN
could open the programing area.
Also if there is no program, users can right click [Program] folder and select [New], as Figure 3-8 shows.
Figure 3-8
Figure 3-7
Figure 3-9
When create a new project, it will create an empty program named [MAIN] in [Program] folder, users
could right click [MAIN] and delete it.
Note: one project only has one MAIN program.
75
3.2.2 Device Comment
One PLC project only has one [Device Comment] file, right click [COMMENT], users can delete it. And
also users can create new COMMENT (The file must be named COMMENT), if there is no file in [Device
Comment] folder, as Figure 3-10 shows,
Figure 3-10
Operating procedure
1) Double click [COMMENT], the setting windows will pop up automatically, as Figure 3-11 shows;
76
Figure 3-11
2) Enter the device comments and device alias one by one. Or Import the comments and alias from
existing .csv file
Description of window
[Device]: Enter the name of the Device correctly and press [Enter] in keyboard, Device list (on the right
of window) will locate the device and selected (shown in blue).
[Device display window]: It has three column, [Device Name], [Device Comment] and [Device Alias].
The column of [Device Name] is in gray, it means it is not editable, others are in white, it means it is editable.
The select row in [Device display window] is in blue, and double click to edit the [Device Comment] and
[Device Alias]. The maximum length for [Device Comment] is 16 characters, and [Device Alias] is 8
characters.
[Select the device range]: Software list all the devices, users can select the device in this list to change the
display window. Blue indicates that the devices range is selected; black indicates that the devices have
comment or alias; white indicates that the devices don’t have comments section or alias. LX1S and LX3V
77
section of the device are different.
3.2.3 PLC parameter

PLC parameter is for setting PLC project parameter, one project only has one PLC parameter, users can’t
delete it and can’t add new one.
The Figure 3-12 shows the parameter setting window, the left one is for LX1S, the right one is for LX2N
and LX3V.
Figure 3-12
Operating buttons
1) [Check]: Check the current settings, whether the "program capacity" is greater than zero. If
program capacity is less than or equal to zero, the examination is not successful;
2) [Default]: Click this button to set all settings to be default values;
3) [Finished]: Complete the PLC parameter setting;
4) [Cancel]: Cancel the PLC parameter settings and close the window;
3.2.3.1 Memory capacity

The Memory capacity setting including Memory Capacity, Comment capacity, File registers capacity and
Program Capacity.
An error occurs when Comment capacity and File registers capacity are out of range, the modification
fails.
Project capacity= Memory capacity – Comment capacity*500- File registers capacity*500. The
Project capacity must be greater than zero, otherwise an error occurs and modification fails.
3.2.3.2 Device
Device window includes various types of devices. In the table the cells in white are editable; the cells in
78
gray are not editable. The latched range is editable in LX3V series PLC. The setting window as Figure 3-13
shows.
Figure 3-13
3.2.3.3 PLC name

It is used for entering the name of the PLC, it allows up to 32 bytes. The setting window as Figure 3-14
shows.
79
Figure 3-14
3.2.3.4 I/O Assignment

I/O assignment is to show the total I/O point of PLC host and extend module. The window as Figure 3-15
shows.
3.2.3.5 PLC System (1)

It is used for setting the PLC input terminal as RUN/STOP DIP switch. For example select X0 in this
setting window, when PLC is running, if the X0 turn ON, PLC is in RUN mode, if the X0 turn off, PLC is in
STOP mode, the setting windows as Figure 3-16 shows.
80
Figure 3-15
Figure 3-16
81
3.2.3.6 PLC System (2)
1) [Communication Setting]: Check it to enable the communication setting;
2) [Protocol]: Select protocol for communication
3) [Data Length]: This is one of communication parameter; users can select 7bit or 8bit;
4) [Parity Bit]: This is one of communication parameter; users can none, odd or even;
5) [Stop Bit]: This is one of communication parameter; users can select 1bit or 2bit;
6) [Transmission Rate]: This is one of communication parameter; users can select baud rate;
7) [Header]: Check it for enable header requirements;
8) [Terminator]: Check it for enable terminator requirements;
9) [Transmission procedure]: so far there is only one mode;
10) [H\W type]: It is used for select the commutation mode; users can select Regular/RS-232 and
RS485
11) [Station number setting]: Set up the station number, range 00H~0FH (Hex)
12) [Control mode]: Default;
13) Transmission speed: Choose the transmission speed;
Figure 3-17
82
3.2.4 Setting Security for Projects
This section explains how to set security for projects to protect the projects themselves and the data in
projects.
Setting security not only restricts an access to projects but also prevents the data, such as device
comments, and parameters, that are created by the user from erroneous modification and/or disclosure to
unauthorized users.
This function can restrict writing/reading of data to/from a PLC.
Figure 3-18
Click the [Check] button will display the current project password information, as Figure 3-19 shows.
Figure 3-19
3.2.4.1 Program PSW

Set/Modify/Clear the program password for opening project, if project with program password, when
open the project, it will pop-up password enter screen, as Figure 3-20 shows.
83
Figure 3-20
Operating procedure for setting

1) Enter the 8-code password in [Enter new password];
2) Enter the 8-code password in [Confirm password];
3) Click [Set] button;
Software will display the following two tips according to setting result.
Figure 3-21
Operating procedure for modifying

1) Enter the old password in [Enter old password];
2) Enter the 8-code password in [Enter new password];
3) Enter the 8-code password in [Confirm password];
4) Click [Set] button;
Software will display the following three tips according to setting result, as Figure 3-22 shows.
84
Figure 3-22
Operating procedure for clearing

1) Click [Clear] button;
2) Software display windows as Figure 3-23 shows;
3) Enter program password;
4) Click [OK] button;
Software will display the following two tips according to setting result, as Figure 3-34 shows.
Figure 3-23
Figure 3-24
85
Note:
1) The password must be 8 codes;
2) Please make sure the new password and confirm password be the same;
3.2.4.2 Download PSW

Set/Modify/Clear download password for opening project, if project set download password, it requires
check password before executing downloading operation.
Figure 3-25
Operating procedure
The procedure for setting, modifying and clear are the same as program password, please refer to the
3.2.4.1.
3.2.4.3 Upload PSW

Set/Modify/Clear upload password for opening project, if project set upload password, it requires check
password before executing uploading operation.
Figure 3-26
Operating procedure
The procedure for setting, modifying and clear are the same as program password, please refer to the
3.2.4.1.
86
3.2.4.4 Clock PSW
Set/Modify/Clear clock password for opening project, if project set clock password, it requires check
password before setting clock operation.
Figure 3-27
Operating procedure
The procedure for setting, modifying and clear clock password is the same as program password, please
refer to the 3.2.4.1.
3.2.4.5 PLC code

In order to make the project can be dedicated to the designated PLC. WECON PLC Editor introduces
the identification code for project and PLC device. The downloading operation only executes when the
identification codes match. So the identification code can make the project only be used for specific PLC
device.
Figure 3-28
Operating procedure
The procedure for setting, modifying and clear identification code is the same as program password,
please refer to the 3.2.4.1.
Note
1) It requires connecting PLC device for setting identification code for PLC device;
2) [Clear PLC Memory] can’t clear PLC identification code, so please backup the identification code.
87
[Type here]
4 Editing programs
This chapter explains the functions of the program editors used to edit programs.
4.1 Programming
This sector explains the functions in programming area, including ladder program, instruction list
program and right-click menu.
4.1.1 Ladder program

Program the ladder program in programming area.
4.1.1.1 Enter instruction in ladder

There are five methods to enter instruction in ladder.
 Direct enter
 Instruction enter
 Double-click
 Instruction help
 Ladder Symbol
Direct enter
1) Move the mouse, left-click on the cell in programming area;
2) Enter instruction in keyboard, such as [LD]; the [Edit]window will pop up automatically;
3) Enter the complete instructions and operands in [Edit] window;
4) Click [OK] or press [Enter] key in the keyboard;
5) The system will verify the enter instruction, and then generate the graphic represented by the
instruction;
6) If the check fails, the instruction cannot be saved, please find the cause of the error;
Figure 4-1
Instruction enter
1) Open the [Program Manager], which on the left of software main screen;
2) Open [Instruction];
3) Open the instruction tree;
4) Select the need instruction, hold the mouse to select instruction and drag it to the programming
area, placed it in a designated location;
88
[Type here]
5) The [Edit] window will pop up automatically with selected instruction, as Figure 4-2 shows;
Figure 4-2
6) Enter the operands in [Edit] window;
Double-click
1) Move the mouse to the designated location, and double-click mouse;
2) The [Edit] window will pop up automatically;
3) Enter the complete instructions and operands in [Edit] window;
instruction;
Instruction help
1) Move the mouse to the designated location, and double-click mouse;
2) The [Edit] window will pop up automatically;
3) Click [Help] in [Edit] window, as Figure 4-3 shows, it will pop up [Help] windows for all the PLC
instructions, as Figure 4-4 shows;
Figure 4-3
[Type here]
Figure 4-4
4) Select the needed instruction, and click [Details] to open the instruction guide window as Figure
4-5 shows;
5) Enter the right operands, and click [OK] to save instruction;
[Type here]
Figure 4-5
Ladder Symbol
There is [Ladder Symbol] toolbar for ladder editing.
1) Click instruction icon[Ladder Symbol], the [Edit] window pop up automatically;

2) And the enter operand in [Edit] window
3) Enter the operands in [Edit] window;
instruction;
[Type here]
Note
1) Some instructions only be enter in the instruction list (IL), cannot enter in the ladder, such as MPS、
MPP. When enter such instructions in ladder editing area, it can generate the graphic represented
by the instruction;
2) Since the coils and application instructions represent the end of a line of ladder program, so users
cannot enter any device behind them;
3) Due to the vertical line can take up two rows of space. So if there is device in second line, this
vertical line cannot be entered;
4) The maximum number of columns is 13 in ladder program;
4.1.1.2 Modify/Delete devices in ladder

Operating procedure of modify devices
1) Ensure software is in [Edit Mode];
2) Select the device by mouse;
3) Double-click device or press [Enter] key in keyboard to open the [Edit] window;
4) Enter the new device or operand
5) Click [OK] to save the modification
Note:
1) Modifications must be able to verify the correct instruction, it can be saved.
2) Contact devices of occupying a cell (normally open, normal close, rising edge, failing edge,
inversion, Stepping) should not be modified to the compared devices.
3) All of the contact device can't modify each other with coil or application instructions.
Operating procedure of delete devices

1) Ensure software is in [Edit Mode];
2) Select the delete area by mouse;
3) Right-click and select [Delete], or press [Delete] key in keyboard;
4) Delete horizontal line and vertical lines, please select the lines, and then click the corresponding
icon in [Ladder Symbol] toolbar or press [F9] and [F11] in keyboard;
4.1.1.3 Copy and paste function

When ladder needs a large number of the same device, use copy and paste function can improve
programming efficiency.
Operating procedure
1) Enter the program programming area;
2) Select the copy content in program programming area;
[Type here]
3) Select [Copy] in right-click Menu or in [Edit] toolbar, or click [Ctrl] + [C] in keyboard to copy the
contents to the clipboard;
4) Paste the contents to the certain area;
Note:
1) When there is a vertical in copying area, only when the vertical across the top and bottom cells is
within the range of choice. The vertical will be copied to the clipboard.
2) No matter to use which edit mode, when you perform paste function, only to use the overlay mode.
Make the devices clear within the range of pasting, and then paste every devices of the clipboard
one by one.
4.1.2 Instruction list programming

WECON PLC Editor Software not only supports ladder, but also supports instruction list. Instruction list
is used for enter of instruction and operand. The way of enter instruction is the same as ladder. System will
calculate the steps of instruction, and automatically align instruction, operands, when completed programing.
The programming area as Figure 4-6 shows.
Figure 4-6
4.1.2.1 Entering instructions in instruction list

Enter instruction in programming area
Operating procedure of entering instruction

1) Create a new project;
2) Click [Switch] in [Program] toolbar into Instruction list editing mode;
Figure 4-7
3) If there is uncompelled program in the ladder editing mode, please click [Compile] in [Program]
toolbar firstly;
4) Move the mouse to the end row of instruction list editing area, and double-click to open [Edit]
[Type here]
window;
Figure 4-8
5) Enter the instruction and operand in [Edit] window, and click [OK] to save the instruction and
operand;
4.1.2.2 Copy, cut and paste instructions

This feature is completely consistent with the function of windows, the contents of the copy, cut to the
clipboard, and then paste to the user specified location.
1) Create a new project and switch to instruction list editing mode.
2) Select the area or element that need to be copied or cut, and click [Ctrl] + [C] or [Ctrl] + [X] on the
keyboard.
3) Move the mouse to user specified location. And then click [Ctrl] + [V].
4.1.3 Right-click menu

In the program editing area, right click mouse will display menu, this menu contains commonly functions.
It can greatly improve the development efficiency of developers.
Figure 4-9
 Undo: Cancel the current operation and back the previous step;
 Redo: Undo operation;
 Cut: Cut the selected ladder in the ladder editing area. Cut the selected command line in the list of
instruction. The content is store in the clipboard;
 Copy: Copy the selected ladder diagram in the ladder diagram. Copy the instruction row in the
instruction list editing area. The content is stored in the clipboard;
[Type here]
 Paste: Paste the data in the clipboard;

 Delete: Delete the program in editing area;
 Compile: Compile the current program;
4.1.3.1 Edit
Figure 4-10
 Insert Row above: Add a new row above in the certain row;
 Insert Statement: Add a statement for certain row;
 Delete Row: Delete a certain row;
 Insert Column to the left: Add a new column on the left of certain column;
 Delete Column: Delete a certain column in the PLC program;
4.1.3.2 Find
There are three options in Find menu, and all of them could open the [Search/Replace] window, but
different option for different function.
Figure 4-11
 Find Device: Open the [Search/Replace] window, and the default search page is Device. And if
users selected device, this device will be display in [Search] bar, otherwise, [Search] bar is empty;
Figure 4-12
 Find Instruction: Open the [Search/Replace] window, and the default search page is Instruction.
And if users selected instruction, this instruction will be display in [Search] bar, otherwise, [Search]
[Type here]
bar is empty;
Figure 4-13
 Find String: Open the [Search/Replace] window, and the default search page is String. And if
users selected instruction, this instruction will be display in [Search] bar as string, otherwise,
[Search] bar is empty;
Figure 4-14
4.1.3.3 View
It used for setting display content, the menu as Figure 4-15 shows.
Figure 4-15
 Show Comment: The device comment is displayed in ladder (Instruction list is not available).
 Show Alias: The alias of device is displayed in ladder and instruction list.
[Type here]
4.1.3.4 Debugging
Figure 4-16
Modify the current value: Users can change the device value in monitoring mode and simulator mode
(Write mode is not available).
4.1.3.5 Subroutine program encryption

It is used for the part of the ladder program encryption; it can be used for encrypting the subroutine and
interrupt program. WECON PLC Editor provides encryption function in [Tool] toolbar, including program
password, upload password, download password; all are for the entire ladder program.
Figure 4-17
 Encrypt
It is used for set password for subroutines, when subroutines are encrypted; they are not displayed
in programming area, as Figure 4-18 shows.
Figure 4-18
Operating procedure
a) Select the subroutine;
b) Click subroutine pointer, such as P1;
c) Right click, and select [Subroutine program encryption] -> [Encrypt];
d) Enter the password;
e) Click [OK] button;
 Decrypt
Decrypt the encrypted subroutine, it requires enter password, when subroutine decrypted, it is displayed
[Type here]
in programming area.
Operating procedure
a) Select the encrypted subroutine;
c) Right click, and select [Subroutine program encryption] -> [Decrypt]
 Modify passwords
Modify the passwords for encrypted subroutine, it requires enter old password.
Operating procedure
c) Right click, and select [Subroutine program encryption] -> [Modify passwords]
d) Enter the old password;
e) Enter the new password;
f) Click [OK] button;
Figure 4-19
 Show encrypted content this time

It used for showing encrypted content in programming area, it requires enter password for displaying.
Operating procedure
c) Right click, and select [Subroutine program encryption] -> [Show encrypted content this time]
[Type here]
4.2 Labels
This sector explains how to edit labels in programming area, including device comments and program
statements.
4.2.1 Comment
Edit comment for devices, its prerequisite is a program.
Operating procedure
1) Click [Comment], if the background color of the [Comment] changed, then this function is enabled.
If the background does not change, please save the current project and restart the software as
administrator;
2) When enable edit comment mode, and double click the device, it will pop-up [comment edit]
window;
3) Enter the comment for this device;
4) Click [Execute] to save;
Figure 4-20
Note:
Comments supports maximum 27 characters and it only contains 16 characters after downloading into
PLC.
[Type here]
4.2.2 Statement
Edit statements for program, its prerequisite is a program.
Operating procedure
1) Click [Statement], if the background color of the [Statement] changed, then this function is enabled.
If the background does not change, please save the current project and restart the software as
administrator;
2) When enable edit statement mode, and double click the certain project line, it will pop-up
[Statement Edit] window;
3) Enter the statement for this line;
4) Click [Execute] button to save;
Figure 4-21
Note:
There is no limit of characters in statement, but the statement can’t be downloaded into PLC.
4.3 Compile
This sector explains how to compile the program. The [Compile] is in [Program] toolbar.
If the compile is successful, the [Compile] is unavailable.
Figure 4-22
As the Figure 4-23 shows, if the program isn’t compiled, the program background is in purple, the
[Type here]
[Compile] is available. Users can click it for compiling program.
Figure 4-23
Operating procedure
1) Run the software, and then create a new program;
2) Click [Compile] in [Program] toolbar when complete program;
3) If there is no error, software will show the following tip message;
Figure 4-24
4) If there is any error, software will show the following tip message;
Figure 4-25
5 Transfer project
This chapter explains the operation methods for transfer project between PLC and PC.
5.1 Communication test

The main purpose of the communication test is to improve the stability of the communication between
PLC and PC.
Operating procedure
1) Open WECON PLC Editor software;
2) Click [Transfer Setup] in [Online] toolbar, as Figure 5-1 shows;
Figure 5-1
3) Open the [Transfer Setup] windows as Figure 5-2 shows, this [Transfer Setup] is available in
V1.1.0 and later software version;
Figure 5-2
 USB Connection: It is for programming and monitor PLC via Micro USB port (PLC produced after
February 2016);
 Serial Connection: it is for programming and monitor old PLC devices via Micro USB port
produced before February 2016, and also for programming and monitor all PLC devices via RS422
port (round port);
Figure 5-3
 Software selects connection mode automatically according to the PLC device, but if old PLC and
new PLC were connected to PC at the same time, the software would ask user to select connection
mode.
4) Check [More] for communication parameters setting, as following figure shows, user can set
communication parameters according requirements;
Figure 5-4
5) Click [Connection test] for communication testing, the testing tip message as Figure 5-6 shows,
Figure 5-5
6) If successfully connect with PLC, users can check PLC information by click [Device Info], as
Figure 5-7 shows, the version also can be check by D8001 and D8101.
Figure 5-6
Note:
Please use micro USB cable with strong anti-interference ability.
5.2 Download project

This section explains download project from PC to PLC.
Operating procedure
1) Click [Write to PLC] in [Online] toolbar;
Figure 5-7
2) The download window as Figure 5-8 shows:
Figure 5-8
3) Select downloading content by click buttons, such as [Param + Prog (P)], as Figure 5-9 shows.
Figure 5-9
 If users need to download comments into PLC, please modify the PLC capacity in [PLC
Parameters].
4) After clicking [Execute (E)], if PLC device still in running state, it would pop-up following tip
message, users need to confirm safety and click [Yes] to continue downloading.
Figure 5-10
5) The information for downloading is displayed in bottom of screen, as following figure shows.
Figure 5-11
6) Complete message for downloading as following figure shows.
Figure 5-12
5.3 Upload project

This section explains upload project from PC to PLC.
[Read from PLC] is for uploading PLC project from PLC device to programming software. If there is no
communication between PLC and software, this function can’t work. The uploading window as Figure 5-13
shows.
Figure 5-13
1) [Param+Prog (P)]: Upload parameters and project from PLC;
2) [Select All (A)]: Upload parameters, PLC project, comments, and device memory from PLC;
3) [Cancel all select (N)]: Deselect all;
4) [Execute (E)]: Executeupload operation;
5) [Stop]: Terminate upload operation;
6) [Close]: Exit the current window;
7) [Show]: Shows upload progress and other information, as Figure 5-14 shows:
Figure 5-14
The setting for memory setup is enabled when users check [Device Memory] in [Online Operation]
windows
Figure 5-15
The default name of Device data is MAIN, users can rename it, also set Device data.
Figure 5-16
5.4 Upload prohibited
This section explains upload prohibited function and set upload prohibited.
Upload prohibited can ensure that the project once downloaded to the PLC, cannot be uploaded to PC.
Operating procedure
1) Open downloading window;
2) Check [Upload prohibited] in window, as Figure 5-17 shows;
Figure 5-17
3) Click [Execute(E)] button;
When upload the project from PLC to PC, user will get following tip message.
Figure 5-18
6 Debug program
This chapter explains how to debug sequence programs. WECON PLC Editor provides two methods to
debug program.
6.1 Monitor mode

This section explains [Monitor mode] function, and how to debug sequence program in monitor mode.
Monitor mode is used for changing the value of device, when PLC is running.
Operating procedure
1) Completed program;
2) Connect PLC to PC;
3) Select [Monitor mode (R)];
4) Select device;
5) Right-click and select [Debug]-> [Modify the current value (M)]
Figure 6-1 is for bit device, Figure 6-2 is for word device.
Figure 6-1 Figure 6-2
6.2 Monitor edit

This section explains [Monitor edit] function, and how to debug sequence program in monitor mode.
Monitor edit is not only for changing the value of device, but also changing the program, when PLC is
running.
Operating procedure of changing value
3) Select [Monitor Edit (W)];
4) Select device;
5) Right-click and select [Debug]-> [Modify the current value (M)]
Figure 6-1 is for bit device, Figure 6-2 is for word device.
Operating procedure of changing value

3) Select [Monitor Edit (W)];
4) Editing the program;
5) Click [Compile] in [Program] toolbar, software will shows following tip message;
6) Click [Yes] button, when complete download, software pop-up window as Figure 6-4 shows;
Figure 6-3
Figure 6-4
7 Shortcuts list
This chapter shows the list of shortcuts that can be used for WECON PLC Editor.
7.1 Common shortcuts list

The following table lists the common shortcuts.
Table 7-1
Shortcuts Corresponding menu Description
Ctrl + N New Create a new project
Ctrl + O Open Open an existing project
Ctrl + S Save Save the project
Ctrl + X Cut Cut the selected data
Ctrl + C Copy Copy the selected data
Ctrl + V Paste Paste the cut/copied data at the cursor position
Ctrl + Z Undo Cancel the previous operation
Ctrl + Y Redo Perform the operation canceled by [Undo]
Ctrl + F Find Device Search for a device
Show/Hide toolbar Show/hide toolbar menu
Ctrl + F1
menu
F3 Start monitoring Start monitoring the window being operated.
Ctrl + F3 Stop monitoring Stop monitoring the window being operated
Transform/transform + Compile (Transform) current program
F4
compilation
Exit Close the project being edited and exits WECON
Alt+F4
PLC Editor
7.2 Shortcuts list in programming area

The following table lists the shortcuts in programming area.
Table 7-2
Shortcuts Corresponding menu Description
F5 Open contact Insert an open contact at the cursor position
Shift + F5 Open branch Insert an open contact branch at the cursor
position
F6 Close contact Insert a closed contact at the cursor position
Shift + F6 Close branch Insert a closed contact branch at the cursor
position
F7 Coil Insert a coil at the cursor position
F8 Application instruction Insert an application instruction at the cursor
position
F9 Horizontal line Insert a horizontal line at the cursor position
F11 Vertical line Insert a vertical line at the cursor position
Ctrl + F9 Delete horizontal line Delete the horizontal line at the cursor position
Ctrl + F11 Delete vertical line Delete the vertical line at the cursor position
Shift + F7 Rising pulse Insert a rising pulse at the cursor position
Shift + F8 Falling pulse Insert a falling pulse at the cursor position
Ctrl + Alt + F7 Rising pulse branch Insert a rising pulse branch at the cursor position
Ctrl + Alt + F8 Falling pulse branch Insert a falling pulse branch at the cursor position
Ctrl + Alt + Invert operation results Insert an operation result inversion at the cursor
F11 position
Ctrl + Shift + Insert line statement Insert statement line statement at the cursor
Insert position
Shift + Insert Insert row Insert a row at the cursor position
Shift + Delete Delete row Delete the row at the cursor position
Ctrl + Insert Insert column Insert a column at the cursor position
Ctrl + Delete Delete column Delete the column at the cursor position
Ctrl + ĺ Enter/Delete HLine Enter/delete a line at the right of the cursor
rightward position
Ctrl + ĸ Enter/Delete HLine Enter/delete a line at the left of the cursor position
leftward
Ctrl + Ļ Enter/Delete VLine Enter/delete a line at the downward of the cursor
downward position
Ctrl + Ĺ Enter/Delete VLine Enter/delete a line at the upward of the cursor
upward position
Ctrl + / Switch open/close Switch an open contact to closed contact, and vice
contact versa
Ctrl + G Jump Display the specified row
Ctrl + F5 Comment Display device comments
Ctrl + F7 Statement Display statements
F1 Open the instructions Display the instructions help
help
A human-machine interface (HMI) is the user interface that connects an
operator to the controller for an industrial system. Industrial control
systems (ICS) are integrated hardware and software designed to monitor
and control the operation of machinery and associated devices in
industrial environments, including those that are designated critical
infrastructure.
Some HMIs also translate data from industrial control systems into
human-readable visual representations of the systems. Through the HMI,
an operator can see schematics of the systems and turn switches and
pumps on or off, for example, or raise or lower temperatures. HMIs are
usually deployed on Windows-based machines, communicating with
programmable logic controllers (PLC) and other industrial controllers.

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Industrial automation can be defined as the use of set technologies and automatic

 Lower operating cost

 High Initial cost

Applications of Industrial Automation

PLC: A programmable logic controller (PLC) is a special form of

The PLC receives information from connected sensors or input devices,

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

1. Rugged and designed to withstand vibrations, temperature, humidity and noise.

The system has four buses:

Outputs are specified as being of relay type, transistor type

 Define capacity input/output

PLC Programming Language:

 Ladder Diagram (LD)

Ladder diagrams are specialized schematics commonly used to document industrial

PLC Power Connection

The inputs of modern PLCs are generally opto-isolators. An opto-isolator is a

Figure: Typical PLC Input circuit.

Figure: PLC input wiring.

Description of Some Common Input Devices

Switch: A switch is a component which controls the openness or closeness of an

Selector switch: A switch that is used to select among alternatives.

It is commonly two types two way/three way selector switch.

Limit Switch: A switch that operates as an automatic control to prevent a

Level Switch: Relay-Based ON/OFF Controller

ON/OFF control is a type of control method commonly applied to process control

Operating Voltage : 110, 220, 240 VAC

Rated frequency : 50/60 Hz

Power Consumption : Approx. 3.2 VA

Pressure switch: A pressure switch is a form of switch that close/open an

Sensors are used to measure physical quantities such as presence, temperature,

Discrete or Digital: 0/1 or On/Off or True/False

Analog: 4-20 mA, 0-20 mA, 0-10 V.

Proximity Sensor: A proximity sensor is a sensor able to detect the presence of

Inductive Proximity Sensor: An inductive proximity sensor is a type of non-contact

Output: Most industrial proximity sensors (inductive, capacitive, ultrasonic and

The working principle is based on the variation in the capacitance. It consists of

Photoelectric sensors are made up of a light source (LED), a receiver

Types of photoelectric Sensor:

Temperature Sensor: A temperature sensor is a device, typically, a thermocouple

Common Temperature Sensor

 RTD (Resistance Temperature Detector)

PT 100(Platinum Resistance Thermometer): A type of resistance temperature

Thermocouple: Thermocouples consist of two wire legs made from different

Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the

Temperature Range: (–270 to 1260 0 C)

Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a

Temperature Range: (–270 to 760 0 C)

Type T Thermocouple (Copper/Constantan): The Type T is a very stable

Temperature Range: (–270 to 370 0 C)

What is the difference between a pressure sensor, transducer, transmitter,

A pressure sensor is any device that measures pressure and converts it to an

Pressure Transducers and Transmitters

Pressure transducers and pressure transmitters are very similar. A pressure

Relay: A relay is an electromagnetic switch consisting with a coil and two

It is an electromagnetic switch operated by a relatively small electric current that

Relay Pin Configuration:

Solenoid Valve: A solenoid valve is an electromechanical device in which the

Miniature Circuit Breaker (MCB)

An MCB or miniature circuit breaker is an electromagnetic device that embodies

Molded Case Circuit Breaker

Earth Leakage Circuit Breaker (ELCB)

An earth leakage circuit breaker (ELCB) is a safety device used in electrical