Industrial Electronics

LAB REPORT NO.3

INTRODUCTION TO INTERLOCK CIRCUITS AND SET, RESET CAOILS,

AND POSITIVE NEGEATIVE TRANSITIONS, RETURN, BRANCH JUMP

CALL AND SUBROUTINE CALL IN PLC

1- Objectives
Upon completion of this lab, one will be able to
 Understanding about interlock circuits, latches with interlock.
 Recognize the diagraming symbols of interlock circuits.
 Understanding about the set and reset coils.
 Understanding about positive and negative transition coils.
 Understanding about self-holding circuits.
 Design examples in Online PLC Simulator to provide a study of the fundamentals of
developing, drawing and understanding event driven devices.

A-Pre task:
2- Interlock circuits:
Interlock circuits use contact to indicate the active state of a device, preventing operation of
related device, in order to protect the device and its user. Or mutually dependent functions.
Interlock circuit is also called priority circuit or operation prevention circuit. Interlock circuit
forms a series circuit between contact b and the subject circuit to prevent other relays from
operation if any one of the circuit is active. As shown

Figure:

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As the R1 relay becomes active after the push button switch PB1 becomes ON, R2 cannot
operate even if PB2 is pressed. Also if PB2 is active first causing R2 to active then R1
cannot become active.

Examples: Elevator, microwave oven (magnetron) explains later.

3- PLC Set and Reset coil Instructions
In setting coil the state of the Boolean variable becomes ON when the input at the left becomes
on and remains set until it is reset by the RESET coil.

RESET coil reset a coil which is at ON state.

4- POSITIVE AND NEGATIVE TRANSITION COIL:

Positive transition coil stays ON for one scan after the rising edge of input going from Off to ON
in the previous scan.

Negative transition coil stays ON for on scan after the falling edge of input going from ON to off
in the previous scan.

5- Latch(self-holding circuit):
A latch is like a sticky switch when pushed it will be turned ON but stick in place.it must be
pulled back by force to turn it off i.e. using another input.

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It has already been mentioned that the relay can be used for memory. Relay can store
information by composing a Self-Holding circuit with its contact.

Figure shows a self-holding circuit of a relay, where self-holding contact R (1) is connected
parallel to the push button switch PB1.

When push button switch is pressed, relay is activated and the contacts R(1) and R(2) close to
illuminate the lamp. Here, even if push button switch PB1 is released, current flows through R1

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and PB2 to the coil, sustaining the active state. In other words, even if PB1 put back to its
original state, the circuit to operate R is preserved by the contact R (1).

The self-holding circuit is released by pressing the push button switch PB2, which recovers R,
and contact R (1) and R (2) opens to reset the circuit to its original state.

6- BRANCH (JUMP) :
• Jump is a way to go to the desired (labeled) location for branching in the LD program.
Destination is represented by a label.

• The jump in the main program must be provided a label within main program as an input,
and the jump in the subroutine domain can only branch to labels within the subroutine.

• Normally, a PLC executes a ladder logic program in a rung by rung sequence. Jump
instruction is a controlled output instruction that allow a PLC to break this sequence and
to move the program execution to another rung.

Fig.1 Jump instruction

The Jump to Label instruction and the Label instruction are used in combination to
redirect the execution of a ladder logic program. The Jump to Label instruction is a
controlled instruction; when its rung is false, the PLC scans the next rung. When the rung
of a Jump to Label instruction is true, the PLC breaks its sequence execution and moves
to the rung with a Label instruction that has the same label number as the Jump to Label
instruction. When a Label instruction is used, it is always the first (most left) instruction
in a rung. It does not cause its rung to be true or false; it only shows the location of the
label.

6.1. Advantages of Jump:

 Allows the PLC to hold more than one program.

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 Sections of a program can be jumped when production fault occurs.

 Reduces processor scan time, allowing more scans to take place within a given period of
time.
 Program information is updated more frequently.

Example: if all inputs are made ON then output will become 1, rather equal to zero in task 9.

7- Return ( <RET>) :
it is the command to terminate execution if encountered during the execution, effectively
blocking the execution of any statement to follow as shown in task 8 .

8- SUBROUTINE (CALL) (<SC>) :

In LD program, the execution is terminated on encountering an END command. However, there
are cases when some program which exists after the END command must be evoked, in which
case the subroutine can be convenient.

Note: here to call the subroutine, labeling of statement is must.

As shown in task .

B- Lab tasks

Task 1

 Making an interlock circuit for the figure given above in interlock circuit.

Ladder diagram:

Simulation

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Task 2
Making a ladder diagram for set and reset coil implementation.

Through set switch, the set coil is magnetized and it will stay ON till it is made OFF by another
switch, say reset switch.

Ladder diagram and simulation:

Task 3

Purpose of experiment:
 Understand the PLC commands Set and Reset.
 Making ladder diagram using Set and Reset commands.
PLC I/O configuration map

1. Build motor’s start/stop circuit by using two (operation, stop) switches.

2. If start switch is turned ON, motor’s SET is activated and operation lamps turns ON.
3. If stop switch is turned ON, motor RESET is activated and operation lamp turns off while
stop lamp turns ON.
4. Even if circuit is interrupted with switch A while being operated by start switch, motor
keeps working until motor’s SET will be RESET.
5. SET command is characterized by the ability of sustaining its effect until RESET
command takes over.
Program practice:

Execution of program:

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1. to verify what was mentioned above, one uses a simulator, which is a characteristic of
GLOFA to perform an experiment to check whether there is any abnormality in the
circuit and its activation.

2. The simulator result show that when the simulator is chosen to execute CPU wit RUN
mood and turns ON the start switch, the operational lamp will glow and motor SET will
be activated.

3. Motor stops only when the RESET is activated by stop switch.

4. Motor maintains operation because the RESET was not activated as the figure above
even if the Switch A is turned ON when operated by start switch.

5. Set command is cleared only by RESET command.

Connection diagram with equipment

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Conclusion:

 Simulation is verified.
 Screen shots of ladder diagram and I/O panel shows that output of set remains the same
when A is pressed.
 SET has been made OFF by the RESET activation.

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Task 4
Purpose of experiment
 To understand the self-holding circuit.
 To make ladder diagram of how to make the self-holding circuit and its stopping
procedure.
Ladder diagram:

Simulation:

Conclusion:

Task 5

Positive and negative transition coil practice:

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Ladder diagram

Simulation:

Task 7

Positive negative transition sensing coil practice 2:

 Build motor’s start/stop circuit by using three (start 1, start 2, stop) switches.

 PLC memory assignment is given as.

 When start switch 1 turns on, positive transition sensing pulse coil is activated for 1 scan
to operate motor(transition sustained by lock up) as start switch 1 switches from Off to
ON (rising edge) and motor is stopped by stop switch.

 When start switch 2 turns ON, negative transition sensing pulse coil is activated for 1
scan to operate motor as start switch 2 switches from ON to Off(falling case), and motor
is stopped by stop switch.

GMWIN program:

Execution of program using simulator:

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Task 8

Return command practice.

Ladder diagram and simulation:

9- Branch jump command practice:

LADDER AND SIMULATION

C- Post task:

Purpose of experiment:

1. Understand motors forward and reverse circuit using PLC.

2. Learn about sequence control and PLC control.

Related knowledge:

1. One should be able to understand motor’s forward and reverse circuit.

2. Should be able to understand interlock circuit.

3. Build motor forward/reverse circuit by using two (forward, reverse rotation) input switch
and stop switch.

4. PLC I/O map is.

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1. when forward switch turns ON, motor does forward rotation (operation lamp ON and
stop lamp off) and when reverse switch is turned ON after turning stop switch ON/OFF,
motor does reverse rotation.

2. Motor operation lamp turns ON when motor operates and motor stop lamp turns ON
when motor stops.

3. One should turn off motor when bring to reverse rotation but this time time motor should
be first stopped and then turns the reverse rotation switch ON.

4. Note: forward operation should be sustained even if one turns ON reverse switch and
interlock circuit should be incorporated.

Ladder diagram:

Simulation:

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