Electric Automation Don Bosco

Eng. Amir George

Coordinator of Electric Dpt.
AField Level (Inputs & Outputs)

● Digital
Gives only 2 states ON or OFF (0 or 1)

Signals are expressed in terms of Normally opened / Normally closed

● Analog
Gives a variable indication of a signal

Standard Signals are: 0 or 4 – 20 mA, 0 – 10 VDC, Thermo-couple, RTD (Pt100, Ni1000 … etc)

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Field Level (Inputs & Outputs)
● Inputs Like
● Switches and Pushbuttons
● Sensing Devices
●Limit Switches
●Photoelectric
●Proximity
● Condition Sensors
●Pressure Switches
●Level Switches
●Temperature Switches
●Vacuum Switches
●Float Switches
● Encoders

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Field Level (Inputs & Outputs)

● Outputs Like
● Valves
● Motor Starters
● Solenoids
● Actuators
● Control Relays
● Horns & Alarms
● Stack Lights
● Fans
● Counter/Totalizer
● Pumps

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PLC
● What is a PLC?
● PLC is the name used for a programmable electronic device for
controlling industrial systems by sequential processing.

● It sends commands to output devices (actuators) based on input data

(sensors), set-points and program.

● A PLC is a device similar to a computer and is used for instance to

control machines on an industrial assembly line.

● A single PLC is enough to do what older automation systems did with

hundreds or thousands of relays .

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The old relays panels

● Old control systems was based on relay logic

panels which consisted mainly of:

● Electro-mechanical relays

● Mechanical timers

● Mechanical counters

● Wires, wires and … wires

The old relays panels

● These old systems was painful to install, operate and

to maintain due to:

● Needs a lot of space

● Long time to install and test
● Mechanical life time for relays are short
● Complete production stop while maintenance
● Error finding difficulties
● Cost of modification is too high

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First Programmable Controllers
● GENERAL MOTORS where the first who recognized
the need to replace the “wired control systems”.

● Micro-Computers were first used to replace relay

logic panels in GM factories. But technicians didn’t
accept it.

● GM Engineers wrote specifications for a required

control system that would replace the wired
systems with programmable ones while keeping the
programming language easy to read by technicians.

● Modicon developed the first device that met

those specifications.

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PLC’s Classification
Program Input
Memory Circuits
Control Unit
Output
Work Memory
Circuits

Power Supply

Modular

Compact

Micro
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PLC Languages

● Four different PLC languages exist in the modern PLC systems:

● Instructions List (IL)

● Structured Text (ST)

● Ladder Diagram (LD)

● Function Block Diagram (FBD)

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The PLC Scan Cycle
Zelio Smart Relay Overview
 Simply select your Zelio Logic
Back-up of data Power supply / Inputs
+ date and time:  
24 VAC Inputs
10 years!  100…240 VAC
 

12 VDC
 Limit switches
  
24 VDC 3-wire inductive
sensors

You seek an optimised Sensors and
potentiometers
solution for your simple (0-10V
applications comprising
10 to 20 I/O? Outputs

  Interface
> Zelio Logic Compact Relay  
   PC programming
Transistor

 
Memory card
You seek a solution for 
demanding applications  Modem 
link Interface
comprising up to 40 I/O? 
Bluetooth

interface
> Zelio Logic Modulaire

Extra large display


 
Back-litLCD display
With Zelio Logic, optimise Standards and 
your installation time certifications: 4 lines of 18
characters and1
line of icons
You seek an optimised solution for your
simple applications comprising 10 to 20 I/O?

Monobloc Version without
modules : display and without
● 10 I/O buttons for
● 12 I/O improved economy
● 20 I/O and confidentiality of
Zelio Logic applications.
Compact - SR2 -
Optimise the cost of the
solution according to
your application
requirements due to the
various versions:

 Version with display

with
display or 
without and buttons for
and buttons
  easy programming
with or without clock
and parametering.
 You seek a solution for demanding
applications comprising up to 40 I/O?
Simply add communication and I/O extension modules on the Zelio
Zelio Logic Logic Modular bases for:
Modulaire - SR3 -   
adding the Modbus adding additional increasing the
Provides you with
(slave) or Ethernet analogue inputs with number of discrete
performance and (server) communication better resolution (10 bits) inputs/outputs at
opportunities for network in addition to those of very little cost (up
the base to 40 I/O)
future development

  
1 modular base of 1communication 1 I/O extension
10 and 26 I/O, expandable extension module modules: 4 input/output
up to 40 I/O Modbus or Ethernet extension modules
(for 24VDC modular base) • 6,10, 14 dicrete I/O,
• 4 analogue I/O
 Optimise your installation time
Simple to assemble Simple to Simple to
mount integrate
59 mm

90 mm

26 I/O Ethernet 14 I/O 71,2 mm

Adherence to modular base communication extension
module module
modular pitch
associated with 45 Add expansion Fixing without Extreme
mm high modules on the accessories which compactness for
protrusion enables modular range by reduces integration reducing the size
perfect integration simple clipping-on, time: DIN rail or panel of your enclosures
in a control panel without screwdriver mounting (retractable and perfect
or an enclosure. or cables. fixing lugs). integration in your
installations.

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Zelio Logic Offer

Zelio Logic Compact SR2 Zelio Logic Modular SR3

● Can be extended up to 40 I/O

● Up to 20 I/O
● Modbus communication extension module
● Versions with or without display unit
● Choice of 2 programming languages
● Versions with LADDER programming
(LADDER or FBD)
language only, or LADDER and FBD
● To meet the needs of OEMs: Increased
● Designed for simple control application
performance, flexibility in terms of I/O
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Symbolization Rules

SR2A102BD
Smart Relay Power supply/inputs:
BD : 24 VDC
JD : 12 VDC
FU : 100 - 240 VAC
B : 24 VAC
Family:
I/O type:
● : Compact
● : Relay output
● : Modular
● : Transistor output

Product type: Number of I/O:

• : With display unit, no clock 10 : 10 I/O
• : With display unit and clock 12 : 12 I/O
● : Without display unit or clock 20 : 20 I/O
● : Without display unit but with 26 : 26 I/O
clock XT : Extension module

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Zelio Logic Compact: SR2

10 I/O 12 I/O 20 I/O 20 I/O

no clock or with clock no clock with clock
analog inputs and 4 analog 2 analog and 6 analog
inputs inputs inputs

Version with
backlit
display unit
SR2A1 SR2B1 SR2A2 SR2B2

Version without
display unit
SR2D1 SR2E1 SR2D2 SR2E2
Programming
language Ladder Ladder + FBD Ladder Ladder + FBD
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Zelio Logic Modular: SR3

The Modular range comprises:

• 2 bases (10 I/O and 26 I/O) with display unit (Ladder or FBD language)
• 3 types of extension module (6, 10 and 14 I/O)

26 I/O base
10 I/O base

10 I/O 26 I/O
SR3B10 (10 I/O base) SR3B26 (26 I/O base)

16 I/O 32 I/O
SR3B10 + SR3XT61 SR3B26 + SR3XT61

20 I/O SR3B10 + SR3XT101 36 I/O

SR3B26 + SR3XT101

24 I/O 40 I/O
SR3B10 + SR3XT141
SR3B26 + SR3XT141

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Front panel view of the product Inputs:
Discrete
3-wire PNP sensors
Power supply/inputs: 0 - 10 V analog
12 and 24 VDC or potentiometer
24 VAC
100 - 240 VAC
Interface:
PC programming
Program memory card
Display unit: Modem connection
Backlit LCD
4 lines of 18 characters
and 1 line of icons Modular case:
Mounting on DIN
rail, on a plate or
at the front
6 keys:
4 navigation keys or
pushbuttons, Outputs:
1 selection and confirmation key, Discrete
1 shift key transistor or relay (8 A)
 Programming Zelio Logic
LADDER language
FBD language

Processing capacity for up to 200 function blocks (FBD)

Processing capacity for 120 lines written in Ladder Diagram language

 5 contacts + 1 coil per program line Pre-programmed functions: timers, counters, etc.

 Function blocks: timers, counters, etc. Grafcet functions (Sequential Function Chart)

 Programming on the module or PC Logic functions: AND, OR, etc.


PC programming only
Presentation of the menus
The functions are grouped together in a main
menu. This menu can be accessed by
pressing the "Menu/OK" key.

FUNCTION Description

> INPUTS/OUTPUTS Display the I/O states, LD/FBD mode used, RUN/STOP state and 1 parameter
> PROGRAMMING Enter the ladder diagrams (accessed in LD mode and in the STOP state)
> PARAMETER Enter parameters (LD or FBD mode)
> MONITORING Display the ladder diagrams in real time, modify the parameters (in the RUN state)
> FBD DISPLAY Display text or values on the display unit (FBD mode)
> RUN/STOP Start/stop the program
> CONFIGURATION Access configuration menus (password, I/O filter, clock, etc.)
> CLEAR PROG. Delete the entire program (if the program is locked, enter the password)
> TRANSFER Program transfer: from the module to the memory cartridge and vice versa
> VERSION Access the module identification: reference, hardware and firmware versions
> LANGUAGE Select the language to be used by the module
> FAULT Access the number of errors/alarms detected by the module and delete them
Basic PLC Instructions

Load

Loadbar

Out
Basic PLC Instructions

● Load

The load (LD) instruction is a normally open contact. It is sometimes also

called examine if on. (XIO) (As in examine the input to see if it's
physically on).

In simple words: PASS CURRENT IF “1” IN MEMORY BIT

Basic PLC Instructions

● Loadbar

The LoadBar instruction is a normally closed contact. It is sometimes also

called LoadNot or examine if closed. (XIC) (as in examine the input to see
if it's physically off).

In simple words: PASS CURRENT IF “0” IN MEMORY BIT

Basic PLC Instructions

● Out

The Out instruction is sometimes also called an "Output

Energize" instruction. The output instruction is like a relay coil.
 LADDER programming
1-
User-friendliness of
the "free input" mode: LADDER or
 electrical symbols
2- 120 lines of control schemes

3- 5 contacts + 1 coil per programming line

 
Functions:

16 text
function 28 auxiliary relays,
blocks,

16 timers, 8 counter comparators,

Langage LADDER 16 up/down

LCD screen with programmable
counters,
back-lighting,
●Simplicity of
programming 1 fast counter,
Automatic 1 hour clock
assured by 16 analogue change: summer/winter,
comparators,
the universal Diversity of coil functions; with
contact 8 clocks, memory (set/reset), remote
switch, contactor.
language.
Sending up to 28 messages via
a modem
 Zelio logic tutorial
1 The Products
Congratulations! You have chosen one of the following Zelio products:

2 Environment
Zelio Logic is programmable using the Zelio Soft program or in Direct Entry Mode (Ladder
language). Zelio Soft allows you to program your software in FBD language or in Ladder
language. You must be connected to your PC in order to use the software program.
Use an SR2CBL01 cord to connect to your PC's serial port.

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3 Introduction to Zelio Soft
3.1 STARTING THE PROGRAM

When the Zelio Soft program is launched, the following window appears:

Click on Create a new program to start or choose New in the File menu if the program
has already been launched.

The smart relay option window now appears:

(1) (2) (3)

(4) (5) (6)

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In this example, we will choose the SR2 B121 BD module:

Click on the category (1) 10/12_I/O_WITHOUT_EXTENSION

The selected category is highlighted in yellow and followed by the list of corresponding
modules:

Click on the corresponding line to select the SR2 B121 BD module:

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Then click on Next.
The program type option screen now appears:

Ladder language is selected by default (yellow outline), click on Next to program in

Ladder. Click on the FBD icon then on Next to program in FBD.
Refer to 3.2 (Ladder language) or 3.3 (FBD) for an example.

3.2 EXEMPLE IN LADDER LANGUAGE

3.2.1 Program Editing:

We are going to use the following example:

I1—————Q1

Input I1 is connected to output Q1, which will be in active status (coil in contact mode).

To reproduce this example in the wiring sheet:

- Move the mouse arrow over the Discreet Input icon in the lower left corner:

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A chart with the different contact possibilities (I1 à IE) appears.

Select contact I1 in the chart by clicking and dragging the contact to the first cell in the
upper left corner of the wiring sheet. Release the mouse button: Contact I1 is now

- Now move the mouse arrow over the Discreet Output icon at the bottom of the
screen:
A chart with the different contact or coil possibilities appears.

- Select the coil [ in the first line of the chart by clicking and dragging the appropriate coil
to the first line of the coil column in the wiring sheet. Release the mouse button: Coil
[Q1 is now in place.

Wire the contact to the coil by clicking on the corresponding dotted lines.

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3.2.2 Program simulation

Simulate the program chosen by clicking on the simulation icon in the upper right corner:

The chosen program is now compiled and the simulation screen appears.
Next click on the RUN icon to simulate the module start-up:

A contact or a coil appears in blue if inactive (0) and in red if active

(1). Click left to force input
Click on the I1 contact to activate. The Q1 coil is now activated. When you click a second
time on I1 to disactivate, Q1 is also disactivated.

3.2.3 Program transfer

Power on the module and connect it to the computer before transferring the program:

- Click on the corresponding icon to return to Edit mode:

- In the Transfer menu, select Transfer Program then click on PC>MODULE.

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Note 1: You cannot write in the module when it is running. Click on STOP Module in the Transfer menu to stop the module.
Note 2: If the module connected to the computer is not the module selected when starting the program, you may select another
module by clicking on Module/programming option in the Module menu.
Note 3: When you have loaded a program in FBD in the preceding module (or when you first use it), the program should update the
module firmware. You will be offered the option to update during transfer.
After confirmation, the program is transferred to the module.

You can then test the program that is in the module by starting it up (in the application:
Click on RUN Module in the Transfer menu).

As in the simulation, if the Zelio Logic I1 input is active, Q1 will be active, and if the I1 is inactive, so is Q1.

3.2.4 Monitoring Mode

When the module is connected to the PC, it is possible to run it in real-time with the program.

Note: Monitoring mode is only possible when the program contained in the module is identical to that in the application.

- Click on the corresponding icon to select Monitoring mode:

Then click RUN to start the module. As in simulation mode, click on the contacts to activate (a left click on the mouse forces the
entry status). The contacts are then activated in real time on the module.
For example, click on I1 to activate the Q1 coil on the screen (red color) and on the module.
3.2.5 Moving around the module

Use the ! and " buttons to navigate the different module menus. The selected function flashes. To enter the function, click on
Menu/Ok. Click on#to return to the previous menu. The Shift key (white key) will display additional functions, in particular when
performing front panel programming.

For example, find the program transferred to the module screen when the module is in
OFF mode (STOP Module): In the main menu, select PROGRAMMATION using the ! and " keys (the selected word will flashes).
Press Menu/OK to confirm. You may now visualize the chosen program. Double click on Menu/Ok to return to the previous menu.