ROJAS, EMMANUEL A EEN23

BSEE IV GI ENGR. MELLER GONZALES

Experiment No. 1
INTRODUCTION TO PROGRAMMABLE LOGIC
CONTROLLERS (PLC)

I. OBJECTIVES

This experiment generally aims to study the operation of control system

equipment and devices. Specifically, it aims to achieve the following
objectives:

1. To familiarize the students with different control system

equipment, and devices used in control system laboratory.
2. To identify and discuss the different components of electro-
pneumatic systems.
3. To learn the fundamentals of the Programmable Logic Controller.
4. To make a sketch of the different equipment and devices in
control system.

II. INTRODUCTORY INFORMATION

Programmable Logic Controller

• It is a digitally operating electronic system.

• Designed for use in an industrial environment, which uses a programmable
memory for the internal storage of user – oriented instructions.
• Capable of storing instructions to implement specific functions such as logic,
sequencing, timing, counting and arithmetic operations to control various
types of machines or processes through digital or analog inputs and outputs.

A PLC handles the tasks of:

 (Auxiliary) contactors and relays
 Counters and timers
 Closed-loop controllers or proprietary electronics

The signal connections to the outside world are:

 Digital inputs (ON [24V] or OFF [0V])
 Digital outputs (ON [24V] or OFF [0V])
 Analog inputs (0-10V / 0-20mA)
 Analog outputs (0-10V / 0-20mA)

 Inputs:
Parts of the PLC to which the input signal lines are connected.
 CPU:
Core of the PLC that executes the commands from the PLC program and
manages process data, as in a PC.
 Outputs:
Parts of the PLC to which the actuators, such as power contactors, are
connected.

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The PLC evaluates signals from sensors such as limit switches, pushbuttons,
light barriers or incremental encoders, combines these as in a circuit diagram using a
PLC program, and switches actuators ON or OFF or signals process states. The PLC
program is stored in a fixed form but can be edited or modified as required, that is, it is
‘programmable’.

PLC Basics
How Does a PLC Work?

A cycle comprises reading of the inputs, one execution pass of the PLC program and
writing to the outputs. This process is repeated continuously in the CPU.

The process image is a special memory area in the programmable controller. It is

divided into the process-image input (PII) and the process-image Output (PIQ). At
the start of program execution, the signal states of all inputs are transferred
simultaneously (!) to the PII. Signal changes during program execution are not taken
into account until the next cycle. At the end of program execution, the PIQ is
transferred to the outputs.

The PLC System Components

• Central Processing Unit (CPU)

• Memory
• Input Module
• Output Module
• Power Supply

CPU: Brain of a PLC

• Update inputs and outputs
• Performs logic and arithmetic operations
• Communicates with memory
• Scans application programs such as a ladder logic program
• Communicates with a programming terminal.

Memory
• A component to store information, programs and data.

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Input Modules
• Input devices used with a PLC include push buttons, limit switches, relay
contacts, photo sensors, proximity switches, and temperature sensors.• Input
modules provide interface between the input devices and the CPU. Convert the
input signals to DC voltages acceptable by the CPU.

Output Modules
• Output devices include relays, alarms, solenoids, fans, lights, and motor
starters. Convert the low DC voltage PLC control signals to the voltages
required by the controlled circuits or devices.

Power Supply

• PLC’s are powered by commercial AC power lines.

• Converts AC power into DC power to support other components of the PLC.

Programming Terminal

• It is for programming the PLC and monitoring the PLC operation.

• Download a ladder logic program (send a program from terminal to PLC)
• Upload a ladder logic program (send a program from PLC to programming
terminal).

Conversion of Conventional Control Circuit to PLC Ladder Diagram

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Conventional Circuit for Sorting Machine

In this example, you have to determine again the number of input and
output device used for the control circuit. Assign the I/O for the PLC and
then wire it according to the actual I/O devices. The wiring circuit is
above. The input devices such as PB1 is assign to the input 0, LS1 as
input 1, LS2 as input 2 and PB2 as input 3. The output device such as
conveyor motor is assigned to output 1000, cylinder solenoid as output
1001 and End Cycle Bell as output 1002.

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Wiring Circuit of PLC for Sorting Machine

Ladder Diagram of PLC

Program modules can be displayed and edited in different
programming languages:

1) IL: The programming language Instruction List consists of a series of instructions

(commands) in a low-level programming language.
In the IL, the program module consists of individual command lines (instruction
lines). A comment can be appended to the instruction part.

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 The Instruction List according to IEC 61131-3 is a low-level programming
language. Low-level means that the instructions can directly be converted into the
binary machine code of the PLC. Contrary to the ST programming language,
multiple program lines are required in IL to formulate an instruction.

2) LD: The programming language Ladder Diagram is a graphical combination of

binary variables (digital logic operations). The ladder diagram resembles the
circuit diagram of earlier relay control systems with contacts and coils.

The program module in the LD represents a graphic operation of binary variables

(digital operations). The Ladder Diagram is similar to a circuit diagram with
contacts and coils of previous relais controllers. The spelling is modelled on the
IEC 1131-3 norm. All LD function elements which can not be illustrated, are
displayed as IL command lines. Thus, a mixed representation with IL lines and LD
elements develops.
3) FBD: The Function Block Diagram is a graphical combination of different function
elements. In FBD, binary (digital) logic operations as well as timer, counter and
comparator functions and program and module jumps can be displayed.
All other function elements which cannot be represented are temporarily
displayed in IL mode.
In the FBD representation, the program module is a graphical combination of
different function elements. It allows to display binary (digital) logic operations,
timer, counter and comparator functions as well as program and module jumps.

4) SFC: The programming language Sequential function chart (SFC) makes the
graphic programming of a complex task in clear units possible. The control flow of
these parts can be arranged gradually in sequential or parallel processes (also
known as sequence cascade programming). To be able to activate this
programming language, it is necessary to specify an SFC file.

5) ST: The Structured Text is a textual language. Contrary to the low-level IL

language, ST is a programming language that uses comprehensive constructs to
allow a very compact formulation of the programming task. ST offers the
advantage that it allows a clear program structure. The disadvantage of this
language is its lower efficiency. The programs are slower and longer. To be able
to activate this programming language, it is necessary to specify an ST file in the
Presets.

III. MATERIALS AND EQUIPMENT

1. PLC module
a. DC power supply
b. Push button switches
c. Toggles switches
d. Connecting wires
2. Electro-pneumatic system
a. DC power supply
b. Air compressor
c. Directional valves
d. Solenoid valves
3. Switches and relays
a. Limit Switches
b. Reed switches

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 c. Latching rocker switch
d. Electronic sensor
e. Control relay
f. Timer relay

IV. PROCEDURES

1. Observe and study the different equipment and devices provided by

the instructor.
2. Give the function of each device or parts of the equipment.
3. Make a sketch of each device and label each part/components of the
equipment.

V. SET-UP/DRAWINGS

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DC POWER It provides direct current to
SUPPLY power the relays, swtichboards
and the I/o module

It is a component that has

pushbuttons and detent swtiches
SWITCH BOX

It is a component that has the

relays, an electromechanical
swtiches
RELAY

It is where the input sensors and

outpus are located, to be used
IO MODULE on the handling trainer.

It is a pneumatic device used to

provide air to the cylinder on
the trainer
AIR
COMPRESSOR

It is a conductor used to send

signal to the control and power
circuit and used to connect
CONNECTING circuits
WIRES

Used to switch on and off an

electrical circuit

TOGGLE
SWITCH

It opens or closes an orifice in a

valve body by energizing the
coil.

SOLENOID

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VALVE

It allows fluid to flow into

different paths from valve parts
which provide pathways for
DIRECTIONAL flow to other components
VALVE

It is an electromechanical
device used to detect the
presence or absence of an object

LIMIT SWITCH
It is a switch that when
switched on, it remains on until
switch off again.

LATCHING
ROCKER It is an electromagnetic switch
SWITCH used to control flor of electricity
by acting as proximity sensors

It is a relay where the contacts

REED SWITCH open or close before or after a
preselected time interval.

TIMER RELAY
It is part of the trainer that is
able to transfer a specific object.

HANDLING
MACHINE

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VI. OBSERVATIONS

With the help of a PLC program, the PLC analyzes signals from sensors like limit
switches, pushbuttons, light barriers, or incremental encoders, combines them as shown
in a circuit diagram, and then turns on or off actuators or changes the status of signals.
The PLC program is saved in a set form, but it is 'programmable,' meaning that it may be
altered or changed as needed. Push buttons, limit switches, relay contacts, light sensors,
proximity switches, and temperature sensors are examples of input devices used with a
PLC. Input modules operate as an interface between the input devices and the CPU.
Transform the input signals into DC voltages that the CPU can use. Relays, alarms,
solenoids, fans, lights, and motor starters are examples of output devices. Convert PLC
control signals with low DC voltage to the voltages needed by the controlled devices or
circuits.

VII. CONCLUSIONS

The aim of laboratory experiment no. 1, Introduction to Programmable Logic Controllers

(PLC) is to to familiarize the students with different control system equipment, and devices used
in control system laboratory. Also to identify and discuss the different components of electro-
pneumatic systems and to learn the fundamentals of the Programmable Logic Controller. Lastly,
to make a sketch of the different equipment and devices in control system. Using the above
elements, instrument, and values, and following the protocol, we arrived at the following result.
This was also done to broaden the student’s expertise and laboratory skills on the subject. The
following conclusions were drawn from the experiment
- PLC is a digitally operating electronic system
- It is designed for usage in an industrial setting and storing user-oriented instructions
inside in a programmable memory.
- It has the ability to store instructions that will be used to carry out certain tasks
including logic, sequencing, timing, counting, and arithmetic operations to control a
variety of devices or processes using digital or analog inputs and outputs.
- It consist of series of instruction to monitor process