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PLC
CONTENTS
1. PLC GENERAL 3
2. ALLEN BRADLEY PLC 19
3. WONDERWARE INTOUCH SCADA 29
4. SIEMENS S7 200 PLC 43
5. SIEMENS S7 300 PLC 53
6. MODICON PLC 65
7. AC DRIVES 77
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PLC GENERAL
Automation
Industrial automation is the use of control systems such as computers to
control industrial machinery and processes, replacing human operators. In the scope
of industrialization, it is a step beyond mechanization. Automation greatly reduces the
need for human sensory and mental requirements.
PLC (Programmable Logic Controller)

NEMA (National Electrical Manufactures Association) defines PLC’s as
“Programmable logic Controller is a digital electronic device which uses a
programmable memory to store instructions and data and implements specific
functions such as timing, counting, logics etc to control various machines or process”.
A PLC is a device that was invented to replace the necessary sequential relay
circuits for machine control. The PLC works by looking at its input and depending
upon their state, turning ON / OFF its inputs. The user enters a program, usually
through software, that gives the desired result. A PLC can be defined as a solid state
device. It is capable of storing instructions to implement control functions such as
sequencing, timing, counting, arithmetic, data manipulation and communication to
control industrial machines and processes.
Architecture of PLC
Inputs Input Output Outputs

CPU
Interface Interface
Memory
Processor
Power supply
CPU
A PLC is composed of two basic sections namely CPU (Central Processing

Unit) and I/O (Input / Output) section. The CPU section is formed by three
components namely Processor, Memory and Power supply. The CPU controls all
arithmetic and logical operations, control signals to various outputs etc. During
operation the CPU reads or accepts the input data or status of the field devices
through the input interfaces; executes the control program stored in memory and
writes or updates the output devices through output interfaces.
The I/O system forms the interface by which field devices are connected to the
controller. The main purpose of interface is to condition the various signals received
from or sent to external field devices. Incoming signals from sensors such as push
buttons, limit switches analog sensors etc are wired to the terminals on the input
interfaces. Devices that will be controlled like motors, starters, solenoid valves etc are
connected to the terminals on the output devices. The system power supply provides
all necessary voltages required for the proper operation of the various CPU sections.
Advantages of PLC
1. Reduced Space
PLC’s are fully solid state devices and hence extremely compact compared to
hard-wired controller which uses electromechanical devices.
2. Energy Saving
The power consumption is very less compared to other controllers. The
average power consumption is just 1/10th of power consumed by an equivalent Relay
Logic Control.
3. Ease of Maintenance
We can easily replace the different modules of PLC’s. Trouble
shooting and error diagnostics with programmer are also very easy in PLC’s.
4. Economical
Considering one time investment PLC is most economical system.
Cost of PLC’s recovers with in a short period.
5. Greater Life and Reliability

PLC is a solid state device and they have greater life than any other
devices. It is also a static device; hence lesser number of moving parts reduces wear
and tear. In case of hard wired logic control , hardwire is either electromechanical or
pneumatic and therefore it is more prone to faults due to wear and tear and tear of
moving parts results in lesser ON time of system.
6. Tremendous Flexibility
To implement changes in control logic no wiring is required so
considerable time is saved.
7. Advanced Computation Supported

PLC can carry out complex functions such as generation of time
delays, counting, comparing, arithmetic operations etc.
8. Speed and Flexibility
It gives high processing speed and great flexibility in the processing of
both analog and digital signals.
9. Closed Loop Control Supported

PLC’s are suitable for closed loop control and also it can handle
several closed loop tasks.
10. Shorter Project Time
The hard-wired control system can be constructed only after the task is
fully defined. In the PLC, however, the construction of controller and wiring are
independent of control program definition. This means that the total hardwire is
standard and desired control is achieved through program.
Programming Languages in PLC
Different programming languages are there in PLC. Some of the main

programming languages are
1. Ladder Logic (LAD)

2. Structured Text (ST)
3. Instruction List (IL)
4. Sequential Function Chart (SFC)
5. Functional Block Diagram (FBD)
Main Symbols Used in Ladder Logic
Basic
Electrical
Symbols Normally open Normally Closed Output
(NO) (NC)
PLC Normally open Normally Closed Output
Symbols (NO) (NC)
Structure of Ladder Logic
Rung 0
S1 O1
Positive Negative
Rail S2 O2 Rail
Rung 1
Figure shows an example for a ladder diagram. Positive and negative

logic rails are there in the ladder diagram. Current flow is from positive to negative
and from top to bottom. Each positive to negative section are known as rungs. The
outputs connected becomes ON when the positive to negative path completes.
Scan Time
A PLC works by continually scanning a program. The scan cycle
consists of three important steps.
Check Input Status

Execute Program
Update Output Status
1. Check Input Status

PLC first checks all input status that are connected in it. That means it
checks whether the input is ON / OFF. PLC records all data that into its memory.
2. Execute Program
After checking all input status PLC executes the program according to
the various input data that are collected. It will store the execution result for use in the
later step.
3. Update Output Status
Finally PLC updates the status of outputs. It updates the outputs based
on which were on during the first step and the results of executing the program during
the second step.
After the whole process the PLC goes back to the step 1 and repeats
the steps continuously. These three steps are known as Scan Cycle. The time taken to
complete one scan cycle is known as Scan Time.
Sinking and Sourcing
Normally two types of sensors are used in industries. They are
1. Sourcing Type
2. Sinking Type
The difference between two types is whether the load is switched to

ground or positive voltage. An NPN type sensor has the load switched to ground
whereas a PNP device has the load switched to positive voltage.
NPN Sinking Sensor
To PLC Input
Sensor
Output
Circuit
Ground (0 V)
On the NPN sensor we connect one output to the PLC’s input and the other
output to the power supply ground.
PNP Sourcing Sensor
To Positive (V+)
Sensor
Output
Circuit
To PLC Input
On the PNP sensor we connect one output to the Positive voltage and the other
output to the PLC’s input.
Basic Gates
1. AND Gate
Symbol Truth Table
Input Input Output
A B Y
A 0 0 0
Y 0 1 0
B 1 0 0
1 1 1
Ladder Diagram
A B Y
2. OR Gate
Symbol Truth Table
Input Input Output
A B Y
A 0 0 0
Y 0 1 1
B 1 0 1
1 1 1
Ladder Diagram
A Y
3. NAND Gate
Symbol Truth Table

Input Input Output
A B Y
A 0 0 1
Y 0 1 1
B 1 0 1
1 1 0
Ladder Diagram
A Y
4. NOR Gate
Symbol Truth Table

Input Input Output
A B Y
A 0 0 1
Y 0 1 0
B 1 0 0
1 1 0
Ladder Diagram
A B Y
5. NOT Gate
Symbol Truth Table
Input Output
A Y
A Y
0 1
1 0
Ladder Diagram
A Y
5. Ex-OR Gate
Symbol Truth Table

Input Input Output
A B Y
A 0 0 0
Y 0 1 1
B 1 0 1
1 1 0
Ladder Diagram
A B Y
A B
Example
Draw a PLC program to latch an output when START switch is pressed. The output
should remain in latch condition until STOP switch is being pressed?
Ladder Diagram
START STOP OUTPUT
OUTPUT
General Classification of PLC

PLC’s are generally classified into two types
1. Modular Type PLC
2. Integrated type PLC
1. Modular Type PLC
0 1 2 3 4
Power Digital Digital Analog Analog
Supply CPU Input Output Input Output
In modular type PLC each modules means Digital Input module, Digital
Output module, Analog Input Module and Analog Output Module are placed in each
separate racks or modules. The addressing of these PLC’s comes with the slot
number. We can place the different modules according to our needs. We can also
increase the number of inputs according to our needs in these types of PLC’s. So it is
called as Modular Type PLC.
2. Integrated Type PLC
Field Inputs
PLC
Field Outputs
In Integrated Type PLC the inputs and outputs are fixed. All the inputs are
comes in single module. We cannot increase the number of inputs and outputs in these
types of PLC’s.
ALLEN BRADLEY
PLC
ALLEN BRADLEY PLC
Allen-Bradley is the brand-name of a line of Factory Automation
Equipment manufactured by Rockwell Automation. The company manufactures
programmable logic controllers (PLC), human-machine interfaces, sensors, safety
components and systems, software, drives and drive systems, contactors, motor
control centers, and systems made of these and similar products. Rockwell
Automation also provides asset management services including repair and consulting.
Allen Bradley PLC’s are mainly classified into three types according to
the number of inputs and outputs. They are
Plc Types No: of Digital No: of Analog Memory

I/O I/O
Pico 24 2 8K
Low end
Micrologix 256 2 8K
Medium end SLC-500 4096 8 8K
PLC 10000 16 16 K
High end Flexlogix

> 20000 256 256 K
Controllogix
Here we use Micrologix and SLC-500 PLC’s. Micrologix PLC is an

integrated type PLC. Micrologix PLC’s are mainly classified into three types. They
are
Micrologix PLC
1000 1200 1500
Series A Series A Series A
Series B Series B Series B
Series C Series C Series C
SLC-500 is a modular type PLC. It is mainly classified into five

different CPU versions. They are
SLC-500 PLC
5/01
5/02
CPU Types 5/03
5/04
5/05
Memory
Program Files Data Files
File No: File Name File Type
SYS-0 Reserved Files 0 Output O
SYS-1 1 Input I
LAD-2 Main Program 2 Status S
LAD-3 3 Binary B
4 Timer T
Sub Routines 5 Counter C

6 Control Register R
LAD-255 7 Integer N
8 Floating F
Memory is mainly classified into two types.
1. Program Files
Program file consists of SYS-0, SYS-1, Ladder-2, Ladder-3 etc up to Ladder-

255. SYS-0 and SYS-1 are reserved files. They are used for the initial start up of the
Plc. Ladder-2 is the main program. Ladder-3, Ladder-4 ------ Ladder-255 are
subroutines.
2. Data Files
Data Files consists of inputs, outputs, status, timer, counter etc. Inputs and
outputs are used for input and output addressing. Status register is used for monitor
any error status, also setting of real time clock etc. Timers are used for setting time
delay functions. Counters are used for counting number of pulses given to it. Control
register is used for controlling and taking some outputs which are used in some
instructions. Integer register is used for storing integer values used in arithmetic or
logical operations. Floating register is used for storing floating point values.
Addressing syntax
Addressing syntax for SLC-500

SLC-500 is a Modular Type PLC.
0 1 2 3
Power Digital Digital Analog
Supply CPU Input Output Input &
Output
Syntax is File Type : Slot Number . Word / Bit
Digital Input Digital Output
I:1.0/0 O:2.0/0
I:1.0/1 O:2.0/1
I:1.0/2 O:2.0/2
I:1.0/15 O:2.0/15
I:1.1/0 O:2.1/0
I:1.1/1 O:2.1/1
Addressing syntax for Micrologix

Micrologix is an Integrated Type PLC.
Syntax is File Type : Slot Number . Word / Bit
I:0.0/0 O:0.0/0
I:0.0/1 O:0.0/1
I:0.0/2 O:0.0/2
I:0.0/15 O:0.0/15
I:0.1/0 O:0.1/0
I:0.1/1 O:0.1/1
Analog Addressing
If we are using digital signal we can store it in a single bit. But if we are using
analog signals we cannot store the values in a bit so it should be stored in a word. The
analog signals used in industries are normally 0-10 V and 4-20 mA.
0 4 0000 0000 0000 0000 0
10V 20mA 0111 1111 1111 1111 32767

Combinations
Parity Bit
Parity bit can be zero or one. Parity bit becomes zero when the analog value is
positive and it becomes one when the analog value is negative. If we give one analog
signal the PLC converts it into 0 to 32767 combinations. We get the corresponding
digital signal and it should be stored in memory locations. We can use this value for
controlling analog signals.
Analog Addressing Syntax is File Type : Slot Number . Word
Analog Input Analog Output
I:3.0 O:3.0
I:3.1 O:3.1
I:3.2 O:3.2
Addressing Syntax For Others Except Binary
Syntax is File Type File Number : Element
Status S2:0, S2:1, S2:2, --------- S2:255

Timer T4:0, T4:1, T4:2, --------- T4:255
Counter C5:0, C5:1, C5:2, --------- C5:255
Control Register R6:0, R6:1, R6:2, --------- R6:255
Integer N7:0, N7:1, N7:2, -------- N7:255
Floating Point F8:0, F8:1, F8:2, --------- F8:255
Addressing Syntax For Binary
Syntax is File Type File Number : Word / Bit
B3:0/0
B3:0/1
B3:0/2
B3:0/15
B3:1/0
B3:1/1
Binary bits are used in programs for certain applications. In some programs
we have to take some intermediate outputs which are not used as field outputs. In such
outputs if we use normal output address then these outputs are wasted. So in those
cases we use Binary outputs and thus we can save the outputs.
Driver Software
Driver Software is used for interfacing personal computer with PLC. The
driver software used for Allen Bradley PLC is RS Linx.
Personal Direct Connection Allen Bradley

Computer PLC
19.2 Kb/Sec
RS-232 RS-232
Personal computer supports only RS-232 Protocol. Allen Bradley PLC also
supports RS-232 Protocol. So we can directly connect Allen Bradley PLC to personal
computer. If the PLC didn’t support RS-232 protocol then a converter is also used.
The Baud rate for Allen Bradley PLC is 19200 Bits/second.
Programming Software
The programming software’s used in Allen Bradley PLC’s are

For Medium end PLC’s and Low end PLC’s RS Logix 500 English
For High end PLC’s RS Logix 5000 English
WONDERWARE
INTOUCH
SCADA
WONDERWARE
Wonderware is a supplier of industrial automation and information software

solutions, having sold more than 500,000 software licenses in over 100,000 plants
worldwide. Wonderware has customers in virtually every industry including utilities,
mining, oil & gas, food & beverage, pharmaceuticals, transportation, pulp & paper,
semiconductors and metals. Wonderware is a business unit of Invensys.
Wonderware has been an industrial software leader since 1987, when the
company introduced InTouch® software, the first human-machine interface (HMI)
based on the Microsoft Windows® operating system.
Wonderware is a market leader in real-time operations management industrial

software which includes: Supervisory HMI, GeoSCADA, Production Management,
Performance Management etc. Wonderware delivers significant cost reductions
associated with designing, building, deploying and maintaining secure and
standardized applications for manufacturing and industrial operations. Wonderware
software solutions enable companies to synchronize their production operations with
business objectives, obtaining the speed and flexibility to attain sustained profitability.
SCADA
SCADA means Supervisory Control and Data Acquisition Software. SCADA

software is used for controlling the process in industries. SCADA software is also
used for monitoring the process parameters. Through SCADA software we can
control the whole process or whole plants in industries.
Block Diagram of SCADA
SCADA Software
I/P O/P I/P O/P I/P O/P
The above figure shows the block diagram of SCADA. In industries normally
number of PLC’s are there for controlling various plants. Each plant is controlled by
one or more than one PLC’s. The input and outputs of each PLC’s are connected to
SCADA through RTU’s. RTU means Remote Terminal Unit. The RTU act as an
interlink between PLC’s and SCADA. The RTU’s can be a Junction Box or a Master
PLC for controlling auxiliary PLC’s. SCADA software is being used in the control
room. Through SCADA software we can control the entire plants.
Types Of Communications
The different types of communications are
1. Landline Communication
2. Optical Communication
3. Satellite Communication
Landline Communication
In landline communication the communication is achieved through
normal wires or cables. Different protocols are used in these types of
communication. The different communication protocols are RS-232, RS-485,
DH-485, DH+.
RS-232
Maximum communication length = 15 Meters
Baud rate = 19200 bits/second
Maximum number of nodes supported = 1
RS-485
Maximum communication length = 1.3 KMs
Baud rate = 9600 – 18700 bits/second
DH-485
Maximum communication length = 1.2 KMs
Baud rate = 9600, 19200 bits/second
DH+
Maximum communication length = 18 - 25 KMs
Baud rate = 19200 bits/second
Optical Communication
In optical communication optical fibers are used. In optical
communication we can communicate to a longer distance than normal cables. The
main advantages are low noise, greater life, high data transfer speed, etc.
Satellite Communication
Normally satellite communication is used in remote places. In satellite
communication transmitter, receiver, encoders, decoders etc are used.
Different SCADA Software
Sl.No. Company Name SCADA Software
1. Wonderware Intouch
2. Rockwell Automation RSview
3. Siemens Win CC
4. Intellution iFix
5. GE Fanuc Cimplicity
6. Merz Aspic
7. Kpit Astra
SCADA To PLC Communication Software
For communicating with PLC to SCADA we need communication software.

The different communication software’s used are
Allen Bradley PLC ABKF2

S7200 PPI (For Low End PLC)
SCADA Siemens PLC
ATS DDE (For Medium End PLC)
Modicon PLC Modbus Communication
Different Packages in InTouch

The InTouch software package consists of Tags (Memory + I/O). The package
is available in 64, 256, 1000 and 64,000 Tags with the two options
1. Development + Runtime + Network (DRN)
2. Runtime + network (RN).
With DRN package you can develop as well as run the application but in case
of RN you cannot develop or modify the application. The application can be
developed by using DRN package and can be installed on RN package.
Features of SCADA
1. Real Time Trend

We can monitor the real time values by using Real time trend. Real-time
trends are dynamic. They are updated continuously during runtime. The real time
trend is plotted graphically. We can give many parameters in this Real time trend.
Different parameter variations are plotted by different colours. They plot the changes
of up to four local Tag Names or expressions as they occur.
2. Historical Trend
By using historical trend we can store the previous values. By giving correct
date, time etc we can easily get the parameter variations at that time. They plot the
changes of up to eight local Tag Names or expressions.
3. Alarms
Any hazardous conditions are monitored in industries by using these alarms.
Human safety is the most important factor in all industries. Usually the alarms give
the variations in any parameters as sound information or any light indication. The
alarms becomes off when the change in variation goes into normal conditions. In
SCADA, 1-999 alarms are there and they are mainly classified into four groups. They
are
Alarm Number Alarm Type

1- 249 Hazardous Alarms
250-499 Major Alarms
500- 749 Minor Alarms
750-999 Advisory Alarms
4. Security
Security on an application is an optional feature. If implemented, it provides
the ability to control specific operators to perform specific functions or changing
specific parameters. Normally passwords are used for locking SCADA. By giving
passwords only the user can enter into the SCADA programs. 1 – 9999 access levels
are there in SCADA. One access level is given to each person. The access level of
administrator is always greater than 9000. The person who has access level greater
than 9000 can change any thing in SCADA. The administrators also have their own
user name and password. He can also enter into the programs by giving their user
name and passwords.
5. Report Generation
By using Report generation we can generate the parameter variations
as report in excel sheet automatically. We can create the parameter variations for each
scan cycle.
6. Recipe Management
Recipe management is an important feature in SCADA. By using
recipe management we can set the values for different ingredients. For example in
medicine manufacturing industries the ingredients are same for different medicines
but their ratio will vary. So in those cases we can set the ratio of different ingredients
by using SCADA. When we select the medicine the values are automatically loaded
and we get the correct medicine. The recipe functions are done by using Recipe
Manager in SCADA.
7. Scripts for Program Development
Normally the Programs are called as scripts.
Tag Name
Tag name is the user defined address for a particular variable. For
example if we are using some objects in SCADA we have to give some names for
indicating that objects and also for using it in programs. These names are known as
Tag Names. Tag Names are mainly classified into four types. They are
1. Discrete
2. Integer
3. Real
4. Message
If we give any Tag Name we have to define or save it according to its

conditions. Discrete conditions mean 0/1 or ON/OFF. That means if we are using Tag
Names for switches, lamps etc then we have to define it into Discrete. If the Tag
Name is varying values like tanks, temperatures etc, then we have to define it into
Integer. If there are some floating values then Tag Name should be defined as Real.
The string values are stored as Message.
Each Tag Name is again classified into two types. They are
1. Memory
2. I/O
If we are using only SCADA programming then the Tag Names are
saved in Memory. If PLC to SCADA or PLC to excel communication is there, then
the Tag Names are saved in I/O.
Script
Script is the Programming language used to link two or more Tag

Names. Generally the programs are called as Scripts.
Types of Scripts
Scripts are mainly classified into six. They are
1. Application scripts
2. Window scripts
3. Key scripts
4. Conditional scripts
5. Data change scripts
6. Quick function scripts
1. Application scripts
The script which is applicable for the entire project is known as
Application scripts. We can use application scripts to start other applications, create
process simulations, calculate variables etc. Three options are there in Application
Scripts.
On Startup Executes one time when the application is initially started up
While running Executes continuously at the specified frequency while the
application is running.
On shutdown Executes one time when the application is exited
2. Window scripts
The script which is applicable for a particular project is known as
Window scripts. Three options are there in Window Scripts.
On Show Executes one time when the window is initially shown

While showing Executes continuously at the specified frequency while the
window is showing.
On Hide Executes one time when the window is hidden.
The initial conditions of Tag names are given in On Show. The On show
conditions are applicable during starting of run time. For example if we want one
switch becomes OFF during starting run time then we have to give it as zero in On
Show. The main program is known as While show. On hide means the conditions of
objects that we have to give when return back from run time. Normally in SCADA we
avoid On Hide because we don’t need the conditions during return back from run
time.
3. Key scripts
The programs which are assigned to a particular key is known as Key
Script. They are executed when the operator presses the correct key. Three options are
there in Key Scripts.
On Key Down Executes one time when the key is initially pushed
While Down Executes continuously at the specified frequency while the key
is held down
On Key Up Executes one time when the key is released.
4. Conditional scripts
The program which is executed when satisfying a particular condition
given to it is called as Conditional scripts. Four options are there in Conditional
Scripts.
On True Executes one time when the condition transitions to true.

On False Executes one time when the condition transitions to false.
While True Executes continuously while the condition is true.
While False Executes continuously while the condition is false.
5. Data change scripts

The program which is used for data transfer purpose is called as Data
change scripts.
6. Quick function scripts

Sub routines or sub programs are called as Quick function scripts.
Window Properties
Replace
Automatically closes any window(s) it intersects when it appears on the screen
including popup other replace type windows. You can change a window's type
whenever it is open in Window Maker by using the Window Properties command.
Overlay
Appears on top of currently displayed window(s) and can be larger than the
window(s) it is overlaying. When an overlay window is closed, any window(s) that
were hidden behind it will reappear. Clicking on any visible portion of a window
behind an overlay window will bring that window to the foreground as the active
window.
Popup
Similar to an overlay window except, it always stays on top of all other open
windows (even if another window is clicked). Popup windows usually require a
response from the user in order to be removed.
Programming Syntax
The programming syntax is

IF ‘CONDITION’ THEN ‘ASSIGNMENT’; ENDIF;
In conditions the symbols used are ‘= =, > =, < =, >, <, ><’. In
assignment only symbol used is ‘=’.
Sample program
Write a program to ON/OFF a lamp when we press the switch?
For doing the program first select one switch and lamp from SCADA. After
selecting the objects first give the tag names for each object. After that the tag names
must be defined according to their properties.
Tag name=S1 Tag name=L1

Save as both tag name as Memory discrete. Then write the program in window
scripts.
Window Scripts
On Show
S1=0; L1=0;
While Show
IF S1= =1 THEN L1=1;ENDIF;

IF S1= =0 THEN L1=0;ENDIF;
We can write the above program in single line by using ELSE.

IF S1= =1 THEN L1=1;ELSE L1=0;ENDIF;
SIEMENS S7 200
PLC
SIEMENS PLC
Siemens is the Europe's largest engineering conglomerate and the

largest electronics company in the world. Siemens international headquarters are
located in Berlin and Munich, Germany. The company is a conglomerate of three
main business sectors namely Industry, Energy and Healthcare. Siemens six
operational business areas were Automation & Control (Automation & Drives,
Industrial Solutions & Services, Siemens Building Technologies), Power (Power
Generation, Power Transmission & Distribution), Transportation (Transportation
Systems, Siemens VDO), Medical (Siemens Medical Solutions), Information &
Communication (Siemens Communications, Siemens IT Solutions and Services), and
Lighting (OSRAM GmbH, OSRAM Sylvania).
Siemens PLC’s are generally classified into two types.
Siemens PLC
S5 Series S7 Series
S5 series is DOS based version and S7 series is windows based
version. The different S5 series versions PLC’s are 100u, 110u, 115u etc. S5 series is
the old version PLC. Almost all of the S5 series PLC’s are replaced in all industries.
Handheld programming can also do in this type of PLC’s. S7 Series PLC’s are again
classified into three types according to the number of inputs and outputs.
Plc Types No: of Digital I/O No: of Analog I/O
Low End S7 200 256 32
Medium End S7 300 1024 256
S7 400 16384 ≈ 1500
High End C7
> 20000 256
M7
Here we use S7 200 low end PLC. The different CPU versions of S7
200 PLC’s are
S7 200 Plc
21 X Series 22 X Series
210 221
211 222
212 223
213 224
214 225
215 226
216
Here we use S7 200 PLC with CPU version 216. It has 24 digital inputs and
16 digital outputs.
The programming software used for S7 200 PLC is STEP 7 MICROWIN 32
Personal PPI Siemens

Computer PLC
RS-232 RS-485
Siemens PLC supports only RS-485 protocol. So a converter is used

for connecting with personal computer. The converter is called as PPI (Point to Point
Interface). The baud rate for Siemens PLC is 9600 bits/sec.
Addressing syntax
Siemens PLC addressing is basically Byte oriented. One byte means
eight bits.
Addressing syntax for Digital Input And Output
Syntax is File Type Byte . Bit

I0.0 Q0.0
I0.1 Q0.1
I0.2 Q0.2
I0.7 Q0.7
I1.0 Q1.0
I1.1 Q1.1
I2.7 Q1.7
Addressing syntax for Analog Input And Output
Syntax is A File Type W Word

AIW0 AQW0
AIW2 AQW2
AIW4 AQW4
Memory
Memory is mainly classified into four types. They are
1. Special Memory (SM)
2. Memory (M)
3. Variable Memory (V)
4. Local Memory (L)
1. Special Memory (SM)

In special memory each bit is having its own predefined function.
These bits can be used in programs. For example
SM0.0- Always ON
SM0.1- ON for the first scan cycle only.
SM0.2- ON for one scan cycle if retentive data is lost.
SM0.3- ON for 1 scan cycle when RUN mode is entered from a power-up condition.
SM0.4- Clock pulse that is ON for 30 s, OFF for 30 s, for a duty cycle time of 1 min.
SM0.5- Clock pulse that is ON for 0.5 s, OFF for 0.5 s, for a duty cycle time of 1 s.
Pot0 Value SMB28- This byte stores the value entered with analog adjustment 0.
Pot1 Value SMB29- This byte stores the value entered with analog adjustment 1.
2. Memory (M)
Memory is used for storing integer or floating values. Mathematical

and logical operations are done in these Memory locations.
3. Variable Memory (V)
Variable memory is used in FIFO and LIFO applications.
4. Local Memory (L)
Local Memory is used as addressing memory.
Memory Addressing
1. Special Memory Addressing
Bit Byte Word Double word
SM0.0 SMB0 SMW0 SMD0

2. Memory Addressing
M0.0 MB0 MW0 MD0

M0.1 MB1 MW2 MD4
M0.2 MB2 MW4 MD8
M0.3 MB3 MW6 MD12
3. Variable Memory Addressing
V0.0 VB0 VW0 VD0

V0.1 VB1 VW2 VD4
V0.2 VB2 VW4 VD8
V0.3 VB3 VW6 VD12
4. Local Memory Addressing
L0.0 LB0 LW0 LD0

L0.1 LB1 LW2 LD4
L0.2 LB2 LW4 LD8
L0.3 LB3 LW6 LD12
In all these memory addressing, in the word wise classification next

memory location of MW0 is MW2 and also in double word wise classification the
next memory location of MD0 is MD4 . The reason is that Siemens PLC addressing is
byte oriented. The memory locations MW0 and MD0 consists of
MW0 = MB0 + MB1

MW1 = MB1 + MB2
MW2 = MB2 + MB3
So in MW0 and MW1, the MB1 location is common. So if we use

MW0 and MW1 then memory clash will occurs. So to avoid this MW2 is used after
MW0. Like that in double word also next three locations are not used.
Timers
Timer Type Resolution Maximum Value Timer Number
TONR 1 ms 32.767 s T0, T64
10 ms 327.67 s T1-T4, T65-T68
100 ms 3276.7 s T5-T31, T69-T95
TON, TOF 1 ms 32.767 s T32, T96
10 ms 327.67 s T33-T36, T97-T100
100 ms 3276.7 s T37-T63, T101-T255
In Siemens PLC normally 255 numbers of timers are there. The types
of timers are TON, TOF and TONR. In siemens PLC we cannot use any timer number
for different types of timers. The timer number is predefined. We have to give the
correct timer number for different types that means TON, TOF and TONR. Also in
Siemens PLC the highest time base is 100ms. So we have to calculate correct preset
value for giving a time. For calculating time delay one formula is there.
Time delay = Preset value * Time Base
For example if we are using T37 timer and we need 10s time delay. So
T37 is a 100ms timer. Formula is
Time delay = Preset value * Time Base

10s = Preset value *100
10 *1000ms = Preset value *100
Preset value = 100
So for giving 10s time delay by using T37 timer we have to give preset
value as 100. Like that we can calculate the time delay according to our need.
The On-Delay Timer (TON) instruction counts time when the enabling
input is ON. When the current value (Txxx) is greater than or equal to the preset time
(PT), the timer bit is ON. The On-Delay timer current value is cleared when the
enabling input is OFF. This timer continues counting after the Preset is reached, and it
stops counting at the maximum value of 32767.
SIEMENS S7 300
PLC
SIEMENS PLC
Siemens is the Europe's largest engineering conglomerate and the

largest electronics company in the world. Siemens international headquarters are
located in Berlin and Munich, Germany. The company is a conglomerate of three
main business sectors namely Industry, Energy and Healthcare. Siemens six
operational business areas were Automation & Control (Automation & Drives,
Industrial Solutions & Services, Siemens Building Technologies), Power (Power
Generation, Power Transmission & Distribution), Transportation (Transportation
Systems, Siemens VDO), Medical (Siemens Medical Solutions), Information &
Communication (Siemens Communications, Siemens IT Solutions and Services), and
Lighting (OSRAM GmbH, OSRAM Sylvania).
Siemens PLC’s are generally classified into two types.
Siemens PLC
S5 Series S7 Series
S5 series is DOS based version and S7 series is Windows based
version. The different S5 series versions PLC’s are 100u, 110u, 115u etc. S5 series is
the old version PLC. Almost all of the S5 series PLC’s are replaced in all industries.
Handheld programming can also do in this type of PLC’s. S7 Series PLC’s are again
classified into three types according to the number of inputs and outputs.
Plc Types No: of Digital I/O No: of Analog I/O
Low End S7 200 256 32
Medium End S7 300 1024 256
S7 400 16384 ≈ 1500
High End C7
> 20000 256
M7
Architecture of S7 300 PLC
Rails/ Slots
Rack 0
1 2 3 4 11
Power CPU IM DI /
Supply DO
Rack 1
1 2 3 4 11
IM
Rack 2
1 2 3 4 11
IM
The above figure shows the architecture of Siemens S7 300 PLC. Siemens S 7
300 PLC is Modular type PLC. The architecture is based on Rack and Rail
configuration. The above figure each full block is known as Rack. Eleven slotted
Rails are there in each Rack. In Rack 0 the first Rail (Rail 1) is allotted for Power
Supply, Rail 2 is allotted for CPU, Rail 3 for Interfacing Module (IM) and in other
Rails we can add Digital Input Module, Digital Output Module, Analog Input
Module, Analog Output Module etc according to our needs.
In Siemens S7 300 PLC one CPU can supports four Racks. So for
communicating with other Racks, each Rack contains one Interfacing Module (IM).
So in Rack 1, Rack 2 and Rack 3 the first Rail is allotted for Interfacing Module (IM).
The connection from CPU of Rack 0 is given to the Interfacing Modules of others.
The CPU and Power Supply are common for all four Racks.
Here we use S7 300 Medium end PLC. The different CPU versions of S7 300
PLC’s are CPU 312 ---------318. Here we use S7 300 CPU 312 C. In CPU 312 C, ‘C’
indicates Compact. SIMATIC S7-300 is optimized for high performance machines
and factory automation. The SIMATIC S7-300 saves space, and it is compact and
modular.
Features of S7 300
 Built-in functions (eg: high-speed counting, closed-loop control, motion
control, etc.).
 Extensive selection of CPUs and modules for almost every application.
 Compact design reduces control cabinet size.
 Integrated system diagnostics assure high degrees of controller availability.
 Innovative Micro Memory Card provides maintenance- free (no battery
required) program backup plus the ability to store production and project
information.
 Fail-safe version provides machine safety and standard automation in a single
controller.
The programming software used for S7 300 PLC is

SIMATIC MANAGER 5.1 – 5.5
Personal PPI Siemens

Computer PLC
RS-232 RS-485
Siemens PLC supports only RS-485 protocol. So a PPI (Point to Point

Interface) converter is used for connecting with personal computer. The baud rate
used is 9600 bits/sec.
CPU Memory Concept
CPU Memory
Load Memory System Memory Work Memory
1. Load Memory
The Load memory is located on the SIMATIC Micro Memory Card (MMC).
The size of the load memory corresponds exactly to the size of the SIMATIC Micro
Memory Card. It is used to store code blocks, data blocks and system data
(configuration, connections, module parameters, etc). Blocks that are identified as non
runtime related are stored exclusively in load memory. You can also store all the
configuration data for your project on the SIMATIC Micro Memory Card.
2. System memory
The System memory is integrated in the CPU and cannot be expanded. It
contains the address areas for address area memory bits, timers and counters, the
process image of the I/Os, local data.
3. Work Memory
The Work Memory is integrated in the CPU and cannot be extended. It is used
to run the code and process user program data. Programs only run in RAM and system
memory.
Retentivity of Load Memory, System Memory and

Work Memory
CPU is equipped with a service-free retentive memory, i.e. its operation does
not require a buffer battery. Data is kept in retentive memory across Power OFF and
Restart.
1. Retentive data in load memory:

Program in load memory is always retentive. It is stored on the SIMATIC
Micro Memory Card, where it is protected against Power Failure or CPU memory
Restart.
2. Retentive data in system memory:
The diagnostic buffer, MPI address and operating hour counter data and
generally written to Retentive Memory area on the CPU. Retentivity of the MPI
address and baud rate ensures that the CPU can continue to communicate, even after a
power loss, memory reset or loss of communication parameters (e.g. due to removal
of the SIMATIC Micro Memory Card or deletion of communication parameters).
3. Retentive data in Work Memory:
The contents of retentive DBs are always retentive at Restart and Power
ON/OFF. CPUs V2.1.0 or higher also support volatile DBs (the volatile DBs are
initialized at restart of Power OFF-ON with the in initial values from load memory).
Figure: Compact PLC S7-300 (CPU xxx C)
(1) Status and Error Displays

(2) Micro Memory Card (MMC)
(3) Connection of Integrated I/O
(4) Power Supply Connection
(5) 2 connected X2(PtP nebo DP)
(6) 1 connected X1( MPI)
(7) Mode Selector Switch
Status and Error Indicators: CPU 31xC
LED designation Colour Meaning

SF Red Hardware or Software error
BF ( for CPUs with Red Bus error
interface only s DP)
DC5V Green 5-V power for CPU and S7-300
which indicates bus is Ok
FRCE Yellow Force is active
RUN Green CPU in RUN
STOP Yellow CPU in STOP and HOLD or
STARTUP
Features of S7 300 312-C
 Work Memory: 32 Kb
 Number of timers/counters: 128/128
 Digital Channels: 256
 Analog Channels: 64
 Networking: MPI (Multi Point Interface)
Addressing syntax
Siemens PLC addressing is basically Byte oriented. One byte means
eight bits. In Siemens PLC for Digital I/O they allocate 4 Bytes for each slot and for
Analog they allocate 16 Bytes for each slot.
Addressing syntax for Digital Input And Output
Syntax is File Type Byte . Bit

I0.0 Q0.0
I0.1 Q0.1
I0.2 Q0.2
I0.7 Q0.7
I1.0 Q1.0
I1.1 Q1.1
I3.7 Q3.7
Addressing syntax for Analog Input And Output
Syntax is A File Type W Word

AIW0 or PIW0 AQW0 or PQW0
Memory Addressing
M0.0 MB0 MW0 MD0

M0.1 MB1 MW2 MD4
M0.2 MB2 MW4 MD8
M255.7 MB255 MW254 MD252
In all these memory addressing, in the word wise classification next

memory location of MW0 is MW2 and also in double word wise classification the
next memory location of MD0 is MD4 . The reason is that Siemens PLC addressing is
byte oriented. The memory locations MW0 and MD0 consists of
MW0 = MB0 + MB1

MW1 = MB1 + MB2
MW2 = MB2 + MB3
So in MW0 and MW1, the MB1 location is common. So if we use
MW0 and MW1 then memory clash will occurs. So to avoid this MW2 is used after
MW0. Like that in Double word also next three locations are not used.
MODICON PLC
MODICON PLC
Schneider Electric is a French global company. It was founded in 1836 by two

brothers, Eugene I and Adolphe Schneider. Different brand names are there for
Schneider electric such as Merlin Gerin, Telemecanique and Square D. Today, the
company has grown into a world leader in Power and Control solutions. Schneider
electric also has a number of R&D centers like
 Global Technology Center India in Bangalore

 Global Technology Center Mexico at Monterrey City.
 CRDC in Shanghai, China
which mainly focus on Electromechanical, Electronic and software developments to

meet the global product requirements.
Modicon PLC’s are mainly classified into three types they are
Plc Types No: of No: of Analog Software
Digital I/O I/O
Zelio 24 0 Zelio Soft
Low End
Nano 48 2 PL7 Junior
Twido 144 2 Twido Soft
Medium End
Micro 248 8 PL7 Pro ver:3.1-3.4
Premium 5000 16 PL7 Pro ver:4.1-4.4
High End
Quantum 20000 256 Modsoft
Analog 1 3 5
Display
Port
16 4
CPU TER Digital Analog
UP Input Input
+Ve AUX 2 4 6
H P
-Ve C
S
Down M 12 2
C 230 C Digital Analog
V I Output Output
A
HSC – High speed counter. It is used for counting high speed pulses from
Tachometers.
PCMCIA – Personal Computer Memory Card International Association. It is used as
extra memory cards for Modicon PLC’s.
Driver Software
Driver Software is used for interfacing personal computer with PLC.

The driver software used for Modicon PLC is X Way Driver Manager.
The programming software’s used in Modicon PLC’s are.

For Micro PLC’s PL7 Pro Ver 3.4
For Premium PLC’s PL7 Pro Ver 4.3
Processor Types
For Micro PLC’s TSX 3722 V 3.3 and TSX 3721 V1.0
For Premium PLC’s TSX 57203 V 5.1
Addressing syntax
Addressing syntax for Digital Signals
Syntax is % Type Slot Number . Element
%I1.0 %Q2.0
%I1.1 %Q2.1
%I1.2 %Q2.2
%I1.15 %Q2.11
Addressing syntax for Analog Signals
Syntax is % Type W Slot Number . Word

%IW3.0 %QW4.0
%IW3.1 %QW4.1
%IW3.2
%IW3.3
Memory
Memory is used for storing integer and floating point values. It is also
used in arithmetic and logical operations.
Memory Addressing
%M0 %MB0 %MW0 %MD0

%M1 %MB1 %MW1 %MD2
%M2 %MB2 %MW2 %MD4
%M3 %MB3 %MW3 %MD6
%MW0 = %MB0 + %MB1

%MW1 = %MB2 + %MB3
%MW2 = %MB4 + %MB5
In word wise classification the values are stored in two bytes. But the
memory locations are different. So in Modicon PLC we can take all the Word
Memory locations. That means we can take %MW0, %MW1, %MW2 etc. The
storing byte location can be calculated using the formula
%MWi = %MBj + %MB(j+1) ,

Where j = 2i
For example if we want to calculate the storing locations for the word
%MW10. Then first calculate the value of j.
ie j = 2i
j = 2 * 10
j = 20
Then %MWi = %MBj + %MB(j+1)
%MW10 = %MB(20) + %MB(20 + 1)
%MW10 = %MB20 + %MB21
Thus we can calculate the memory locations in word wise
classification. But in double word wise classification the values are stored in two
Words. So if we use one double word location then the next location is not used. In
%MD0 and %MD1, the %MW1 location is common. So if we use %MD0 and %MD1
then memory clash will occurs. So to avoid this %MD2 is used after %MD0.
%MD0 = %MW0 + %MW1
%MD1 = %MW1 + %MW2
%MD2 = %MW2 + %MW3
Timers
Timers are mainly classified into three categories. They are
1. Timer (TON / TOF /TP)

TON AND TOF is like that of normal ON Delay and OFF Delay
timers. Another timer is there TP (Pulse Timer). In TP we get constant output for a
single input pulse. We get constant output for a predetermined preset value. For
example consider the preset value as five and time base as one second then we get
constant output for five seconds for an input pulse. The input and output waveforms
are shown below. The addressing of these three timers is
%TM0, %TM1, %TM2 ---------- %TM63
Input
Output
5 Sec 5 Sec
2. Series 7 Timer
Series 7 Timers are Retentive timer’s, means the accumulator values
are retained in these timers even if the input is OFF. In Modicon PLC’s initially the
number of timers is zero. So if we want Series 7 Timer we have to decrease the
number of normal timers and increase the Series 7 Timer as required numbers. After
that we have to save it and thus we can use Series 7 Timer. Addressing of Series 7
Timer is
%T0, %T1 ……….
3. Monostable Timer
Monostable Timer is almost same as that of Pulse Timer. In

Monostable Timers when an input pulse is given we get constant output as that of
Pulse Timer. But if we give a second input pulse at the time of working then the timer
starts from that time and the ON time duration is thus increased. For example consider
the preset value as five and Time Base as one second, then the input and output
waveforms are shown below. Addressing of Monostable Timers is
%MN0, %MN1 ----------- %MN7
Input
2 Sec
Output
5 Sec 2 Sec 5 Sec

7 Sec
4. Counters
In Modicon PLC Up and Down Counter block is used. The addressing
of Counters is
%C0, %C1, %C2 ----------- %C31
5. Registers
Registers are used in FIFO and LIFO operations. The addressing of
Registers is
%R0 ----------- %R3
6. Drums
Drums are used as sequencer output function. Addressing is
%DR0, %DR1 ----------- %DR7
Operator Block
Operator Block is used for performing Move, Shift and Mathematical
operations.
Move Function
Example:
%MW0 := 100
%MW0 := %MW1
In first example the value 100 is moved to the location %MW0. The
destination is %MW0. In second example the value stored in memory location
%MW1 is moved to %MW0.
Math function
Example:
%MW0 := %MW1 + %MW2
%MW0 := %MW1 - %MW2
%MW0 := %MW1 * %MW2
%MW0 := %MW1 / %MW2
%MW0 := SQRT(%MW1)
Shift function
%MW0 := SHL(%MW1,4)
%MW0 := SHR(%MW1,4)
%MW0 := ROL(%MW1,4)
%MW0 := ROR(%MW1,4)
Comparison Block
Two types of comparison blocks are there in Modicon PLC. They are
1. Horizontal Comparison Block

2. Vertical Comparison Block
1. Horizontal Comparison Block
%TM0.V > 10
We can compare timer values using Horizontal comparison block. For

example consider one Timer %TM0. For comparing accumulator value of Timer give
%TM0.V then comparison symbol and value.
For calling Accumulator value of Timer %TM0.V

For changing Preset value of Timer %TM0.P
2. Vertical Comparison Block
Compare
EN C
%TM0.V
In Vertical comparison block we get four outputs corresponding to one

compare value.
AC DRIVES
AC Drives
AC motor
An AC motor is an electric motor that is driven by an alternating current. It

consists of two basic parts, an outside stationary stator having coils supplied with AC
current to produce a rotating magnetic field, and an inside rotor attached to the output
shaft that is given a torque by the rotating field.
STATOR
AC 1Ø SHAFT
ROTOR
There are two types of AC motors, depending on the type of rotor used. The
first is the synchronous motor, which rotates exactly at the supply frequency or a
submultiple of the supply frequency. The magnetic field on the rotor is either
generated by current delivered through slip rings or by a permanent magnet.
The second type is the induction motor, which turns slightly slower than the
supply frequency. The magnetic field on the rotor of this motor is created by an
induced current.
Specifications of Motor
1. Voltage rating (V)

2. Current rating (A)
3. Phase (1Ø or 3Ø)
4. AC or DC
5. RPM
6. Power Rating (HP)
7. Casing
Block Diagram of Drives

AC to DC DC to AC
Converter Converter AC Motor
(Rectifier) (Inverter)
Pulse
Generator PWM
Ac supply is given to the input of Drives. Then the AC supply is

converted into DC supply. In low power applications diodes are used. But in high
power applications Thyristors (SCR’s) are used. Then the DC supply is again
converted into AC. In this also in high power applications IGBT’s are used. Then the
output signal is then given to AC Motor.
Drives Connection Diagram in Industries
MCB Choke Coil Drives Motor
In industries the main power supply is given through MCB (Miniature Circuit
Breaker). Then one Choke coil is used to avoid voltage fluctuations. Then AC Drives
is connected and last section is the Load or Motor.
Classification of Drives
Drives
AC Drives DC Drives
VVD VFD
VVD Variable Voltage Drive

VFD Variable Frequency Drive
Drives are mainly classified into two types, AC Drives and DC Drives. AC
Drives are again classified into two types VVD and VFD. VFD’s are commonly used
in industries because we can easily change the frequency. But in VVD some voltage
drop occurs and we don’t get the desired output.
Here we use Altivar 28 AC Drive. The company name of Altivar 28 is

Schneider Electric. Altivar 28 has four Digital inputs namely LI1, LI2, LI3 and LI4. It
also has three analog inputs namely AI1, AI2 and AIC. AI1 and AI2 are voltage
inputs and AIC is current input. We can assign either AI2 or AIC at one time but not
both. One Analog output is also there named as AO. One Common (GND) terminal is
also there for both analog and digital inputs.
Digital Inputs LI1, LI2, LI3 and LI4

Analog Inputs AI1, AI2 and AIC
Analog Output AO
Common (Ground) Both for Analog and Digital
General formula for calculating Motor speed is
Speed (Ns) = 120 f

P
Where f = Frequency
P = Number of Poles
In our Motor Number of Poles (P) = 2. Then the formula becomes

Speed (Ns) = 120 f
P
= 120 f
2
= 60 f
Modes of Operation
Altivar 28 AC Drive can be mainly operated in two modes
Modes of Operation
2C (2 Wire Configuration) 3C (3WireConfiguration)
2C 4 Speed 2C 8 Speed
In 2C configuration the main control inputs are Forward and Reverse and
hence it is known as 2C configuration. In 3C configuration the main control inputs are
Forward, Reverse and Stop.
2C Configuration
2C 4 Speed Configuration
In 2C 4 Speed Configuration the four digital inputs are used for

controlling different speeds.
LI1 Forward Direction

LI2 Reverse Direction
LI3 and LI4 inputs are used for adjusting different speeds.
LI4 LI3 Speed
0 0 LSP
0 1 SP2
1 0 SP3
1 1 HSP
2C 4 Speed Configuration Settings
Up Down Enter Esc
For setting 2C 4 Speed Configuration first press Enter.

IO Mode setting
Press Enter
SET DRC IO SUP
Select IO by using Up and Down Switch.
IO Tcc = 2C
LI2 = Rrs
LI3 = PS2 (2 Preset Speeds)
LI4 = PS4 (4 Preset Speeds)
Set Mode setting
After setting IO mode then go to SET Mode and set different frequency for
LSP, HSP, SP2 and SP3.
2C 8 Speed Configuration
In 2C 8 Speed configuration LI2, LI3 and LI4 inputs are used for
controlling different speeds. Remaining is one input; LI1 is used for forward
direction. So only forward direction option is there in 2C 8 Speed Configuration. For
setting 2C 8 Speed configuration change LI2 as PS8.
LI2 LI4 LI3 Speed
0 0 0 LSP
0 0 1 SP2
0 1 0 SP3
0 1 1 SP4
1 0 0 SP5
1 0 1 SP6
1 1 0 SP7
1 1 1 HSP
IO Mode setting
Press Enter
IO Tcc = 2C
LI2 = PS8
LI3 = PS2
LI4 = PS4
Set Mode setting

LSP, HSP, SP2, SP3, SP7.
Analog Control of Motor Using Drives
For controlling the motor using analog voltage, connect the voltage inputs
(AI1 or AI2) to 0-10 V. Also for controlling with Analog current connect the Current
input (AIC) to 4-20 mA. By varying the current or voltage we can vary the motor
speed. Using Analog Output AO we get Analog Output Voltage corresponding to
motor speed. This Analog Output can be used for controlling other devices.
3C Configuration
In 3C configuration the main control inputs are Forward, Reverse and Stop. In
3C Configuration one normal speed and jog speed occurs. The normal speed can be
set only in LSP.
LI1 Stop
LI2 Forward Direction
LI3 Reverse Direction
LI4 Jog Speed
IO Mode setting
Press Enter
IO Tcc = 3C
LI2 = For
LI3 = Rrs
LI4 = Jog
Set Mode setting

LSP and JOG.
DC Injection Breaking
An important feature in this AC Drive is DC Injection Breaking. Normally if

we press the stop button of a high speed motor then it stops only slowly. By applying
DC Injection Breaking we can suddenly stops the motor. The general principle is that
if we give DC Injection Breaking then the drives cuts the AC input applied to the
motor and continuous DC is injected to it. Thus the motor cannot able to rotate and it
suddenly stops. Thus we can suddenly stop a high speed running motor. For setting
DC Injection Breaking in 3C Configuration change the value of LI3 as DCI. So if we
use DC Injection Breaking feature in 3C Configuration then the reverse option is not
there because we change the reverse input to DCI function.
For DC Injection Breaking LI3 = DCI

Advantages of Drives
1. Energy Saving.
2. We can run the motor at Constant Speed.
3. We can run the motor at Variable Speed.
4. We can run the motor in both directions (Forward and Reverse).
5. We can run the motor at Jog Speed.
6. We can suddenly stop the motor by using DC Injection Breaking.

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PLC

2. ALLEN BRADLEY PLC 19

3. WONDERWARE INTOUCH SCADA 29

4. SIEMENS S7 200 PLC 43

5. SIEMENS S7 300 PLC 53

PLC (Programmable Logic Controller)

Inputs Input Output Outputs

A PLC is composed of two basic sections namely CPU (Central Processing

5. Greater Life and Reliability

7. Advanced Computation Supported

9. Closed Loop Control Supported

Programming Languages in PLC

Different programming languages are there in PLC. Some of the main

1. Ladder Logic (LAD)

Main Symbols Used in Ladder Logic

Structure of Ladder Logic

Figure shows an example for a ladder diagram. Positive and negative

Check Input Status

Update Output Status

1. Check Input Status

Sinking and Sourcing

Normally two types of sensors are used in industries. They are

The difference between two types is whether the load is switched to

NPN Sinking Sensor

PNP Sourcing Sensor

Symbol Truth Table

Symbol Truth Table

Symbol Truth Table

Symbol Truth Table

START STOP OUTPUT

General Classification of PLC

2. Integrated Type PLC

Plc Types No: of Digital No: of Analog Memory

Medium end SLC-500 4096 8 8K

High end Flexlogix

Here we use Micrologix and SLC-500 PLC’s. Micrologix PLC is an

1000 1200 1500

Series A Series A Series A

Series B Series B Series B

Series C Series C Series C

SLC-500 is a modular type PLC. It is mainly classified into five

CPU Types 5/03

Program Files Data Files

File No: File Name File Type

SYS-0 Reserved Files 0 Output O

LAD-2 Main Program 2 Status S

Sub Routines 5 Counter C

Memory is mainly classified into two types.

Program file consists of SYS-0, SYS-1, Ladder-2, Ladder-3 etc up to Ladder-

Addressing syntax for SLC-500

Syntax is File Type : Slot Number . Word / Bit

Digital Input Digital Output

Addressing syntax for Micrologix

Digital Input Digital Output

10V 20mA 0111 1111 1111 1111 32767

Analog Addressing Syntax is File Type : Slot Number . Word

Analog Input Analog Output