FAKULTAS TEKNOLOGI INDUSTRI

ITS SURABAYA
2014
23/05/2014

Instrument 2

MATERI :
Konsep dasar Programmable Logic Control
Sequential Process
Safety Instrument System (SIS)
SCADA

23/05/2014

Instrument 2

Konsep dasar PLC

Invented in 1968
as a substitute for hardwired relay panels.

"A digitally operating electronic apparatus which uses a programmable

memory for the internal storage of instructions by implementing specific
functions such as logic sequencing, timing, counting, and arithmetic to
control, through digital or analog input/output modules, various types of
machines or processes. The digital computer which is used to perform the
functions of a programmable controller is considered to be within this
scope. Excluded are drum and other similar mechanical sequencing
controllers."
23/05/2014

National Electrical
Manufacturing Association (NEMA)
Instrument 2

Komponen PLC
CPU

Input

Input
Module

Flag
System

Output

Output
Module

User Ladder
Diagram

Working
memory
registers

23/05/2014

Instrument 2

A large size PLC

The main module measures
19 x 20 x 14.5.
have up to 10,000 I/O points
supports all functions
expansion slots to
accommodate PC and other
communication devices.

Allan-Bradley PLC-3

A small size PLC

Measures 4.72x 3.15 x 1.57.
32 I/O points
Standard RS 232 serial
communication port
Allan-Bradley
23/05/2014 Micrologic-1000

Instrument 2

SWITCHES
No n -lo c kin g

Lo c kin g

No rm a lly O p e n

No rm a lly C lo s e d

DPST

P1

SPDT

P2

23/05/2014

Mu ltip le Th ro w

Mu ltip le P o le

Bre a k- b e fo re -m a ke

Ma ke -b e fo re -b re a k

Instrument 2

TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual
circuits).
SPDT

A serial switch box (A-B box) has

two 25 pin serial ports to switch from.

B
Output

DPST

Input

Knob
How is this switch classified?
23/05/2014

Instrument 2

TYPES OF SWITCHES
Selector switches
Pushbutton switches
Photoelectric
switches
Limit Switches
Proximity switches
Level switches
Thumbwheel
switches
Slide switches

23/05/2014

Instrument 2

RATING:

24 Volts AC/DC
48 Volts AC/DC
120 Volts AC/DC
230 Volts AC/DC
TTL level
(Transistor-to-transistor
5V)
Isolated Input

RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact

coil

input

Relay coil
R1
Output contact
23/05/2014

R1
Instrument 2

COUNTER
Digital counters output in the form of a relay contact when a preassigned count value is
reached.
input
Re giste r

Accumulator
re se t
conta ct
output

Input
Re se t
Output
Count

23/05/2014

Instrument 2

12

10

TIMER
A timer consists of an internal clock, a count value register, and an accumulator. It is
used for or some timing purpose.
Clock

Accumulator
re se t
Re giste r

conta
Contact
ct
output

Clock
Reset
Output
Count

Time 5 seconds.
23/05/2014

Instrument 2

11

AN EXAMPLE OF RELAY LOGIC

For a process control, it is desired to have the process start (by turning on a motor)
five seconds after a part touched a limit switch. The process is terminated
automatically when the finished part touches a second limit switch. An emergency
switch will stop the process any time when it is pushed.
L1
LS1

PB1

LS2

R1

R1

R1

TIMER

R2

PR=5

PB1
LS1

LS2

TIMER
5

23/05/2014

Instrument 2
R1

Motor
R2
12

PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring by software programming.

Progr am
Loade r

PC
Switche s

Printe r
Proce ssor

I/O
M odule s

M emory

Powe r
Supply

M achine s

Casse tte
Loade r
EPROM
Loade r

Exte r nal De v ice s

Pe riphe rals

A typical PLC

23/05/2014

Instrument 2

13

PLC COMPONENTS
1. Processor

Microprocessor based, may allow arithmetic

operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.

2. Memory

Measured in words.
ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electric Erasable Programmable ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.

23/05/2014

Instrument 2

14

PLC COMPONENTS
3. I/O

Modular plug-in periphery

AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g., high speed timers,
Stepping motor controllers, etc. PID, Motion

4. Power supply AC power

5. Peripheral

23/05/2014

hand-held programmer (HHP)

CRT programmer
operator console
printer
simulator
EPROM loader
graphics processor
network communication interface
Instrument 2
modular PC

15

Discrete I/O

AC Voltage I/O
DC Voltage I/O
numerical input and output
special-purpose modules, for example,
high-speed timers, and stepping motor
controllers

23/05/2014

Instrument 2

16

Analog I/O
Analog inputs:
Flow sensors
Humidity sensors
Potentiometers
Pressure sensors
Temperature sensors

Analog outputs:
Analog meters
Analog valves and actuators
DC and AC motor drives

23/05/2014

Instrument 2

17

Some special I/O

Thermocouple input

Low level analog signal, filtered, amplified, and digitized

before sending to the processor through I/O bus.

Fast input

50 to 100 microsecond pulse signal detection.

ASCII I/O

Communicates with ASCII devices.

Stepper motor output

Provide directly control of a stepper motor.

Servo interface

Control DC servo motor for point-to-point control and

axis positioning.

PID control

The Proportional Integral Derivative is used for closed

loop process control.

Network module
23/05/2014

Instrument 2

18

A Hand Held Programmer

An Allen-Bradley hand-held programmer for MicroLogix 1000

23/05/2014

Instrument 2

19

Ladder diagram
A ladder diagram (also called contact symbology) is a means of graphically
representing the logic required in a relay logic system.

Rail
start
PB1

emergency stop
PB2
R1

Rung

R1

R1
A

23/05/2014

Instrument 2

20

PLC WIRING DIAGRAM

A

Input
01

02

Output

PLC
01

02

20

11

12
20

03
11

20

External
switches

Stored program

23/05/2014

Instrument 2

21

Input Connections

AC

23/05/2014

DC

TTL

Instrument 2

22

Output Connections

AC

23/05/2014

DC

TTL

Instrument 2

23

SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to
the bottom. Usually, all the outputs are updated based on the status of the internal
registers. Then the input states are checked and the corresponding input registers are
updated. Only after the I/Os have been resolved, is the program then executed. This
process is run in a endless cycle. The time it takes to finish one cycle is called the
scan time. In some controllers the idle state is eliminated. In this case, the scan time
varies depends on the program length.
Output
Input
begin
Idle
Scan cycle
Resolve
logic
23/05/2014

Instrument 2

24

PLC Programming

Ladder Diagram - most common

Structure Text Programming (ST)
Functional Block Programming (FB)
Instruction List (IL)
Sequential Function Chart (SFC)

23/05/2014

Instrument 2

25

PLC Ladder Diagram INSTRUCTIONS

1) Relay,

2) Timer and counter,

3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.
23/05/2014

Instrument 2

26

LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize, etc.
Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.

(In the notes we use the symbol "~" to represent negation. AND
and OR are logic operators. )

23/05/2014

Instrument 2

27

AND and OR LOGIC

PB1

PB2

R1
R1 = PB1.AND.PB2

AND

PB3

PB4

R2

R2 = PB2.AND.~PB4

PB1

R1
R1 = PB1 .OR. PB2

OR

23/05/2014

PB2

Instrument 2

28

COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

R1

PB1

PB2

23/05/2014

pb3

Instrument 2

29

RELAY
A Relay consists of two parts, the coil and the contact(s).
Contacts:

a. Normally open

-| |-

b. Normally closed

-|/|-

c. Positive transition sensing -|P|d. Negative transition sensing -|N|()

Coil:
a. Coil

-( )-

b. negative coil

-(/)-

c. Set Coil

-(S)-

d. Reset Coil

-(R)-

23/05/2014

Instrument 2

30

Relay (continue)
Coil:
e. Retentive memory Coil

-(M)-

f. Set retentive memory Coil

-(SM)-

g. Reset retentive memory Coil

-(RM)-

h. Positive Transition-sensing Coil

-(P)-

h. Negative Transition-sensing Coil

-(N)-

(set coil latches the state, reset coil deenergize the set coil. retentive
coil retain the state after power failure.)

23/05/2014

Instrument 2

31

TIMERS AND COUNTERS

Input
Timers:

True

a. Retentive on delay

-(RTO)-

b. Retentive off delay

-(RTF)-

c. Reset

-(RST)-

RTO counting stop

RTF

stop

True
counting
resume

counting stop

RTO reach PR value, output ON

RTF reach PR value, output OFF

Counter:
a. Counter up

-(CTU)-

b. Counter down

-(CTD)-

c. Counter reset

-(CTR)-

23/05/2014

False

Instrument 2

PR value in 0.1 second

32

SEQUENCER
Sequencers are used with machines or processes involving repeating
operating cycles which can be segmented into steps.

Output
Step

Dwell time

ON

OFF OFF

5 sec.

ON

ON OFF

10 sec.

OFF OFF ON

3 sec.

OFF

9 sec.

23/05/2014

ON OFF

Instrument 2

33

A-B PLC
I/O points are numbered, they correspond to the I/O slot on the PLC.
For A-B controller used in our lab
I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932

Status 951-982

23/05/2014

Instrument 2

34

PROGRAMMING EXAMPLE 1
Bar code re ader
microswitch

Stopper
Conveyor

Part

Robot

Machine

id
description
MSI
microswitch
R1
output to bar code reader
C1
input from bar code reader
R2
output robot
R3
output robot
C2 input from robot
R4
output to stopper
C3 input from machine
C4
input from machine
23/05/2014

Instrument 2

state
1
1
1
1
1
1
1
1
1

explanation
part arrive
scan the part
right part
loading cycle
unloading cycle
robot busy
stopper up
machine busy
task complete

35

SOLUTION
Input
MS1

Outpu t

01

11

C1
C2

02

12

03

13

C3

04

14

C4

05

01

Pro grammable
Controlle r
PLC

23/05/2014

Rung 1. If part arrives and no part

is stopped, trigger the bar code
reader.
Rung 2. If it is a right part, activate
the stopper.
Rung 3. If the stopper is up, the
machine is not busy and the
robot is not busy, load the part
onto the machine.
Rung 4. If the task is completed and
the robot is not busy, unload the
machine.

14

02

14

04

05

03

03

R4

15

11

14

R1
R2
R3

12

13

Instrument 2

36

23/05/2014

Instrument 2

37