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PROGRAMMABLE
LOGIC
CONTROLLER
DEGEM® SYSTEMS
Copyright © 1989 by I.T.E. Innovative Technologies in Education. All
rights reserved. This book, or parts thereof, may not be reproduced in any
form without prior written permission from I.T.E. This publication is based
on the exclusive methodology of Degem Systems Ltd.
The exercises set out in the following pages should be solved by using
LADDER DIAGRAM language.
PLC's (Programmable Logic Controller) currently in use have contact and relay
functions which replace the hardwired logic with programmable logic.
Today, most PLC's serve more complex functions than contacts alone, and usually
include timers, counters, etc.
The exercises in this course do not cover applications that require elements
that are more complex than the above functions.
The relay logic for the PLC is based on the three basic logic functions - AND, OR,
NOT - explained in the theory section of this book.
The Ladder Diagram uses contacts and coils (at least in the ON/OFF control), so
that ON/OFF circuits based on relays and contacts are easy to make. Thus, the
transition from a conventional electrical control drawing to a ladder diagram is
almost 1:1.
PN-2500 ii
LADDER DIAGRAM
The structure of the diagram is that of a ladder, consisting of two vertical lines
connected by a sequence of horizontal contacts and coils. One vertical line represents
the Hot Line, the other the “0”, common or earth.
The flow of current in the horizontal "rungs" is from left to right depending on the
state of the contacts (open or closed - conducting or not conducting current). The
output coils depend on the passage of this current through the contacts.
In order to express the logic of the exercises by means of the ladder diagram, the
various symbols and connections need to be explained:
Symbol Explanation
Normally Open Contact- represents all components
serving as an input to the control logic followed by
reference number, as explained in the Theory Section.
If the status of the N.O. Contact is logic “1”, the contact
will conduct current; if the status is in logic position “0”,
the current will not pass through the contact. To obtain “1”
the contact must be activated.
Normally Closed Contact- represents all components
serving as an input to control logic followed by reference
number.
If the status of the N.C. Contact is logic position “0”, the
contact will remain closed, that is, current will pass through
the contact. When the status changes to position “1”, the
contact opens and current will not pass through. The
contact must be de-activated to hold it in logic position “0”
to allow current to pass through it.
Output coil - activated by input logic conditions. The
output could represent an external output device connected
to a controller or an internal logic output of the controller.
Current form the left vertical line of the ladder travelling
along a rung via the various contacts energizes the output
coil at the right end of the rung.
This is a diagram of a function box used for timers/counters,
which is actuated when the input is switched on.
2. I/O ALLOCATION
Figure 1.1
PN-2500 1-2
4. PROCEDURE
4.1 PLC Programming
Before you start you should see a screen similar to the picture below.
To insert a normally open contact press on the symbol -| |- and then press in
the screen on the place you want to insert the contact (should be where the
gray box is) you will get a dialog box like the picture below.
PN-2500 1-3
At the allocation number field write I0. At the Tag Name Comment field
write X1 press "OK". You should see this screen.
Follow the same routine for inserting the out coil by using the -0-| symbol
but write Q0 at the allocation number field and write Y9 in the Tag Name
Comment field. Press "Enter". You should see the following screen.
Insert another contact to the above circuit using the mouse and the method
described before. At the allocation number field, write I2 and write X2 at the
Tag Name Comment field. Press "Enter". You should see this screen.
5. QUESTIONS
5.1 If X2 is changed to a N/C contact, what happens to the circuit?
5.2 Give a practical example of where to use a series actuation.
5.3 Build a Truth Table for Network “C”.
PN-2500 2-1
Figure 2.1
PN-2500 2-2
4. PROCEDURE
4.1 PLC Programming
OR Circuit
Figure 2.2
2. I/O ALLOCATION
Component Name TI- DEGEM IZUMI
Solenoid A+ Y9 Q0
Solenoid A- Y10 Q1
P.B.1 S2 X1 I0
P.B.2 S3 X2 I1
Switch S4 X3 I2
Limit Switch S5 X4 I3
Figure 3.1
4. PLC Programming
Figure 3.1
PN-2500 3-3
6. QUESTIONS
6.1 What happens if Y9 is activated and you try to activate Y10 at the same
time.
6.2 How can activation of A+ and A- be prevented by simple commands in
the PLC?
6.3 What happens to SV3 if X2 is an N/C contact?
PN-2500 4-1
Figure 4.1
4. PLC PROGRAMMING
Figure 4.2
PN-2500 4-2
4. PLC Programming
Figure 5.3
6. QUESTIONS
6.1 Would you recommend using a circuit of this kind in many
cases? Give your reasons.
6.2 Give practical examples of cases where you think this type
of circuit could be used.
Figure 6.1
PN-2500 6-2
Figure 6.2
PN-2500 6-3
This also opens X4 contacts which were closed because of the pressure
appled by the piston on MS4.
PN-2500 6-4
6. QUESTIONS
6.1 What happens if C1 contacts are accidentally programmed the wrong way
round - that is, changing the contact of C1 from N/O to NC N/C or visa versa?
6.2 The MS4 switch is out of order and is jammed in the pressed position.
What happens to the circuit?
Figure 7.1
PN-2500 7-2
Figure 7.2
Sequence of activation: A+ B+ A- B-
The Pneumatic Control Circuit
Figure 7.3
.
5. QUESTIONS
5.1 How is the operation of a lift affected if we reverse the order of MS5 and
MS6 in the program?
5.2 If MS1 remains depressed all the time, what will the circuit
cycle be?
PN-2500 8-1
IMPORTANT!
1. Because the TI-DEGEM timer does not have its own contacts, an
internal logic coil C1 is needed, to serve as the timer output coil.
2. The T1 timer is accurate to 0.1 seconds.
3. The T1 timer has a Reset line which must be connected through at least
one contact. The IZUMI has only the input contact.
3. CONNECTION OF COMPONENTS
Connect the components to their appropriate connection points.
4. PROGRAMMING THE PLC
Figure 8.1
PN-2500 8-2
5. OPERATIONS
1. On the screen:
Return to main display screen “ Online->Monitor”. On X1 you will
see that the Timer starts counting down from 100 to 0.
As the Timer reaches 0, C1, i.e. the Timer’s output coil, lights up.
C1 activates Y9 and shuts off Y10.
To activate the circuit, S4 mus t be de-activated. The Timer begins to
count down from 100 and on reaching zero C1 lights up, de-activating
LED2 and activating LED1.
6. QUESTIONS
6.1 What happens if X1 is a push button?
6.2 Change the program of operation for a situation where X1 is a push button.
6.3 Explain the meaning of “On Delay” in the above circuit.
PN-2500 9-1
Figure 10.1
PN-2500 10-2
6. QUESTIONS
6.1 Change the spring return SV2 Valve for an electrically operated valve by
adding CY1-Y10. What has to be added or modified in the circuit to
obtain the same results?
6.2 Give an example of an application in which the circuit can be incorporated.
6.3 Draw a time motion diagram of the circuit, involving all its components.
PN-2500 11-1
Figure 11.1
2. I/O ALLOCATION
3. CONNECTION OF COMPONENTS
Connect all components to the appropriate I/O Unit.
PN-2500 11-2
4. PLC PROGRAMMING
Figure 11.2
5. OPERATIONS
Note: The value of the counter increases whenever a Y9 contact changes
position from open to closed, provided that C10 is conducting current.
After the fifth time, count = 5 activates that C10 output, resetting contact
C10 which is connected to the counter’s reset.
1. Now explain the whole operation of the circuit.
2. Put the circuit into operation and write down the results of the trial.
3. CONNECTION OF COMPONENTS
Figure 12.1
PN-2500 12-2
Figure 12.2
5. OPERATIONS
Explain how the program operates.
6. QUESTIONS
Figure 13.1
PN-2500 13-2
Figure 13.2
5. QUESTIONS
1. Draw a time motion diagram.
2. How many cycles will the given circuit perform? How can this situation
be changed?
PN-2500 14-1
2. THE PROCESS
1. The paper feed belt will be activated one second after the previous
roll of paper has been cut and removed.
2. The motor of the removal belt (at the outlet) will be activated.
3. A pulser that pulsates every 5th millmeter of the paper-roll’s
progress, is attached to the feed system.
Figure 14.1
PN-2500 14-2
3. I/O ALLOCATION
Component Name TI- DEGEM IZUMI
Feed Motor M1 Y9 Q0
Removal Motor M2 Y10 Q1
Pneumatic Cutter A+ Y11 Q2
End-of-process light L1 Y12 Q3
Pulser P1 X3 I2
Material Sensor S1 X4 I3
Operation Switch PB1 X1 I0
Stop Button PB2 X2 I1
4. CONNECTION OF COMPONENTS
Connect components to appropr iate inputs and outputs.
Figure 15.2
5. TIME MOTION DIAGRAM
Figure 15.3
6. PROGRAMMING THE PLC
1. Write the ladder diagram program according to the time
motion diagram.
PN-2500 16-1
Figure 16.1
2. REQUIRED ACTION
1. Concrete is poured into the mold.
2. Cylinder A is retracted to below cylinder B.
3. Cylinder B compacts the concrete.
4. Cylinder A is activated.
5. Cylinder C is activated to remove the block produced.
3. CONNECTION OF COMPONENTS
Figure 16.2
PN-2500 16-2
4. QUESTIONS
1. What is the corresponding pneumatic sequence?
3. How many internal relays are needed for this circuit and
why?
PN-2500 17-1
2. REQUIRED ACTION
1. Activation of A+ to rotate fixture one station ahead each
move.
2. The full bottle reaches station B/C and activation of B+
pushes the cork into the bottle.
3. After closing the bottle, the C+ piston is actuated to stick
the label on the bottle.
3. CONNECTION OF COMPONENTS
Figure 17.2
PN-2500 17-2
4. QUESTIONS
1. Draw the time motion diagram.
Figure 18.2
PN-2500 18-2
4. QUESTIONS
1. Draw the appropriate ladder diagram.
PN-2500 19-1
Figure 19.1
2. MODE OF OPERATION
1. Simultaneous pressing of press buttons A and B enables operations.
2. The door of the forge opens.
3. The tray of parts for forging is inserted.
4. 60 second time delay.
5. The tray is removed from the forge.
6. The door of the forge closes.
3. CONNECTION OF COMPONENTS
Draw the connection of components to appropriate I/O’s.
PN-2500 19-2
4. I/O ALLOCATIONS
5. QUESTIONS
1. Write the appropriate sequence of operations.
Note: Since there are only eight inputs and eight outputs, the starting button
is not actually used, although it is included in the ladder diagram as an
internal “C” coil that can be operated through the computer keyboard:
PB1 = C15.
2. CONNECTION OF COMPONENTS
Figure 20.1
3. I/O ALLOCATION
Draw the I/O Table.
PN-2500 20-2
5. QUESTIONS
1. Can you list the start-up and shut-down conditions of relays RL1 and RL2?
2. Draw the time motion diagram.