PLC: Konsep, Pemrograman dan Aplikasi

(Omron CPM1A/CPM2A dan

ZEN Programmable Relay)
oleh Agfianto Eko Putra (c) 2004

Kata Pengantar
Syukur Alhamdulillah penulis panjatkan ke hadirat Alloh Yang Maha
Kuasa, karena atas karunia-Nya penulis dapat menyelesaikan buku ini. Tiada
lain buku ini saya persembahkan untuk siapa saja yang ingin mempelajari
konsep-konsep dasar PLC atau Programmable Logic Controller, pemrograman
hingga contoh-contoh aplikasinya.
PLC yang digunakan dalam buku ini adalah produk dari Omron, mengapa
tidak juga dibahas merek-merek yang lain? Selain konsep pemrograman
diagram tangganya yang sama, tentu akan memakan ribuan halaman untuk
menjelaskan satu persatu dari merek-merek PLC yang ada. Selain itu
kesempatan yang diperoleh penulis adalah menggunakan produk Omron, yaitu
seri CPM2A 20 I/O dan ZEN Programmable Relay, yang juga sebagai materi
kuliah dan praktikum PLC di Program Studi Elektronika dan Instrumentasi,
Fakultas MIPA Universitas Gadjah Mada, Yogyakarta, atau yang lebih dikenal
dengan ELINS UGM.
Buku ini saya susun dalam 7 Bab, Bab 1 membahas dasar-dasar atau
konsep dasar PLC (Programmable Logic Controller) mulai dari sejarah, konsep
dasar PLC hingga jalur-jalur keluaran dan masukan PLC secara umum. Pada
Bab 2 dibahas tentang PLC Omron seri Sysmac atau yang dikenal dengan tipe
CPM1A/CPM2A mulai dari konsep jalur keluaran dan masukan hingga struktur
memori di dalam PLC tersebut.
Selanjutnya pada Bab 3 dibahas tentang ZEN Programmable Relay
secara garis besar, fitur-fitur yang dimiliki, area memori hingga catatan khusus
untuk pengguna PLC Omron Sysmac jika ingin menggunakan ZEN
Programmable Relay. Kemudian di Bab 4 dijelaskan konsep-konsep
pemrograman diagram tangga ditinjau dari PLC Omron Sysmac.
Pada Bab 5 dijelaskan tentang perangkat lunak yang digunakan
dalampemrograman PLC, baik Syswin v3.4, ZEN Support Software v3.0 (serta
simulatornya) dan PLC Simulator v1.0 karya Tang Tung Yan yang bisa
digunakan untuk belajar pemrograman diagram tangga tanpa harus memiliki
PLC Sysmac yang harganya mahal.

Aplikasi untuk masing-masing PLC, Sysmac dan ZEN Programmable

Relay dibahas pada Bab 6 dan Bab 7. Khusus untuk PLC Sysmac, saya
membagi dua macam aplikasi, yaitu dasar dan lanjut, sedangkan pada ZEN
dikelompokkan berdasar fungsi-fungsi yang ada pada ZEN tersebut.
Tak lupa juga penulis ucapkan terima kasih kepada pak Diman selaku
pegawai Lab. Elins atas minuman teh-nya setiap hari (kecuali di hari Ahad) yang
menemani penulis di kantor saat menulis maupun mengerjakan pekerjaanpekerjaan lainnya, istri dan anak-anakku yang telah membuat kehidupan penulis
menjadi lebih dewasa dan kompleks, juga segenap pihak yang tidak bisa saya
sebutkan satu persatu disini. Semoga mendapatkan pahala dari Yang Maha
Kuasa, Alloh SWT. Amin.
Tiada gading yang tak retak, karenanya saran, kritik dan diskusi silahkan
dilayangkan ke agfi@ugm.ac.id serta informasi tambahan bisa dilihat di website
http://agfi.staff.ugm.ac.id, terima kasih.
Yogyakarta, Juli 2004

Agfianto Eko Putra

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DAFTAR ISI
KATA PENGANTAR .......................................................................................................................................... I
DAFTAR ISI.......................................................................................................................................................III
BAB I : SISTEM KONTROL PROSES DAN PLC........................................................................................1
I.1. PENDAHULUAN ............................................................................................................................................1
I.2. SEJARAH PLC ..............................................................................................................................................2
I.3. PENDEKATAN SISTEMATIK DALAM PERANCANGAN SISTEM KONTROL PROSES.......................................3
I.4. KOMPONEN-KOMPONEN PLC .....................................................................................................................4
I.4.1. Unit Pengolah Pusat (CPU Central Processing Unit) .................................................................4
I.4.2. Memori ................................................................................................................................................5
I.4.3. Pemrograman PLC.............................................................................................................................5
I.4.4. Catu Daya PLC ..................................................................................................................................6
I.4.5. Masukan-masukan PLC .....................................................................................................................6
I.4.6. Pengaturan atau Antarmuka Masukan .............................................................................................7
I.4.7. Keluaran-keluaran PLC.....................................................................................................................7
I.4.8. Pengaturan atau Antarmuka Keluaran.............................................................................................8
I.4.9. Jalur Ekstensi atau Tambahan ..........................................................................................................8
I.5. MENGHUBUNGKAN P IRANTI MASUKAN DAN KELUARAN .........................................................................8
I.5.1. Konsep Dasar .....................................................................................................................................8
I.5.2. Jalur-jalur Masukan...........................................................................................................................9
I.5.3. Jalur-jalur Keluaran ........................................................................................................................10
I.6. OPERASIONAL PLC ...................................................................................................................................11
BAB II : TENTANG PLC OMRON CPM1A/CPM2A................................................................................13
II.1. MENGAPA OMRON? .................................................................................................................................13
II.2. PLC O MRON CPM1A DAN CPM2A .......................................................................................................13
II.3. JALUR-JALUR KELUARAN PLC OMRON CPM1A DAN CPM2A.............................................................15
II.4. JALUR-JALUR MASUKAN PLC O MRON CPM1A DAN CPM2A ..............................................................17
II.5. STRUKTUR DAN O PERASIONAL PLC CPM1A/CPM2A .........................................................................17
II.5.1. Struktur Unit CPU ..........................................................................................................................17
Memori I/O ..............................................................................................................................................................17
Program ....................................................................................................................................................................18
Setup PC...................................................................................................................................................................18
Saklar Komunikasi ..................................................................................................................................................18

II.5.2. Mode Kerja......................................................................................................................................18

Mode PROGRAM...................................................................................................................................................18
Mode MONITOR ....................................................................................................................................................19
Mode RUN...............................................................................................................................................................19

II.6. STRUKTUR MEMORI PLC OMRON CPM1A DAN CPM2A .....................................................................19

Daerah IR .................................................................................................................................................................19
Daerah SR ................................................................................................................................................................20
Daerah TR................................................................................................................................................................20
Daerah HR ...............................................................................................................................................................20
Daerah AR ...............................................................................................................................................................21
Daerah LR................................................................................................................................................................21
Daerah Pewaktu/Pencacah (Timer/Counter) T/C Area......................................................................................21
Daerah DM ..............................................................................................................................................................21

BAB III : TENTANG OMRON ZEN PROGRAMMABLE RELAY........................................................23

III.1. GARIS BESAR ..........................................................................................................................................23
III.2. FITUR-FITUR LAIN ..................................................................................................................................24
III.3. AREA MEMORI ........................................................................................................................................28

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III.3.1. Bit-bit I/O, Work dan Penyimpan Internal (Internal Holding)...................................................28

III.3.2. Pewaktu dan Pencacah .................................................................................................................30
III.3.3. Bit-bit Penampil.............................................................................................................................32
III.4. CATATAN UNTUK P ENGGUNA PLC (NON ZEN) ...................................................................................34
BAB IV : DIAGRAM TANGGA (LADDER) UNTUK PLC SYSMAC CPM1A/CPM2A.....................41
IV.1. DIAGRAM TANGGA (LADDER ) DASAR ...................................................................................................41
IV.1.1. Istilah-istilah Dasar.......................................................................................................................41
IV.1.1.1. Kondisi Normal Terbuka dan Normal Tertutup ....................................................................................41
IV.1.1.2. Kondisi Eksekusi .....................................................................................................................................42
IV.1.1.3. Bit-bit Operan ..........................................................................................................................................42
IV.1.1.4. Blok-blok Logika.....................................................................................................................................42
IV.1.1.5. Blok-blok instruksi ..................................................................................................................................42

IV.1.2. Kode Mnemonik .............................................................................................................................43

IV.1.3. Struktur Memori Program.............................................................................................................43
IV.1.4. Instruksi-instruksi Tangga.............................................................................................................44
IV.1.4.1. LOAD (LD) dan LOAD NOT (LD NOT).............................................................................................44
IV.1.4.2. AND dan AND NOT...............................................................................................................................45
IV.1.4.3. OR dan OR NOT .....................................................................................................................................45
IV.1.4.4. Kombinasi instruksi AND dan OR.........................................................................................................46

IV.1.5. Instruksi OUTPUT dan OUTPUT NOT .......................................................................................47

IV.1.6. Instruksi END.................................................................................................................................47
IV.1.7. Instruksi-instruksi Blok Logika .....................................................................................................48
IV.1.7.1. AND LOAD (AND LD) .........................................................................................................................48
IV.1.7.2. OR LOAD (OR LD)................................................................................................................................49
IV.1.7.3. Instruksi-instruksi Blok Logik dalam seri..............................................................................................49
IV.1.7.4. Mengkombinasi AND LD dan OR LD ..................................................................................................51
IV.1.7.5. Diagram Tangga yang Lebih Kompleks ................................................................................................52

IV.1.8. Pengkodean Instruksi Sisi-kanan Multipel...................................................................................57

IV.1.9. Garis Pencabangan Instruksi........................................................................................................57
IV.1.9.1. Bit-bit TR .................................................................................................................................................58
IV.1.9.2. Bit-bit INTERLOCK...............................................................................................................................60

IV.1.10. Instruksi Lompatan (JUMP) .......................................................................................................62

IV.2. MENGONTROL STATUS BIT ....................................................................................................................63
IV.2.1. SET dan RESET .............................................................................................................................63
IV.2.2. DIFFERENTIATE UP dan DIFFERENTIATE DOWN...............................................................64
IV.2.3. Instruksi KEEP...............................................................................................................................64
IV.2.4. Bit-bit Penyimpan (Self-maintained) ............................................................................................65
IV.3. BIT-BIT KERJA (WORK BITS) ATAU RELAI INTERNAL ...........................................................................65
IV.3.1. Aplikasi-aplikasi Bit Kerja ............................................................................................................66
IV.3.2. Mengurangi Kerumitan Diagram Tangga ...................................................................................66
IV.3.3. Kondisi Terdiferensiasi..................................................................................................................67
IV.4. CATATAN PENTING P EMROGRAMAN TANGGA......................................................................................67
IV.5. EKSEKUSI PROGRAM ..............................................................................................................................69
BAB V : PROGRAM SYSWIN V3.4, SIMULATOR PLC DAN ZEN SUPPORT SOFTWARE........70
V.1. PENDAHULUAN ........................................................................................................................................70
V.2. INSTALASI SYSWIN V3.4 ..........................................................................................................................70
V.3. PETUNJUK SINGKAT P ENGGUNAAN SYSWIN 3.4 ....................................................................................72
V.3.1. Memulai membuat Diagram Tangga .............................................................................................72
V.3.2. Menyimpan Diagram Tangga.........................................................................................................77
V.3.3. Sarana penyuntingan Diagram Tangga lainnya ...........................................................................77
V.3.4. Pencetakan Diagram Tangga.........................................................................................................79
V.3.5. Pengaturan komunikasi PLC dengan komputer............................................................................80
V.3.6. Ringkasan tombol singkat (shortcut) .............................................................................................82
V.4. PLC S IMULATOR V1.0 .............................................................................................................................83
V.5. ZEN S UPPORT SOFTWARE VERSI 3.0......................................................................................................85

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V.5.1. Memulai Dan Mengakhiri...............................................................................................................86

V.5.2. Konfigurasi Layar ...........................................................................................................................87
V.5.3. Dasar Diagram Tangga pada ZEN................................................................................................92
V.5.3.1. Diagram Tangga ZEN Programmable Relay ..........................................................................................92
V.5.3.2. Konfigurasi Dasar Diagram Tangga........................................................................................................92
V.5.3.3. Bit-bit Keluaran dan Masukan (I/O)........................................................................................................93

V.5.5. Penyuntingan Komentar ...............................................................................................................100

V.5.6. Menyimpan dan Membuka Diagram Tangga..............................................................................101
V.5.6.1. Menyimpan Diagram Tangga ................................................................................................................101
V.5.6.2. Membuka Diagram Tangga....................................................................................................................101

V.5.7. Mencetak Diagram Tangga ..........................................................................................................102

V.5.7.1. Pengaturan Pencetakan ...........................................................................................................................102
V.5.7.2. Lihat Hasil Pencetakan (Preview)..........................................................................................................103
V.5.7.3. Mencetak .................................................................................................................................................103

V.6. SIMULASI MENGGUNAKAN ZEN SUPPORT SOFTWARE V3.0 ...............................................................104

V.6.1. Memulai Dan Mengakhiri Fungsi Simulasi.................................................................................104
V.6.2. Tampilan Panel Depan ZEN.........................................................................................................105
V.6.3. Tampilan Daftar Nilai Saat ini (PV Present Value List) .........................................................106
V.6.4. Tampilan Jam (Clock)...................................................................................................................108
V.6.4.1. Mengatur Maju dan Mundurnya Jam ....................................................................................................108
V.6.4.2. Mengubah Jam Saat Ini ..........................................................................................................................108

BAB VI : CONTOH-CONTOH APLIKASI ZEN ......................................................................................109

VI.1. APLIKASI PENGGUNAAN BIT LOGIKA..................................................................................................109
VI.1.1. Kontrol Pola Pencahayaan (Lighting Pattern Control)............................................................109
VI.1.1. Kontrol Suplai Tangki Air (Water Supply Tank Control) .........................................................112
VI.2. APLIKASI PENGGUNAAN P EWAKTU DAN P ENCACAH..........................................................................114
VI.2.1. Anunsiator (Flashing Pulse Timer) ............................................................................................114
VI.2.2. Cuci Mobil Pakai Koin (Coint-operated Car Wash).................................................................117
VI.3. APLIKASI PEWAKTU MINGGUAN .........................................................................................................121
VI.3.1. Eskalator Otomatis (Escalator with Automatic Operation Function)......................................121
VI.3.2. Pemanasan Mesin Cetakan (Warming Moulding Machine) .....................................................124
BAB VII : CONTOH-CONTOH APLIKASI CPM1A/CPM2A...............................................................128
VII.1. APLIKASI PLC CPM1A/CPM2A (SYSMAC) D ASAR .........................................................................128
VII.1.1. ON/OFF Dua Tombol atau Saklar (Interlock) .........................................................................128
VII.1.2. Penundaan ON Keluaran (ON Delay) ......................................................................................129
VII.1.3. Tundaan ON dan OFF (ON and OFF Delay) ..........................................................................131
VII.1.4. Tundaan OFF (OFF Delay).......................................................................................................134
VII.1.5. ON Sesaat (One Shot) ................................................................................................................135
VII.1.6. Penggunaan Pencacah (CNT) Bagian I....................................................................................137
VII.1.7. Penggunaan Pencacah Bagian II..............................................................................................139
VII.1.8. Penggunaan Pencacah dan Pewaktu ........................................................................................141
VII.1.9. Penggunaan Fungsi Geser (SHIFT Function) .........................................................................143
VII.1.10. Penggunaan Fungsi MOV(21).................................................................................................145
VII.1.11. Penggunaan Fungsi CMP(20).................................................................................................147
VII.1.12. Penggunaan Fungsi ADD(30) dan SUB(31) ..........................................................................149
VII.2. APLIKASI PLC CPM1/CPM2 (S YSMAC) LANJUT ..............................................................................154
VII.2.1. Aplikasi Penentu Prioritas Bel Kuis..........................................................................................154
VII.2.2. Aplikasi Pegepakan Apel ke dalam Boks ..................................................................................158
VII.2.3. Aplikasi Pengisian dan Pengurasan Tangki Air.......................................................................161
VII.2.4. Aplikasi Sortir Produk................................................................................................................167
VII.2.5. Aplikasi Kontrol Pintu Gudang .................................................................................................169
VII.2.6. Aplikasi Kontrol Parkir Mobil...................................................................................................171
VII.2.7. Aplikasi Kontrol Konveyor.........................................................................................................174
DAFTAR PUSTAKA.......................................................................................................................................178

LAMPIRAN: TENTANG CDROM..............................................................................................................179

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