Lab Manual Control Systems (EEE325)

Name: _________________________________ Year: __________________________________ Batch: _________________________________ Roll No: ________________________________ Majors: BCE BTE

2nd Edition August 2011

Department of Electrical Engineering, COMSATS Institute of Information Technology (CIIT), Islamabad

Experiment 1

Introduction to PLCs and Implementation of Combinational Logic through Ladder Logic

Objectives:
To understand the basics of PLCs and their programming using ladder logic.

Equipment/Tools required:
Trilogi PLC, PC with Trilogi software, connecting leads etc.

Introduction:
A programmable logic controller (PLC) is a specialized computer used to control machines and processes. It uses a programmable memory to store instructions and execute specific functions that include on/off control, timing, counting, sequencing, Arithmetic and data handling. The design of most PLCs is similar to that of other computers. Basically, the PLC is an assembly of solid-state digital logic elements designed to make logical decisions and provide outputs. Programmable logic controllers are used for the control and operation of manufacturing process equipment and machinery. The programmable logic controller is basically a computer designed for use in machine control. It has been designed to operate in the industrial environment and is equipped with special input/output interfaces and a control programming language. Initially the PLC was used to replace relay logic, but its ever-increasing range of functions means that it is found in many and more complex applications. Because the structure of a PLC is based on the same principles as those employed in computer architecture. It is capable not only of performing relay switching tasks but also of performing other applications such as counting, calculating, comparing and the processing of analog signals.

Parts of PLC:
A typical PLC can be divided into following parts: (Figure 1.1) Central processing unit (CPU). Input/Output (l/O) section. Power supply. Programming device.

Fig. 1.1 Parts of PLC

PLC Scan Cycle:

During each operating cycle, the processor reads all the inputs, takes these values and energizes or de-energizes the outputs according to the user program. This process is known as a scan. A typical PLC scan is shown in Figure 1.2 in which PLC scan I/O and program. Since inputs may change continuously so PLC must carry on this process continuously. The PLC scan time specification indicates how fast the controller can react to changes in inputs. Scan time varies with program content and length. The time required to make a single scan can vary from about 1ms to 20ms.

Fig. 1.2 PLC scan cycle

PLC Programming Programming:

According to International Electrotechnical Commission (IEC 61131-3/EN 6131 IEC) standard, PLC can be programmed using following five different languages: lowing Ladder diagram (logic) (logic). Function Block Diagrams (FBDs) (FBDs). Statement lists lists. Structured text languages languages. Sequential function charts.

Ladder Diagrams:
Ladder Diagram is graphical depiction of a process with rungs of logic, similar to the relay ladder logic schemes that were replaced by PLCs. The main function of the ladder logic diagram program is to control outputs based on input conditions. This control is accomplished through the use of what is referred to as a ladder rung. In general, a rung consists of a set of input conditions, represented by contact instructions, and an output instruction at the end of the rung is represented by the coil symbol.

Contacts and Coils:

Normally Open Normally open contact and is short circuited when energized.

Normally Closed Normally closed contact and is converted to open circuit when energized. Coil

Implementation of AND, OR and NOT Gates using Trilogi:

Fig. 1.3 Gates implementation

Lab. Tasks:
Lab Task No 1:
Create a three input NAND Gate and three inputs NOR Gate.

Lab Task No 2 (Mixer process control problem):

o A mixer motor is used to automatically stir the liquid in a tank when the temperature and pressure reach preset values. In addition, direct manual operation of the motor is provided by means of a separate pushbutton station. The process is monitored with temperature and pressure sensors switches that close their respective contacts when conditions reach their preset values.

o Additionally the change requires that the manual pushbutton control should be permitted to operate at any pressure but not unless the specified temperature setting has been reached.

Fig. 1.4 Mixer process control

Lab Task No 3 (Filling operation):

A continuous filling operation requires boxes moving on a conveyor to be automatically positioned and filled. The operation sequence is as follows: o The conveyor starts when the START button is momentarily pressed and Stop when the STOP button is momentarily pressed. o When the process is operating it energize the RUN status light. o When the process stops it energize the STANDBY status light. o When box reaches right edge and sensed by PHOTOSENSOR, the conveyor stops and energizes the STANDBY light. o When the box is in position and the conveyor is stopped. The SOLENOID valve opens and allows box to be filled. Filling stops, when LEVEL sensor goes true. o When the box is full. The FULL light should remain energized until the box clear o the PHOTOSENSOR.

Fig. 1.5 Filling operation

Note:

START: NO contacts STOP: NC contacts Level switch, Photo switch: NO contacts

Home Tasks:
1. Implement Flip-Flop using both NAND and NOR Gates. Truth Table of NOR Gate
S 1 0 0 0 1 Table 1.1 NOR truth table R Q Q 0 1 0 0 1 0 1 0 1 0 0 1 1 0 0

Truth Table of NAND Gate

Table 1.2 NAND truth table S R Q Q 1 0 0 1 1 1 0 1 0 1 1 0 1 1 1 0 0 0 1 1

2.

Implement 3 to 8 line decoder. 6