.

PROGRAMMABLE LOGIC
CONTROLLER (PLC) AND

AUTOMATION
http://modul2poli.blogspot.com/
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Objective ;
1. Understand automation system

a. Understand type of automation
b. Comparison type of automation
2. Understand relays, contactors, electromechanical

timer and electromechanical counter (symbol,
building diagram, operation and application examples)
a. Develop simple logical control/ automation
sequence
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The word Automation is derived from Greek
words
AUTO(SELF) AND MATOS
(MOVING)
Automation therefore is the mechanism for

systems that
MOVE BY ITSELF
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Automation System
Definition:
Automation is a set of technologies

that results in operation of machines and systems
without significant human intervention
and achieves superior performance to
manual operation.
Automasi didefinasikan sebagai sekumpulan teknologi yang memberikan hasil tertentu pada operasi mesin dan sistem
tanpa campur tangan manusia yang ketara bagi mencapai prestasi unggul berbanding penoperasian secara manual.
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Automation System
In the scope of INDUSTRIALIZATION, automation is a step beyond
MECHANIZATION
Whereas mechanization provided human operators with machinery

to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental
requirements as well
Type of Automation system :

fixed/ hardwired automation
programmable automation
flexible automation
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Fixed/ Hardwired Automation
Custom-engineering, special purpose equipment to automate a
fixed sequence of operations.
High production rates, inflexible product design
Programmable Automation
Equipment designed to accommodate a specific class of product
changes.
Batch production, medium volume
Flexible Automation
Design to manufactured a variety of product or parts
Low production rates, varying product design and demand
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Comparison Types of Automation
Automation When to consider Advantages Disadvantages
Fixed High demand volume, long maximum efficiency large initial investment
product life cycle low unit cost inflexibility
Programmable Batch production, products flexibility to deal with new product requires
with the different options changes in product long set up time
low unit cost for large high unit cost relative
batches to fixed automation
Flexible Low production rates, flexibility to deal with large initial investment
varying demand, short design variations high unit cost relative
product life cycles customized product to fixed or
programmable
automation
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Reasons for automating
There is a general shortage of labor in many advanced
To mitigate the nations, and this has stimulated the development of
effects of labor automated operations as a substitute for labor.
shortages
Automating a manufacturing operation usually increases
To increase labor production rate and labor productivity. This means greater
productivity output per hour of labor input.
By automating a given operation, and transferring the

To improve worker worker from active participation in the process to a
safety supervisory role, the work is made safer.
To reduce or An argument can be put forth that there is social value in
remove routine automating operations that are routine, boring, fatiguing,
manual and clerical and possibly irksome.
tasks Ever increasing labor cost has been and continuous to be
the trend in the worlds industrialized societies.
To reduce labor Consequently, higher investment in automation has
cost become economically justifiable to replace manual
operations.
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Reasons for automating
Automation not only results in higher production rates
than manual operations; it also performs the
To improve product manufacturing process with greater uniformity and
quality conformity to quality specifications.
Automation helps to reduce the elapsed time between

To reduce customer order and product delivery, providing a competitive
manufacturing lead advantage to the manufacturer for future orders.
time
Certain operations cannot be accomplished without the
To accomplish what aid of a machine. These processes have requirements
cannot be done for precision, miniaturization, or complexity of
manually geometry that cannot be achieved manually.
The benefits of automation often show up in unexpected and
intangible ways, such as an improved quality, higher sales,
To avoid the high better labor relations, and better company image.
cost of not Companies that do not automate are likely to find themselves
automating at a competitive disadvantage with their customers, their
employees and the general public.
ADVANTAGES OF AUTOMATION
Replacing human operators
in tasks that involve hard physical or monotonous work.
Replacing humans in tasks done in dangerous

environments
i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of

size, weight, speed, endurance, etc.
Economy improvement
Automation may improve in economy of enterprises, society or most of
humanity. For example, when an enterprise invests in automation,
technology recovers its investment; or when a state or country increases
its income due to automation like Germany or Japan in the 20th Century
DISADVANTAGES OF AUTOMATION
Unemployment rate increases
due to machines replacing humans and putting those humans out of their
jobs.
Technical Limitation
Current technology is unable to automate all the desired tasks.
Security Threats/Vulnerability
An automated system may have limited level of intelligence, hence it is
most likely susceptible to commit error
Unpredictable development costs
The research and development cost of automating a process may exceed
the cost saved by the automation itself.
High initial cost
The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product, although the
cost of automation is spread in many product batches.
Relays
Define
A relay is usually an electromechanical device that is actuated by an electrical

current. The current flowing in one circuit causes the opening or closing of another
circuit.
Relays are like remote control switches and are used in many applications because of
their relative simplicity, long life, and proven high reliability.
Relays are used in a wide variety of applications throughout industry, such as in

telephone exchanges, digital computers and automation systems.
Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where
several circuits must be controlled by one signal
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Relays
Define
Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where
several circuits must be controlled by one signal
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Relays
Define
Highly sophisticated relays are utilized to protect electric power systems
against trouble and power blackouts as well as to regulate and control the
generation and distribution of power.
In the home, relays are used in refrigerators, washing machines and

dishwashers, and heating and air-conditioning controls
Symbol
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Building Diagram
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Relay Diagram Bottom View
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RELAY TERMINOLOGY
Normally-open (NO) contacts connect the circuit when the relay is

activated; the circuit is disconnected when the relay is inactive.
Normally-closed (NC) contacts disconnect the circuit when the relay is

activated; the circuit is connected when the relay is inactive.
Double-throw (DT), contacts control two circuits: one normally-open

contact and one normally-closed contact with a common terminal.
Coil- generates a magnetic field that attracts the armature when an electric
current is passed through it.
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There are three (3) basic functions of a relay:
On/Off Control: Example: Air conditioning control, used to

limit and control a high power load, such as a compressor.
Limit Control: Example: Motor Speed Control, used to

disconnect a motor if it runs slower or faster than the
desired speed.
Logic Operation: Example: Test Equipment, used to connect

the instrument to a number of testing points on the device
under test.
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How does a relay work?
All relays contain a sensing unit, the electric coil, which is
powered by AC or DC current.
When the applied current or voltage exceeds a threshold value,

the coil activates the armature, which operates either to close
the open contacts or to open the closed contacts.
When a power is supplied to the coil, it generates a magnetic

force that actuates the switch mechanism.
The magnetic force is, in effect, relaying the action from one
circuit to another.
The first circuit is called the control circuit; the second is called
the load circuit.
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Operation
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Operation
When no voltage is applied to pin 1, there is no current flow

through the coil.
No current means no magnetic field is developed, and the
switch is open.
When voltage is supplied to pin 1, current flow though the coil
creates the magnetic field needed to close the switch allowing
continuity between pins 2 and 4.
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Type of Relay / Application Examples
This is a Single Pole Single Throw (SPST) relay.

Current will only flow through the contacts when the
relay coil is energized.
This is a Single Pole Double Throw (SPDT) relay. Current will
flow between the movable contact and one fixed contact when the
coil is DEenergized and between the movable contact and the
alternate fixed contact when the relay coil is energized. The most
commonly used relay in car audio, the Bosch relay, is a SPDT
relay.
This is a Double Pole Single Throw (DPST) relay. When the

relay coil is energized, two separate and electrically isolated sets
of contacts are pulled down to make contact with their stationary
counterparts. There is no complete circuit path when the relay is
DEenergized.
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Type of Relay / Application Examples
This relay is a Double Pole Double Throw

(DPDT) relay. It operates like the SPDT relay but
has twice as many contacts. There are two
completely isolated sets of contacts.
This is a 4 Pole Double Throw (4PDT) relay. It

operates like the SPDT relay but it has 4 sets of
isolated contacts.
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Figure : Relay Contact Configuration
Single Pole relay have 1 common

Double Pole relay have 2 common
Single Throw relay have NC or NO
Double Throw relay have NC and NO
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EXAMPLE OF CONTROL
Figure : Wiring of relay
Pin no 1 Common
Pin no 2 NC
Pin no 3 NO
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EXAMPLE OF CONTROL
When the relay is at
rest, the switch is not
actuated and the relay
coil is not energized.
The normally close
contact will remain close
and light will be lit.
when the switch is
closed, the relay coil will
be energized and its
associated contacts will
switch. The normally
open contact, now
closed. Light will turn off
as its contact are open,
and Motor will operate
through its normally
open contacts, which
are closed.
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EXAMPLE OF CONTROL
If a relay is connected as
shown in figure 3, it will
become 'latched' on when
the coil is energized by
pressing the Trigger
button. The only way to
turn the relay off will then
be to cut the power supply
by pressing the Reset
button (which must be a
push-to-break type).
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Contactors
Define
Contactors are used to indicate an open or closed path of
current flow. Contacts are shown as normally open (NO) or
normally closed (NC). Contacts shown by this symbol require
another device to actuate them.
Symbol
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Contactors
Define
A contactor is an electrically controlled switch used
for switching a power circuit, similar to a relay except
with higher current ratings.
contactor is controlled by a circuit which has a much

lower power level than the switched circuit.
Contactors are used to control electric motors, lighting,

heating, capacitor banks, and other electrical loads.
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Building Diagram
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Building Diagram
A contactor is composed of three different items:
Power/Main Contact
Auxiliary Contact
Coil Input
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POWER/MAIN CONTACT
Main contact
generally only
normally open
contacts.
It is used for open
and closed power
circuits.
AUXILIARY CONTACT
There are two basic auxiliary contact types:
those that are closed in the non-activated
state or those that are open.
These are known as normally closed (N/C) and
normally open (N/O) contacts.
AUXILIARY CONTACT
Uses of auxiliary contacts:
i-electrical retainer circuit
ii-remote status and trip indication.
COIL INPUT
Driven by either an AC or DC supply
depending on the contactor design.
The coil may be energized at the same
voltage as the motor, or may be separately
controlled with a lower coil voltage better
suited to control by programmable
controllers and lower-voltage pilot devices.
Coil is used to produce electromagnet when
power is supplied.
BASIC CONTACTOR OPERATION
Contactors operate utilizing
electromagnetic principles.
When a DC voltage is applied to
the wire, the iron becomes
magnetic.
When the DC voltage is removed
from the wire, the iron returns
to its nonmagnetic state
CONTACTOR OPERATION
There are two circuits
involved in the operation of a
contactor:
control circuit
power circuit.
The control circuit is
connected to the coil.
The power circuit is
connected to the stationary
contacts.
CONTACTOR OPERATION
When power is supplied to the coil from the
control circuit, a magnetic field is produced
and magnetizing the electromagnet.
The magnetic field attracts the armature to
the magnet, which in turn closes the
contacts.
With the contacts closed, current flows
through the power circuit from the line to
the load.
When the electromagnets coil is de
energized, the magnetic field collapses and
the movable contacts open under spring
pressure.
Operation Normally Open Contact
In the following illustration the circuit is

first shown in the de-energized state.
The contacts are shown in their normally

open (NO) state.
When the relay is energized, the

contacts close, completing the path of
current and illuminating the light.
The contacts have been highlighted to

indicate they are now closed.
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Operation
Normally Close Contact
In the following illustration the contacts

are shown as normally closed (NC),
meaning the contacts is closed when
the relay is de-energized.
A complete path of current exists and

the light is on.
When the relay is energized, the

contacts open turning the light off.
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APPLICATION
3-PHASE MOTOR STARTER - DOL
CONTACTOR CONTROL CIRCUIT
Start/stop station controlling magnetic starter
Start/stop station controlling two magnetic starter with

emergency stop.
Start/stop station with pilot light indicate device deactivation .
Electromechanical Timer
Define
Electromechanical timers are used to start or stop a machine or

other device at preset or delayed intervals.
They consist of both electrical and mechanical components,

and often feature an electric motor that drives one or more
gears.
They typically accept electric or electronic inputs to operate a

mechanical output such as rotating wheels or knobs.
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Symbol Electromechanical Timer
Contact symbols determine the time of timer action:-

On-delay action - TR energized, contacts change state after set time interval
Off-delay action - TR de-energized, contacts change state after set time
interval
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Electromechanical Counter
Define
Electromechanical counters are used to detect, totalize, and

indicate a sequence of events.
They typically accept electric or electronic inputs to operate

mechanical outputs such as rotating wheels or knobs.
These devices may count UP and/or DOWN, support multiple

functions, and provide reset capabilities.
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Symbol Electromechanical Counter
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Simple Logical Control/ Automation Sequence
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Contactor
Relay
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3ph Starter/1ph Motor
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CHAPTER 2
LOGICAL SENSORS
AND ACTUATORS
http://modul2poli.blogspot.com/ Page 1 of 61
BAKISS HIYANA BT ABU BAKAR
Objective
1. Logical Sensor
Understand Logical Sensor
Identify basic logical sensor types and their functions
Contact Switches
Proximity
Photo optics
Capacitive
Inductive
Ultrasonic
Explain logical sensor and switches wiring (sourcing and
sinking).
Develop logical sensor application based on simple logical
control/automation.
2. Logical actuators
Understand solenoid, valves, cylinders and motors.
Logical Sensor
Sensors allow a PLC to detect the state of a process.
Logical sensors can only detect a state that is either true

or false. Examples of physical phenomena that are
typically detected are listed below :
inductive proximity - is a metal object nearby?

capacitive proximity - is a dielectric object nearby?
optical presence - is an object breaking a light beam
or reflecting light?
mechanical contact - is an object touching a switch?
Types of Logical Sensor
Door Contact Switches
1. Contact Switches
Contact switches are available as normally open and
normally closed.
Their housings are reinforced so that they can take
repeated mechanical forces.
These often have rollers and wear pads for the point
of contact.
Lightweight contact switches can be purchased for
less than a dollar, but heavy duty contact switches will
have much higher costs.
Examples of applications include motion limit switches
and part present detectors.
2. Proximity
A proximity sensor is a sensor able to detect the presence of

nearby objects without any physical contact.
A proximity sensor often emits an electromagnetic field or a

beam of electromagnetic radiation (infrared, for instance), and
looks for changes in the field or return signal.
The object being sensed is often referred to as the proximity
sensor's target.
Different proximity sensor targets demand different sensors. For
example, a capacitive photoelectric sensor might be suitable for
a plastic target; an inductive proximity sensor always requires a
metal target.
2.Proximity
2. Proximity
The maximum distance that this sensor can detect is

defined "nominal range".
Some sensors have adjustments of the nominal range
or means to report a graduated detection distance.
Proximity sensors can have a high reliability and long
functional life because of the absence of mechanical
parts and lack of physical contact between sensor and
the sensed object.
3. Photo Optics
Optical sensors require both a light source (emitter) and
detector.
Emitters will produce light beams in the visible and invisible
spectrums using LEDs and laser diodes.
Detectors are typically built with photodiodes or
phototransistors.
The emitter and detector are positioned so that an object will
block or reflect a beam when present.
3. Photo Optics/ Through Beam Sensor
The emitter and detector are positioned so that an

object will block or reflect a beam when present.
In the figure the light beam is generated on the left,

focused through a lens.
At the detector side the beam is focused on the detector

with a second lens.
If the beam is broken the detector will indicate an object

is present.
The oscillating light wave is used so that the sensor can

filter out normal light in the room.
The light from the emitter is turned on and off at a set
frequency.
When the detector receives the light it checks to make
sure that it is at the same frequency.
If light is being received at the right frequency then the
beam is not broken.
The frequency of oscillation is in the KHz range, and too

fast to be noticed.
Benefit of the frequency method is that the sensors can

be used with lower power at longer distances.
3. Photo Optics/ Diffuse Sensor
A diffuse sensor is a single unit that does not use a

reflector, but uses focused light as shown in Figure.
Diffuse sensors use light focused over a given range,
and a sensitivity adjustment is used to select a distance.
These sensors are the easiest to set up, but they require
well controlled conditions.
For example if it is to pick up adjacent wavelength
colored objects such as red and orange, problems
would result.
3. Photo Optics/ Diffuse Sensor
4. Capacitive
Capacitive sensors are able to detect most materials at
distances up to a few centimeters. Recall the basic
relationship for capacitance.
In the sensor the area of the plates and distance
between them is fixed. But, the dielectric constant of the
space around them will vary as different materials are
brought near the sensor.
4. Capacitive
An oscillating field is used to determine the capacitance
of the plates.
When this changes beyond a selected sensitivity the
sensor output is activated.
5. Inductive
` Inductive sensors use currents induced by magnetic
fields to detect nearby metal objects.
` The inductive sensor uses a coil (an inductor) to
generate a high frequency magnetic field.
` If there is a metal object near the changing magnetic
field, current will flow in the object.
` This resulting current flow sets up a new magnetic field
that opposes the original magnetic field.
5. Inductive
` The next effect is that it changes the inductance of the
coil in the inductive sensor. By measuring the
inductance the sensor can determine when a metal
have been brought nearby.
` These sensors will detect any metals, when detecting
multiple types of metal multiple sensors are often used.
5. Inductive
The sensors can detect objects a few centimeters away from the
end.
The magnetic field of the unshielded sensor covers a larger volume
around the head of the coil.
By adding a shield (a metal jacket around the sides of the coil) the
magnetic field becomes smaller, but also more directed.
Shields will often be available for inductive sensors to improve their
directionality and accuracy.
6. Ultrasonic
An ultrasonic sensor emits a sound above the normal
hearing threshold of 16KHz. The time that is required
for the sound to travel to the target and reflect back is
proportional to the distance to the target.
6. Ultrasonic
The two common types of sensors are;
electrostatic - uses capacitive effects. It has longer
ranges and wider bandwidth, but is more sensitive
to factors such as humidity.
piezoelectric - based on charge displacement
during strain in crystal lattices. These are rugged
and inexpensive.
These sensors can be very effective for applications
such as fluid levels in tanks and crude distance
measurement.
Logical Sensor and Switches
Wiring
(sourcing and sinking)
Logical Sensor and Switches Wiring
The term sinking and sourcing are used in the
Motion Engineering Slice I/O part description.
Voltage Sinks current to the ground.
Voltage Sources current from a voltage

source.
Sinking/Sourcing describes a current signal flow
relationship between field input and output
devices in a control system and their power
supply.
Sourcing I/O modules supply (or source)

current to sourcing type field devices.
Sinking I/O modules sink (or pull) current
from sinking field devices.
In general, Sinking (NPN) and Sourcing (PNP) are
terms that define the control of direct current flow
in a load.
They are only pertinent with DC components and
should not be associated with AC control
structures.
Sinking (NPN) provides a path to 0 VDC (-DC)
Sourcing (PNP) provides a path to +24 VDC
(+DC).
Sinking (NPN) Outputs - Are output that Sink or pull
current through the load.
The common connection to the load is the 24 VDC (+DC)
line.
Sinking output modules require the load to be energized by
a current, which flows from +24 VDC (+DC), through the
load, through the NPN output switch device to the 0VDC (-
DC) line
Circuit connection
Figure representation of the Sinking Output

Module connections to sinking type loads.
Sourcing (PNP) Outputs Are outputs that Source or
push current through the load.
The common connection to the load is the 0VDC (-DC) line.
Sourcing output modules require the load to be energized
by a current that flows from +24 VDC (+DC), through the
PNP output switch device, through the load to 0VDC (-DC)
line.
** note: -ve side (0VDC)

common & +ve side
(+24VDC) switched
Circuithttp://modul2poli.blogspot.com/
connection Page 28 of 61
Figure representation of the

sourcing output module
connections to sourcing type loads
Sinking (NPN) inputs - are input that require an
external sensor device to sink of pull current from
input circuitry to 0VDC (-DC).
The external input device provides a current path to

the 0VDC (-DC) common point.
Circuit connection
Notice: common connection is

0VDC (-DC)

sinking input module
connection to sinking type
sensors. http://modul2poli.blogspot.com/ Page 31 of 61
Sourcing (PNP) inputs - Are inputs that require an
external sensor device to Source or push current
from the 24 VDC (+DC) line to the input circuitry.
The external sensor device provides a current path

from the 24 VDC (+DC) common point to the input
circuitry.
Circuit connection
Notice: common connection is

24VDC (+DC)

sourcing input module
connection to sourcing type
sensors. http://modul2poli.blogspot.com/ Page 33 of 61
LOGICAL ACTUATORS
Logical Actuators
1. SOLENOID:
Solenoid is the most common actuator component.
Solenoid is the generic term for a coil of wire used as an
electromagnet.
It also refer to any device that convert electrical energy to
mechanical energy using solenoid.
The device creates magnetic field from electric current and used
the magnetic field to create linear motion.
Solenoid usually consists of a coil and a movable iron core called
the armature.
Solenoid are inexpensive and their use is primarily limited to on-off
applications such as latching, locking, and triggering.
Common applications : home appliances (washing machine
valves), office equipment (copy machines), automobiles (door
latches), pinball machine (plungers & bumpers) & factory
automation.
Logical Actuators
1. SOLENOID:
Figure 1
The basic principle of operation:

There is a moving ferrous core ( a piston ) than will move inside wire
core as shown in figure 1.
Normally the piston is held outside the coil by a spring.
When voltage is applied to the coil and current flow, the coil builds up
magnetic field that attracts the piston and pulls it into the center of the
coil.
The piston can be used to supply a linear force.
Most industrial solenoids will be powered by 24Vdc and draw a few
hundred mA.
Logical Actuators
Figure 2
1. SOLENOID:
HOW A SOLENOID WORKS??
When current flows through a wire,
a magnetic field is set up around the wire.
If we make a coil of many turns of wire,

the magnetic field becomes much stronger.
Flowing around the coil and through its
center doughnut shape.
When the coil of the solenoid is energized with current, the core moves
to increases the flux linkage by closing the air gap between the cores.
Logical Actuators
1. SOLENOID:
HOW A SOLENOID WORKS??
The movable core is usually spring-loaded to allow the core to retract
when the current is switched off.
The force generated is approximately proportional to the square of the

current and inversely proportional to the square of the length of the air
gap.
Figure 3
Logical Actuators
2. VALVES:
What are Valves?
Valves are mechanical devices that controls the flow and pressure
within a system or process.
They are essential components of piping system that conveys liquids,
gases, vapors, slurries etc.
Some valves are self operated while others manually or with an
actuator or pneumatic or hydraulic is operated.
Valves functions:
Stopping & starting flow
Reduce @ increase a flow
Controlling the direction @ flow
Regulating a flow or process pressure
Relieve a pipe system of a certain pressure/ overpressure protection.
Logical Actuators
2. VALVES:
What are Valves?
Logical Actuators
2. VALVES:
The types of control valve symbol

Logical Actuators
2. VALVES:
Solenoid control valve basic operation:
The solenoid is mounted on the side. When actuated, it will drive the central
spool left.
The top of the valve body has two ports that will be connected to a device such
as a pneumatic cylinder.
The bottom of the valve body will be connected to a pressure line.
In one position, the power flow to the right hand of cylinder port.
The left hand cylinder port is allowed to exit through an exhaust port.
In other position, the pressure is now applied to the left hand port and the right
hand port can exhaust.
Valves are also available that allow the valves to be blocked when unused.
Logical Actuators
2. VALVES:
Solenoid Control Valves operation.
The flow of fluids and air can be
controlled with solenoid controlled valves.
The diagram to the right shows the design
of a basic valve, controlling the flow of water
in this example.
At the top figure is the valve in its closed state
The water under pressure enters at A. B is
an elastic diaphragm and above it is a weak
spring pushing it down.
The diaphragm has a pinhole through its
center which allows a very small amount of
water to flow through it.
This water fills the cavity C on the other side
of the diaphragm so that pressure is equal
on both sides of the diaphragm.
Logical Actuators
2. VALVES:
In the previous configuration the small
passage D was blocked by a pin which is the
armature of the solenoid E and which is
pushed down by a spring.
If the solenoid is activated by drawing the pin
upwards via magnetic force from the solenoid
current, the water in chamber C will flow
through this passage D to the output side of
the valve.
The pressure in chamber C will drop and the
incoming pressure will lift the diaphragm thus
opening the main valve.
Water now flows directly from A to F
Logical Actuators
2. VALVES:
When the solenoid is again deactivated and
the passage D is closed again, the spring
needs very little force to push the diaphragm
down again and the main valve closes.
Piloted solenoids usually need full power at
all times to open and stay open, where a
direct acting solenoid may only need full
power for a short period of time to open it,
and only low power to hold it.
Logical Actuators
2. VALVES:
When selecting valves there are a number of details that should be considered,
as listed below:
Pipe size - inlets and outlets are typically threaded to accept NPT
(national pipe thread).
Flow rate - the maximum flow rate is often provided to hydraulic valves.
Operating pressure - a maximum operating pressure will be indicated.

Some valves will also require a minimum pressure to operate.
Electrical - the solenoid coil will have a fixed supply voltage (AC or DC)
and current.
Response time - this is the time for the valve to fully open/close. Typical
times for valves range from 5ms to 150ms.
Enclosure - the housing for the valve

Logical Actuators
3. Cylinders:
A cylinder uses pressurized fluid or air to

create a linear force/motion as shown in
Figure.
In the figure a compress air is pumped into
one side of the cylinder under pressure,
causing that side of the cylinder to expand,
and advancing the piston.
The compress air on the other side of the
piston must be allowed to escape freely.
Logical Actuators
3. Cylinders:
If the incompressible air was trapped the

cylinder could not advance.
The force the cylinder can exert is
proportional to the cross sectional area of
the cylinder.
Single acting cylinders apply force when
extending and typically use a spring to
retract the cylinder.
Double acting cylinders apply force in both
directions.
Logical Actuators
3. Cylinders:
If the incompressible air was trapped the cylinder could not advance.
The force the cylinder can exert is proportional to the cross sectional area
of the cylinder.
Single acting cylinders apply force when extending and typically use a
spring to retract the cylinder.
Double acting cylinders apply force in both directions.
Logical Actuators
3. Cylinders:
Logical Actuators
4. Motors:
DC motors
Logical Actuators
4. Motors:
Basic Principle of DC Motor
Creation of flux at the rotor.

Accomplish by commutator which is produces the alternating current from dc
supply. Alternating current is used to create flux.
Logical Actuators
4. Motors:
Basic principle of single phase ac motor.
Single phase AC motor is different from three phase because resulting field
did not rotate.
The resulting field only alternate between electromagnet.
It is possible to obtain a single phase squirrel cage induction motor using
an electromagnet connected to a single phase AC power.
Stator Windings for Three Phase Motor

Logical Actuators
4. Motors:
Basic principle of single phase ac motor.
However, when the rotor is turned manually, a torque acts in the direction
of rotation is produced. Motor continues to turn as long as ac power is
supplied to the stator electromagnet. This torque due to rotating magnetic
field that results from interaction of the magnetic field produced by the
stator and rotor (current induced).
Motor continues to turn as long as ac power is supplied to the stator

electromagnet.
This torque due to rotating magnetic field that results from interaction of the
magnetic field produced by the stator and rotor (current induced).
Logical Actuators
5. Electro-hydraulics:
Hydraulic:
Use incompressible fluids to supply very large forces at slower speeds &
limited ranges of motion.
If the fluid rate is kept low enough, many of the effects may be avoided.
The system used hydraulic fluid ( normally oil) pressurized by a pump &
passes through hoses & valves to drive cylinders.
At the heart of the system is a pump that will give pressures up to

hundreds/ thousand of PSI.
These are delivered to a cylinder that convert it to a linear force and

displacement.
Logical Actuators
The word electro-hydraulic has two
meanings for two highly different
operations.
It can stand for an electrical control

device that makes precise adjustments in a
hydraulic system.
Also, it can mean a chemical reaction that

is created by firing short, powerful
electrical impulses into or directly beneath
the surface of a body of liquid.
Hydraulic system components:
Hydraulic fluid Perhaps the most well-known electro-
Oil reservoir hydraulic device is an automobile's power
A pump to move oil & apply pressure steering unit also called an electro-
Pressure line hydraulic actuator.
Control valve- to regulate fluid flow
Piston & cylinder to actuate external
mechanisms.
Logical Actuators
The unit combines high power with a high degree of accuracy to adjust for the minute
movements of the steering wheel in a vehicle.
This type of technology, where electrical components are used to increase the accuracy
of hydraulic movements, can be applied to almost any situation where hydraulics is used.
Logical Actuators
5. Electro-pneumatics:
Pneumatics:
Pneumatic system respond very quickly & are commonly use for low force
applications in many locations on the factory floor.
Pneumatic have much in common with hydraulic systems with few

differences.
The reservoir is eliminate as there is no need to collect and store the air
between uses in the system.
Also, because air is a gas, it is compressible & regulator are not needed to
re-circulate flow.
But the compressibility also means that the systems are not a stiff / strong.
Logical Actuators
Pneumatics:
Basic characteristics of pneumatic system:
1. Stroke from a few mm to meters in length ( longer stroke have >

springiness)
2. Pressure up to 85psi above normal atmosphere.
3. Weight of the cylinders can be quite low.
4. Additional equipment may required for a pressurized air supply linear

rotator actuator are available.
5. Dampers can be used to cushion impact at the ends of cylinders travel
Logical Actuators
The electro-pneumatic action is a control system for pipe organs, whereby air
pressure, controlled by an electric current and operated by the keys of an organ
console, opens and closes valves within wind chests, allowing the pipes to speak.
This system also allows the console to be physically detached from the organ itself.
The only connection was via an electrical cable from the console to the relay, with
some early organ consoles utilizing a separate wind supply to operate combination
pistons.
Logical Actuators
The basic operation of the system is as follows:
1. when the organist selects a stop and depresses a key, an electric circuit is
completed, causing a low-voltage current to flow from depressed key, through
the stop-tab switch, and on through the cable to the electro-pneumatic relay.
2. The relay interprets the command from the console and sends an electric
current to the appropriate solenoid.
3. The solenoid is energized, causing the pipe valve connected to it to open,

which emits compressed air into the pipe, allowing the pipe to speak.
CHAPTER 3
INTRODUCTION TO PLC SYSTEM
BAKISS HIYANA ABU BAKAR

COURSE LEARNING OUTCOMES (CLO)
Explain clearly blocks, parts, components

and instructions found in the automation
systems. (C3)
Construct simple automation sequential

control of hardware or PLC system based
on IEC 61131 and NEMA standards. (C4)
Objective :
1. Understand basic characteristics of PLC

PLC terminologies
PLC function/ background
Type / advantages of PLC
2. Understand building structure of PLC
CPU, memory unit, display and indicator unit, input and output
interface
3. Understand PLC hardware unit
Housing unit, programming unit, power supply unit, printer unit
4. Explain input and output device
Introduction PLC (Programmable Logic Control)
A digital device (microprocessor based controller) that uses a programmable

memory to store instructions and to implement functions such as logic,
sequencing, timing, counting and arithmetic in order to control machines and
processes and has been specifically designed to make programming easy.
PLCs are similar to computers but have certain features which are specific to
their use as controllers:
i. They are rugged and designed to withstand vibrations, temperature,

humidity and noise.
ii. The interfacing for inputs and outputs is inside the controller.
iii. There are easily programmed.
3.1.1 Define PLC
What is Programmable Logic Controller (PLC) ?
Definition: National Electrical Manufacturers Association

US (NEMA)
A PLC is a digital operating electronic apparatus which uses a programmable

memory for internal storage of instruction for implementing specific function
such as logic, sequencing, timing, counting and arithmetic to control through
analog or digital input/output modules various types of machines or process.
3.1.1 Define PLC
An electronic system working digitally for the use in industrial

environment with a programmable memory for the internal storage
of user-orientated control instructions for the implementation of specific
functions.
For example: logic operation control, process control, timer, counting-and

arithmetic functions, in order to control various machines and processes
through digital or analog input , and output variables.
The logic programmable controls as well as the peripheral installations

(PLC-system) are designed so that they can be easily integrated in an
industrial control system and be implemented in all their desired functions.
- International Standard IEC 61131-1
3.1.1 Define PLC
9Several different terms used to described programmable controllers:
i. PLC Programmable Logic Controller (UK origin)

ii. PC Programmable controller (US origin)
9Most referring to the functional operation of the machine.
9PLC has been used in this text to avoid confusion with the personal
computer.
**Before the 1980s, programmable controllers were called PCs.
3.1.2 PLC Background
PLC Development factors:
i. Needs for low-cost

ii. Flexible
iii. Easily commissioned/ smart usage
3.1.2 PLC Historical Background:
The first Programmable Logic Controller (PLC) was developed by a group of

engineers at General Motors in 1968
The company was looking for an alternative to replace complex relay control
systems. The PLC must be:
Must be programmable / Easy to program.(and reprogrammable)

Designed to operate in an industrial environment
Must accept 120 V ac signals from pushbuttons, switches
Outputs must switch and continuously operate loads such as motors
and relays of two amps rating
Not need rewiring the control system if change the program.
Smaller in size, cheaper and high reliability.
Simple construction and low maintenance
Cost- competitive
3.1.3 Explain PLC functions
PLC performs the functions of conventional relays, timers, counters.
Capable of storing instructions, such as sequencing, timing,

counting, arithmetic, data manipulation, and communication, to
control industrial machines and processes.
CONTROL TYPE: FUNCTIONS
i. Conventional Relay Control Logic

Sequence Control replacer
ii. Timers/ Counter
iii. PCB Card controller replacer
iv. Auto/Semi-auto/Manual control of
machine and process.
i. Arithmetic operation (+, -, , )

Advanced/ ii. Information Handling
Sophisticated Control iii. Analog Control (Temperature, Pressure )
iv. P.I.D (Proportional Integral Derivation)
v. Servo Motor Control
vi. Stepper Motor control
CONTROL TYPE: FUNCTIONS
i. Process monitoring and alarm.

Supervisory Control ii. Fault Diagnostic and monitoring
iii. Interfacing with Computer (RS-232C/RS
422)
iv. Printer/ ASCII Interfacing
v. Factory Automation Networking
vi. Local Area Network (LAN)
vii. Wide Area Network (WAN)
viii. Factory Automation (F.A), Flexible
Manufacturing System (F.M.S) &
Computer Integrated Manufacturing
(C.I.M).
3.1.4 List types of PLC
PLC Size:
Small :
- It covers units with up to 128 I/Os and memories up to 2 Kbytes.
- Capable of providing simple to advance levels or machine controls.
Medium :
- Have up to 2048 I/Os and memories up to 32 Kbytes.
Large :
- The most sophisticated units of the PLC family. They have up to
8192 I/O and memories up to 750 Kbytes.
- Can control individual production processes or entire plant.
Types of PLC Construction:
i. Compact PLC
ii. Modular PLC
iii. PLC Plug-in Card
Manufacturer:
OMRON, Allen Bradley, Mitsubishi, NAIS, Siemens,Toshiba, Festo etc.
TECOMAT
Type of PLC - compact TC600
Mitsubishi
Omron
Zelio
Compact PLC MELSEC FX3U

Type of PLC - modular
Omron
Type of PLC - plug in card
3.1.5 Advantages of PLC
Shorter project implementation time.
Easier modification
Project cost can be accurately calculated.
Shorter training time required.
Design easily changed using software ( changes and addition to specifications
can be processed by software.
A wide range of control application
Easy maintenance.
High Reliability
Standardization of Controller hardware.
Able to withstand Harsh plant/process environments (Operate normally under
severe conditions of temperature, humidity, voltage fluctuations and noises).
3.2 Building Structure of PLC
Basic PLC Structure

Data BUS
ROM RAM Output

Input
Microproce
ssor/ CPU
Address Bus
Control Bus
Design of Basic Microcomputer
Basic internal structure of PLC consists essentially of :

-processing unit (CPU)
-memory
-input/output units
3.2.1 Functions and Operation of each Block
a. Central Processing Unit (CPU)
The CPU controls, monitors and supervises all operations within PLC.
It is also caries out programmed instructions stored in the memory.
An internal communications highway also known as a bus system,

carries information to and from the CPU, memory and I/O units under
the control of the CPU.
b. Memory Unit
For storage of programs.
The users ladder logic program, the state of I/O in the memory of PLC.
The main program and the other programs necessary for the operation of
PLC.
The organization of the data and information in the memory is called
memory map.
2 types of Memory
ROM RAM
b. Memory Unit (types of memory):
RAM ROM
Random Access Memory Read Only Memory (read)
This memory can be read from and This memory can be read only
written to.
Storing all users programs Storing all systems program
Entire contents will be lost if power is Memory content remain when the
switched off. power is switched off.
c. Display and Indicator Unit
Referring to PLC standard display Internal Relay:
Consoles LCD Display

if user use Mnemonic Code Programming. LCD Display
Monitor Screen
if user use software programming method.
Monitor Screen
I/O Unit
The I/O Unit is the interface unit has function to convert the input signal and
output signal so that the CPU can communicate with the external apparatus like the switch,
stepping motor, solenoid, sensor, etc. The I/O Unit has two type; Discrete I/O and Analog
I/O.
d. Input Interface Unit

Input Unit:
Function as a medium that connects the external input devices
(Switch, sensor & timer)
e. Output Interface Unit

Output Unit:
Function as a medium that connects the external output devices to the CPU
within PLC.
( Lamp, motor & solenoid )
3.3 PLC Hardware Units
Hardware of the PLC
Hardware of the PLC are only consist of several components; such as

Power Supply Unit, CPU Unit, Memory Unit and I/O Unit.
At the small PLC; Power Supply, CPU, Memory and I/O stay in the same
Unit but at the big PLC; Power Supply, CPU, Memory and I/O in the
separate Unit.
3.3.1 Identify and Describe PLC Hardware Units
Hardware of the PLC
a. Housing Unit
Protect PLC circuit and internal component
b. Programming Unit
Use to process operation and system status that will be display
by PLC.
i. Programming Console
ii. Computer
iii. Video Display Unit (VDU)
iv. Program Loader Unit
v. Output Interface Unit
Programming Unit
Programming Console
Hand-held programming devices are sometimes used to program small PLCs

They are compact, inexpensive, and easy to use, but are not able to display as much
logic on screen as a computer monitor
It is often used on the factory floor for troubleshooting, modifying programs, and
transferring programs to multiple machines
Programming Unit
Computer
A personal computer (PC) is the most commonly used programming device

The software allows users to create, edit, document, store and troubleshoot programs
The personal computer communications with the PLC processor via a serial or parallel
data communications link
3.3.1 Identify and Describe PLC Hardware Units
Hardware of the PLC
c. Secondary Storage Unit
This unit related to CPU where all program and information were kept.
d. Power Supply Unit:

Supplies DC power to the Central Processing Unit, Input Unit and Output
Unit. The most PLC works with power 24 VDC or 220 VAC.
The big PLC has the separate power supply and the small PLC has power
supply which is one.
The Power Supply is also provided by the battery back up, when happened the
failure of power, automatically battery will replace the power supply to supply
the CPU, so that the program of memory user do not lose.
e. Printing Unit
Used to print control system programming that controlled by PLC
whether graphically or text.
3.4 Explain Input & Output Device
3.4.1 Input Devices
PLCs can receive input from either automated or manual devices.

The PLC could receive data from the user via a pushbutton switch,
keyboard, or similar device.
Automated input could come from a variety of devices: micro switches,
timers, encoders, photo sensors, and so on.
Some devices, like the Limit Switch shown below, turn ON or OFF when
the equipment actually makes contact with it.
Other devices, like the Photoelectric Switch and Proximity Switch shown
below, use other means, such as light or inductance, in order to get
information about the equipment being monitored.
3.4.1 Input Device
Input Devices Push Button
Limit Switch
Thumbwheel SW
Level SW
Flow SW
3.4.2 Output Device
3.4.2 Output Devices

A PLC can output to a myriad of devices for use in automated control.
Almost anything that you can think of could be controlled (perhaps
indirectly) by a PLC.
Some of the most common devices are motors, Solenoids, Servomotors,
Stepping Motors, valves, switches, indicator lights, buzzers, and alarms.
Some of these output devices; such as the motors, Solenoids,
Servomotors, Stepping Motors, and valves; affect the controlled system
directly.
Others; such as the indicator lights, buzzers, and alarms; provide output
to notify personnel
3.4.2 Output Device
Output Devices Motor
Solenoid
LED Display
Heater Coil
Lamp
CHAPTER 4:
PLC PROGRAMMING

Course Learning Outcomes (CLO)
1. Explain clearly blocks, parts, components and

instructions found in the automation systems.
(C2)
2. Construct simple automation sequential control

of hardwired or PLC system based on IEC
61131 and NEMA standards. (C4).

Specific Objectives:
After completed this chapter, student will know the major component
Familiarize with the PLC Programming system

Able to explain PLC programming method using Ladder Diagram
and mnemonic code, Instruction set and logic function.
Understand and use Ladder Diagram and mnemonic code to solve
control systems circuits.
Explain the following logic instruction set: Load. Load Not, Out,
And, And Not, Or, Or Not, END, No Operation, And Ld and Or Ld.
Explain sequential instruction set: Interlock, Jump, Keep,
Set/Reset, Move, Shift Register, Arithmetic Function and
Differential Up/Down.
Explain the timer and Counter instruction set and execute
timer/counter application solution methods.
Explain the combination logical function sequence.

4.1 PLC PROGRAMMING SYSTEM
DEFINITION
An activity of planning, building and

executing a program to perform the
tasks required

4.1 PLC PROGRAMMING SYSTEM
Here are the parts that should be there in a PLC program:

4.1.1 Famous PLC Programming Method
IEC 1131-3 is the international standard for programmable
controller programming languages.
The following is a list of programming languages specified by this
standard:
i. Ladder Diagram (LD)
ii. Mnemonic Code
iii. Instruction List/Set (IL)
iv. Function Block Diagram (FBD)
v. Sequential Function Chart (SFC)
vi. Structured Text (ST) /Windows Based program
One of the primary benefits of the standard is that it allows multiple

languages to be used within the same programmable controller.
This allows the program developer to select the language best
suited to each particular task.

i. Ladder Diagram (LD)
Ladder Diagram is kind of graphical programming language that
changed the relay control wiring circuit diagram.
Ladder Diagram contains right and left vertical line to represent
bus bar, for +ve & -ve power line .
The horizontal line connects bus bar is called logic line which
placing of switching elements of n NO & NC and OUTPUT
The combination of switching element is called as Rung
Ladder diagram also shows the control circuit and the display
function and a combination of the sequence of operations for each
branch of the horizontal lines separately.

Graphical diagram of Ladder Diagram

Based on the picture above, one should note that a ladder diagram
consists of two basic parts: left section also called conditional, and a
right section which has instructions.
The pairs of vertical lines along the branch line is called the
conditions. These conditions consist of two, namely:
i. Normally open condition (NO)
ii. Normally closed condition (NC)
When a condition is fulfilled, instruction is executed.

Notes:
Normally open condition is ON if the bit operation is ON and will be
OFF if the bit operation is OFF .
Normally closed condition is ON if the bit operation is OFF and will be
OFF if bit operation is ON.

Comparison between relay wiring and Ladder Diagram
RELAY WIRING LADDER DIAGRAM

ii. Mnemonic Code ADDRESS INSTRUCTION DATA
These instructions can be derived 00000 LD 00000
directly from the ladder logic 00001 OR 00001
diagrams and entered into the PLC 00002 AND 00003

through a simple programming 00003 AND LD
terminal.
00004 OUT 01000
Ladder diagrams can not be read by 00005 TIM 000
the programming Console. #0050
Therefore Ladder Diagrams has to 00006 CNT 002

be converted to mnemonic code that #0010
provides the same information as
Ladder Diagram and can be typed
00007 FUN 01
directly on the console
programming.

iii. Instruction List/Set (IL)
This low-level language is similar to Assembly language and is
useful in cases where small functions are repeated often.
Although it is powerful, it is considered to be difficult to learn.
Example:
Calculate new weight by subtracting tare weight from net weight.

iv. Function Block Diagram (FBD)
FBD is a graphical language that allows programming in other
languages (ladder, instruction list, or structured text) to be nested
within the FBD.
In FBD, program elements appear as blocks which are "wired"
together in a manner resembling a circuit diagram.
FBD is most useful in those applications involving a high degree of
information/data flow between control components, such as process
control.
The main concept is the data flow that start from inputs and passes in
block(s) and generate the output.

v. Sequential Function Chart (SFC)
SFC have been developed to accommodate the programming of
more advanced systems.
These are similar to flowcharts, but much more powerful.
This method is much different from flowcharts because it does not
have to follow a single path through the flowchart.
SFC programming offers a graphical method of organizing the
program. The three main components of an SFC are steps, actions
and transitions.

vi. Structured Text (ST) /Windows Based program
Programming has been developed as a more modern programming
language. It is quite similar to languages such as BASIC and Pascal.
ST is ideal for tasks requiring complex math, algorithms or decision-
making.
Its concise format allows a large algorithm to be displayed on a
single.
Benefits of Structured Text:
People trained in computer languages can easily program control logic

Symbols make the programs easy to understand
Programs can be created in any text editor
Runs as fast as ladder

Example 1
We have Motor that will be controlled manually by 2 push buttons
(Start Push Button, and Stop Push Button).
When the Start Push Button is pushed then the Motor will be turned
ON.
When the Stop Push Button is Pushed then we want to stop the
Motor. (Security logic has been taken off this logic, for the purpose
of demonstration.)

4.1.2 Use ladder diagram and mnemonic codes to solve
control system circuits.
Example1:

Example 2:
00000 00003 01000
instruction
00001
ADDRESS INSTRUCTION DATA

00000 LD 00000
00001 OR 00001
00002 AND 00003
00003 OUT 01000
00004 FUN 01

Example 3:
00000 00002 01000

instruction
00001 00003
ADDRESS INSTRUCTION OPERAND / DATA

00000 LD 00000
00001 OR 00001
00002 LD 00002
00003 OR NOT 00003
00004 AND LD ------
00005 OUT 01000
00007 FUN 01

Basic Terms

1. Execution Conditions
Logical combination of the ON and OFF states gathered to establish
an instruction to be implemented. This condition is called Execution
Condition. Refer to figure below.
Instructions will be in the Execution Conditions ON when IR 00000 is

ON, IR 00001 is OFF and IR 00002 is ON.

DATA AREAS BITS FUNCTIONS
2. Operand Bits IR area Input IR00000 - Used as input bit

area IR00915
Output IR01000 Used as output bit
Bit operations for every area IR01915
instruction can be of any bit
in memory areas of IR, SR, Work
area
IR02000
IR04915
Freely used in a program.
No specific function.
HR, TC or TR. IR20000
IR23115
It shows that conditions in SR area SR22800

SR25515
Bit used as flags and
control bit.
Ladder Diagram can be
decided by I/O bit, flags, TR area TR 0 TR 7 Bit used to store
temporary the ON/OFF
work bits, timers/ counters status at program
etc. junction
HR area HR 0000 HR Bit used to store data and
1915 ON/OFF status when
Table shows the memory power off
map refers to the PLC type
Area for TC 000 TC The same number is used
SYSMAC OMRON-CQM1H Timer/Counter 255 for timer and counter.
TC000 to TC002 used for
`interval timer

3. Logic Block
The respond to an instruction is determined by the relationship
between the conditions on the instruction line that connects them.
Any group of conditions that formed to produce a logical result is

called a logical block.

4. Instruction Block
A block of instruction is composed of all the instructions contained in
a block.
Block is obtained by drawing a horizontal line without cutting a

vertical line and vice versa.

HOW PLC WORKS ?
A PLC works by continually scanning a program with
consisting of 3 important steps

1. SCANNING
Scanning is the process of CPU

2. CHECK INPUT STATUS
First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on?
How about the second input? How about the third... It records this
data into its memory to be used during the next step.
3. EXECUTE PROGRAM
Next the PLC executes your program one instruction at a time.
Maybe your program said that if the first input was on then it should
turn on the first output.
4. UPDATE OUTPUT STATUS

Finally the PLC updates the status of the outputs. It updates the
outputs based on which inputs were on during the first step and the
results of executing your program during the second step.

4.2 BASIC LOGIC INSTRUCTION SET
There are a lot of instructions used to

develop the PLC program.
Each instruction has a respective function.

4.2.1 Basic Logic Instruction
a) Load (LD):
These instructions are use to start a line of the program.
It is used in the first contacts in the normally open
condition (NO).
Ladder Diagram Mnemonic Code
Address Instruction Operand/Data

00000 01000
OUTPUT 00000 LD 00000
00001 OUT 01000
Explanation:
The Execution Conditions of the instruction on the right will be ON
when IR 00000 is ON.

Load Not (LD Not):
These instructions are use to start a line of the program.
It is used in the first contacts in the normally closed
condition (NC).
00000 01000 address Instruction Operand/Data
output 00000 LD NOT 00000
00001 OUT 01000
Explanation
when IR 00000 is OFF

b) And (AND):
These instructions are used in the second contact in a normally
open (NO) and a series with previous contacts
00000 00001 01000

Alamat Arahan Operand/Data
output 00000 LD 00000
00001 AND 00001
00002 OUT 01000
Explanation
when IR 00000 and IR 00001 are ON

And Not (AND NOT):

closed (NC) and in series with previous contacts
Address instruction Operand/Data

00000 00001 01000
output 00000 LD 00000

00001 AND 00001
00002 OUT 01000
Explanation
when IR 00000 ON and IR 00001 are OFF.

c) Or (OR):
open (NO) and in line (parallel) with previous contacts.
00000 01000 address instruction Operand/Data

output
00000 LD 00000
00001 OR 00001
00001
00002 OUT 01000
Explanation
when either IR 00000 or IR 00001 are ON.

Or Not (OR NOT):
closed (NC) and in line (parallel) with previous contacts.

00000 01000 Address instruction Operand/Data
OUTPUT 00000 LD 00000
00001 OR NOT 00001
00001 00002 OUT 01000
Explanation
The Execution Conditions of the instruction on the right will be ON when
either IR 00000 is ON or IR 00001 is OFF or IR 00000 ON, IR 00001
OFF simultaneously

d) Out (OUT):
These instructions are used for the coil output.

00000 01000 address instruction Operand/Data
00000 LD 00000
00001 OUT 10000
IR 10000 will ON when IR 00000 is ON .

e) END (FUN (01):
END instruction has no physical contact device.
It is the last instruction required for completion of a program.
If no END instruction, the program cannot be implemented
address instruction Operand/Data
01000
00000 00001
00000 LD 00000
00001 AND NOT 00001
00002 OUT 01000
END
00003 FUN 01
For PLC type OMRON - SYSMAC CQM1H, the instruction FUN 01 is the
END instruction.

f) And Load (AND LD):
The AND LD no physical contact device.
Only a programming tool for solving complex functions such as
AND connects a number of OR, OR NOT, OR LD in the series.

o AND LD instruction is used to connect parallel blocks in series.
o Example:

o The AND LD instruction must be used if the element or serial block
is in front of the parallel block.
o If the parallel block is in front of the element or serial block, AND
instruction can be used to connect all parts together.
o Example:

Example AND LD:
o Remark: If there are more than two blocks are to be connected
serially, they should be connected in a top to bottom sequence.
o For example, block 1 and 2 should be connected first, then connect
block 3 to it and so on.

g) OR load (OR LD):
The OR LD instruction has no physical contact device.
Only a programming tool for solving complex OR function as a series
of contacts LD (or LD NOT), in parallel with a series of other
contacts.

Example OR LD:
o RemarkIf more than two blocks are to be connected in parallel, they
should be connected in a top to bottom sequence.
o For example, block 1 and block 2 should be connected first, then
connect block 3 to it and so on.

OR LD and AND LD:
When both logic block instruction is to be used in Ladder Diagram,
a program must be written from the bottom up to merge logic
blocks.
For example, ladder diagram below:
Logic block of instruction for the last two blocks (blocks b1 and b2
blocks) are written first and then followed by the first logic block
instruction (block a).

h) No operation (NOP):
These instructions do not have a ladder diagram symbols and will
not do any operations.
When you remove the memory in this instruction will be displayed

on the console screen PLC programming.

De-composition of a network
The key process of de-composition of a network is to separate the
circuits that appear between two vertical lines into independent elements
and serial blocks, then coding those elements and serial blocks
according to the mnemonic coding rules and then connect them (with
ANDLD or ORLD instruction) from left to right and top to bottom to form a
parallel or a serial-parallel blocks, and finally to form a complete network.
Sample diagram:

A systematic approach of Control System Design
using A PLC
1. Determine the machine sequence of operation.

2. Assignment of input & output.
3. Writing the program / construct ladder diagram.
4. Convert to mnemonic code.
5. Running the system.

Example Approach of Control System Design:
Design the following sequences:
A grind machine need to be continuously function when ON button,
S1 is pressed and only OFF when stop button, S2 is pressed.
STEP 1: The machine sequence:

The activity The sequence
S1 ; ON Motor, M1 ; ON
S2 ; ON Motor, M1 ; OFF
STEP 2: I/O assignment:

Input Description Output Description
00001 S1 01001 M1
00002 S2

STEP 3: Ladder Diagram:
00001 00002 01001
S1 S2
M1
M1
01001
END
STEP 4: Mnemonic code:

Address Instruction Data
00000 LD 00001
00001 OR 01001
00002 AND NOT 00002
00003 OUT 01001
00004 FUN(01)

4.3 SPECIAL SEQUENTIAL INSTRUCTION SET
A sequence of instructions which usually acts as the last instruction
in the instruction line.
Instruction sequence SET, RESET, KEEP, DIFFERENTIATE UP,

DOWN DIFFERENTIATE, used to ON and OFF state output bits in
the IR. These instructions are used to control the status of the other
bits in the IR or in other areas.
INTERLOCK instruction sequences can overcome the problem of

storing execution conditions, in the branches of the ladder diagram.
JUMP instruction sequence can be used to control devices that

require a product that can last a long time.

a) Keep (FUN (11)):
KEEP instruction is used to maintain the status bit operation based on
two state execution condition.
KEEP (11) operates like a Latching Relay which is set by S and reset
by R.
When S is in the ON state, the operation of a particular product

instruction is ON and remain ON until reset, regardless of whether S is
ON or OFF.
When R is in the ON state, the operation of a particular product

instruction is OFF and remain OFF until reset, regardless of whether R
is ON or OFF.
For PLC type OMRON - SYSMAC CQM1H, the instruction FUN 11 is

KEEP instruction.
Ladder Diagram shows KEEP instruction
Explanation
o Instruction LD 00 002 acts as S (Set)-and the LD 00 003 acts as R
(Reset).
o When the instruction LD 00 002 ON, the output instruction OUT 10004
will be ON and will remain ON even if the instruction LD 00 002 is OFF.
o When the instruction LD 00 003 ON, then the output OUT 10004
instruction OFF and will remain OFF even though the instruction LD 00
002 in OFF or ON state.

Ladder Diagram shows KEEP Operation table
instruction
00002
00003
HR000
01004
Timing diagram
b) Set/Reset (SET/RESET):
SET and RESET instruction will change the status of bit operations
only when the implementation is ON.
In the OFF condition, the instructions will not change the bit
operation status.
Ladder Diagram shows the Set and Reset instruction

Mnemonic Code
Explanation
When the input instruction LD 00 000 is ON, SET instruction
command to ON and always ON regardless of whether the input
instruction LD 00 000 is ON or OFF.
When the inputs instruction LD 00 001 is ON, RESET instruction is

ON and SET instruction will be off .
Its operations can be understood clearly in the KEEP instruction.

c) Jump (FUN(04)) & Jump End (FUN (05)):
Instructions JMP (04) is usually used in pairs with the command JME
(05) for the jump.
JMP (04) is a command to determine the starting point of the jump

and JME (05) is the instruction that the direction of the jump.( where
to jump).
When the instruction JMP (04) is ON, no jump will occur and the
program will be implemented as written.
When the instruction JMP (04) is OFF, a jump to the instruction JME
(05) which has the same number will be done. Further instructions
are the instructions JME (05) will be implemented.

o Instructions JUMP and JUMP END can use the numbers from the
range of 00 to 99.
o To set the instruction for PLC type OMRON - SYSMAC CQM1H, is

FUN 04 for JUMP instruction and FUN 05 instruction is the JUMP
END instruction.
Ladder Diagram shows JUMP instruction

Mnemonic Code
Explanation
o When the input instruction LD 00000 is ON, instruction JMP (04) will
be ON. Subsequent instructions will be implemented as written.
o If the input instruction LD 00 001 is ON, output instruction OUT

10000 will be ON.
o If the input instruction LD 00 001 is OFF, output instruction OUT

10000 will be OFF.

00000
00001
01000
Operation table
Timing diagram
o When the input instruction LD 00 000 is OFF, instruction JMP (04)
will be OFF. Next jumps to Instruction JME (05) will occur.
o All instruction that is between JMP (04) and JME (05) will be
ignored.
o Refer to the table above.

d) Interlock (FUN (02)) & Interlock Clear (FUN (03)):
IL (02) and ILC (03) must be used together.
These instructions are used to solve the problem of storing execution

conditions at branch points.
When the INTERLOCK instruction is ON as shown in Ladder

Diagram, the implementation of the INTERLOCK instruction will
control all of the instruction execution until the instruction
INTERLOCK CLEAR.
When the INTERLOCK instruction is OFF, INTERLOCK CLEAR

instruction will reset the program operation.

To set the INTERLOCK instruction for PLC type OMRON - SYSMAC
CQM1H is FUN 02 for INTERLOCK instruction and FUN 03 is
INTERLOCK CLEAR instruction.
0000
00001
1000
T1 T2 T3 T4
Timing diagram
Ladder Diagram shows IL ( 02 ) dan
ILC ( 03 )

Mnemonic Code
Explanation
When the instruction input LD 00 000 is ON, the instruction IL (02)

will be ON.
Instruction output OUT 10 000 will depend on the instruction input
ON LD 00001 and LD 00000.
If the input instruction LD 00 001 ON, output OUT 10000 will be ON.
If the input instruction LD 00 001 OFF, output OUT 10000 will be
OFF.

Refer the table below:
In the event that the input instructions LD 00 000 OFF, instruction IL

(02) is OFF.
Instructions to the output OUT 10 000 will be OFF.
Next program ILC (03) will reset the program.

e) Differentiate Up (FUN (13))/Down (FUN (14)):
DIFU instructions (13) and DIFD (14) will ON the output within a very
short time.
Instructions DIFU (13) will turn the output to ON when the input
signal changes from OFF to ON.
Instructions DIFD (14) will turn the output to ON when the input
signal changes from ON to OFF.
For PLC type of OMRON - SYSMAC CQM1H, instruction FUN 13 is

instruction DIFFERENTIATE UP and FUN 14 is instruction
DIFFERENTIATE DOWN.

Ladder Diagram shows
DIFFERENTIATE UP instruction Mnemonic Code
01001
0000
01000
01001
T1 T2 T3 T4
Referring to Ladder Diagram,

o When the input instruction LD 00000 is ON (has changes from OFF to ON),
operand bit 01 000 will be ON, the output OUT 10000 will be ON within a very
short time and then OFF.
o We can not see the situation in the products.
o After that the operand bit 01 000 will be OFF regardless of the status of the
input instruction LD 00 000.
Ladder Diagram shows the
DIFFERENTIATE DOWN instruction Mnemonic Code
01001
0000
01000
01001
T1 T2 T3 T4

When the input instruction LD 00 000 is OFF (change from ON to OFF),
operand bit 01000 will be ON, the output OUT 10000 will be ON within a
very short time and then OFF.
We can not see the situation in the products.
After that the operand bit 01000 will be OFF regardless of the status of the
input instruction LD 00 000.
f) Move (FUN (21)):
MOVE instruction copy data from source channel to destination
channel.
IR is the memory areas that can be used for MOVE instruction.
To set the instruction for PLC type OMRON - SYSMAC CQM1H,
FUN (21) is instruction for MOVE.
Symbol:
Ladder diagram:

Mnemonic code:

When the input instruction LD 00000 ON, all data in IR000 will be
copy into IR100.

g) Shift Register (SFT (10)):
Shift Register ( SFT ) move 16 bit data, bit by bit which are 1 or 0 in a
certain channel.
Each bit 1 or 0 represent 1 condition.
Symbol:
SFT ( 10 ) control by three execution condition which are DI , CP and

R.
S and E must in the same memory area such as IR, SR, AR, HR or
LR.

S is at right side of the shift register and E is at left side of the adalah
shift register.
If DI is ON, ` 1 will be move into the register.
If DI is OFF, ` 0 will be move into the register.
When DI move into register, all original bit in the register will be move
to the left.
The last left side bit will be delete.
When R is ON, it will RESET the operation and all bit in the register
will change to 0.
Data
being
delete

Ladder diagram:
Mnemonic code:

h) Arithmetic Function:
SET CARRY STC (40) FUN(40):
Symbol:
If the execution condition OFF, instruction STC ( 40 ) will not function.
If execution condition ON, instruction STC ( 40 ) will ON carry ( Cy ).
SR25504 is carry flag that will ON if carry occur in execution condition.
To set the instruction for PLC type OMRON - SYSMAC CQM1H, FUN
(40) is instruction for SET CARRY.

CLEAR CARRY CLC (41)- FUN (41):
Symbol:
If the execution condition OFF, instruction CLC ( 41 ) will not function.
If the execution condition ON, instruction CLC ( 41 ) will OFF

Cy ( SR25504 ).
CLEAR CARRY use to reset Cy ( 25504 ) to `0.
(41) is instruction for CLEAR CARRY.

ADD ADD(30)- FUN (30):
Symbol:
Instruction ADD is use to add data from two different channel and the
total result will be store in the third channel.
The three channel are:
Augend Channel ( Au )
Addend Channel ( Ad )
Result Channel ( R ).
The range of number for Au dan Ad are # 0000 to # FFFF.
(30) is instruction for ADD ( 30 ).

ADD process:
Result will be store in R.

Cy will be set if the result > # 9999.
Ladder diagram: Mnemonic code:
Refer to ladder diagram:

o Instruction CLC ( 41 ) will reset Cy to ` 0 .
o 21600 to 21915 is bit that dont have any specific
function, so can be freely use.
o ADD result will be store at IR100.

EXAMPLE 1:

EXAMPLE 2:

SUBTRACT SUB ( 31 )- FUN (31):
Symbol:
Instruction SUB is to find the different between 2 data from 2 different

channel and the result will be store in the third channel.
The three channel are:
Minuend ( Mi )
Subtrahend ( Su )
Result ( R ).
The range of number for Mi dan Su are # 0000 to # FFFF.
(31) is instruction for SUBTRACT (31)

SUBTRACT process:
Ladder diagram: Mnemonic code:

EXAMPLE 1:

COMPARE CMP ( 20 )- FUN (20):
Symbol:
Instruction CMP use to compare 2 data from 2 different channel.
(20) is instruction for COMPARE (20).
The COMPARE result can be either one of the three condition:

Greater than (GR)
Less than (LE)
Equal to the data (EQ)

Address for COMPARE instruction:
Ladder diagram:

Mnemonic code: Compare Result:
Refer to ladder diagram:

o 10 will be compare with 5.
o Result: 10 > 5.
o So, OUT 10000 will ON
Explanation:
TR use to temporary store the status ON/OFF at the instruction
branch. Bit TR are from TR0 until TR 7.
When instruction LD 00000 ON, instruction CMP ( 20 ) will execute.
Instruction COMPARE will compare the value in C1 with the value
in C2. Refer to the table above.

4.3.2 Build program using special sequential instructions set
EXAMPLE 1:
A burglar alarm is activated by N.O push button, placed on a door, D1
and window, W1.
When the alarm is armed and a door or window is opened, the alarm
will trigger ON.
The only way to turn OFF the alarm is by disable the power supply or
hit the reset button, S1.
Draw the PLC ladder diagram and write the mnemonic code to
execute the control action.

4.4 TIMER & COUNTER INSTRUCTION
TIMER (TIM) and COUNTER (CNT) is the instructions that require

numbers TIM / CNT (N) and the set value(SV).
The range of numbers TIM / CNT is from 000 to 255, while the range
of set values for the TIM / CNT is #0000 to #9999.
The numbers TIM / CNT can not be used twice. When a number has
been used as definer, such as number 000 for instructions on TIM /
CNT, the number can not be used again.
When a number is defined as the number of TIM / CNT, it can be

used as often as required as an operator operand in other
instructions from the command TIMER or COUNTER.

4.4.1 Timer Instruction Set
Symbol:
Timer numbers (N) is between 000 and 255.

The set value (SV) is between 0000 to 9999.
All numbers TIM / CNT can be used as definer in only one TIMER
or COUNTER instruction.
TIMER is enabled/activated when the execution condition is ON
and will be reset to set value (SV) when the execution condition is
OFF.
The set value (SV) of TIMER is the BCD between # 0000 to # 9999.
For example, if TIMER be set to 5 seconds, then the set value (SV)
is # 0050.

4.4.2 Timer Application Solution Method

Example 1:
Operating Condition:
When the input (LD 00000) is ON, the timer contact will be activated
after 5 seconds.
Next, the output (OUT 10000) will be ON.
0000
5 sec
TIM000
1000
T1 T2 T3 T4
Timing diagram
Example 2:
When the input (LD 00000) ON, the timer (TIM 000) will be activated
after 5 seconds and the output (OUT 10000) will be ON.
While the output (OUT 10 001) will be ON as soon as the supply is
supplied and will be OFF after 5 seconds.
Timer will continue to be active as long as the input 00000 state is ON.

Example 3:
When the input (LD 00000) ON, the timer (TIM 000) will be activated after 5
seconds. Next the output (OUT 10000) will be ON.
After 3 seconds the output (OUT 10000) ON, the timer (TIM 001) will be
activated the next output (OUT 10000) will be OFF and the timer (TIM 001) will
be OFF.
When the timer TM001 OFF, contact TIM 001 (NC) will be ON and the output
(OUT 10000) is ON state.
Output (OUT 10000) will continue ON and OFF until the input (LD 00000) in the
OFF state.
4.4.3 Counter Instruction Set
Symbol:
Number TIM / CNT can be used as definer for either timer or

counter.
Counter numbers are range from 000 to 255.
Counters are used to calculate the count down from the set value
(SV) on the execution condition on the counting pulse (CP) when it
is changed from OFF to ON.
The set value (SV) is range 0000 to 9999.
Counters will reset to the reset (R).

4.4.4 Counter Application Solution Method

Example 1:
Operating Condition
Counter set to count 10. When the input (LD 00,000) is the pulse of
ten, a counter will be activated and thus the output (OUT 10000) will
be ON.
When reset (LD 00,001) ON, a counter will be in original condition

Timing Diagram:
0000
0001
CNT 001
1000

4.5 COMBINED LOGICAL FUNCTION SEQUENCE
The Application Of Timer And Counter Instructions:
The number of Counter cannot be the same number to the number
of timer because both share the same data in the PLC memory.
Ladder diagram:
o Counter set to count 5. When the
input (LD 00,000) is the pulse of five, a
0001 counter will be activated and thus the
output (OUT 10000) will be ON.
o When the output (OUT 10000) ON,
TIM 001 will be activated after 5 seconds
and then the output (OUT 10 001) will be
ON.
o Both the output (OUT 10000) and
(OUT 10 001) will always be ON until
reset (LD 00001) in the ON state.
o Reset will return the counter to its
original condition.
Timing Diagram:
0000
0001
CNT 000
TIM001 5 SEC
5 SEC
1000
1001
5 SEC 5 SEC

EXAMPLE 1 (Timer And Counter Instructions)
The carrier is moved by the forward/reverse motor. The initial position of the
carrier is the left position indicated by the limit switch S4. When the start push
button, S1 is pressed (then release), the carrier will be loaded with 5 pieces of
product, which is sense by photo sensor S3 before it moves to the right until it
touches the right limit switch S5, the automatic carrier will halt for 5 seconds
before it reverse to the left. Once it touches S4, the carrier stop until it is
sufficiently loaded. Then it starts conveying again. The stop button, S2 stops the
motor regardless of which direction it is turning.
Study the description as given. Then design a ladder diagram and mnemonic
code by applying Five (5) sequences of programming method.
Sensor (S3) Conveyor

Start ( S1)
belt
Stop (S2)
LS1 LS2 (S5)

carrier
carrier
(s4)
A B

M1
M2
EXAMPLE 2:
Design a program that will monitor & control the conveyor system for
material testing while adhering the following criteria:
The start button will be used to start the conveyor.

The stop button will be used to stop the conveyor if emergency
occur.
2 sensor which are inductive sensor and through beam sensor.
The conveyor will halt at through beam sensor when material
available for 5 seconds.
If there is non-metal material, the conveyor will continue to run.
If there is metal material, the conveyor will halt again at inductive
sensor for 10 seconds.

CHAPTER 5
APPLICATION IN THE
INDUSTRY
COURSE LEARNING OUTCOME:
Explain clearly blocks, parts, components and
instructions found in the automation systems.
Construct simple automation sequential control

of hardwired or PLC system based on IEC
61131 and NEMA standards.
Objective :
Understand several practical examples of PLC application in
the industry:
i- Develop and assemble conveyor motor control program.
ii- Determine and execute selection of material handling
systems (part sorting).
iii- Determine and execute Package Control System.
iv- Develop and assemble Simple Traffic Light control
program.
v- Analyze and execute Loading and Unloading.
vi- Recognize other related examples
5.1.1 DEVELOP AND ASSESBLE CONVEYOR MOTOR
CONTROL PROGRAM
OPERATION:
In this application, the PLC used to start and stop the motors of a segmented
conveyor belt. This allows only belt sections carrying an object (i.e. metal
plate ) to move.
The position of a metal plate is detected by a proximity switch located next to
each belt segment.
As long as the plate is within the detecting range of the switch, the motor will
work.
If the plate moves beyond the range, a timer is activated and when this set
time has lapsed, the motor of and the belt stops.
1. Operation sequence:
Motor 2 is ON when the sensor 3 detects the objects.
Motor 2 will be OFF when the motor 1 is ON and the object was
outside the range of sensor 2.
Motor 1 will be ON after sensor 2 detects the objects.
Motor 1 will be OFF when the object was outside the range of
sensor 1.
2. I/O table:
Input Description Output Description
00000 Sensor 1 ( S1 ) 01000 Motor 1 ( M1 )
00001 Sensor 2 ( S2 ) 01001 Motor 2 ( M2 )
00002 Sensor 3 ( S3 ) 01002 Motor 3 ( M3 )
3. Ladder Diagram 4. Mnemonic Code
Address Instruction Data
00000 LD 00002
00001 OR 01001
00002 ANDNOT TIM000
00003 OUT 01001
00004 LD 00001
00005 OR 01000
00006 ANDNOT TIM001
00007 OUT 01000
00008 LD 01000
00009 ANDNOT 00001
00010 TIM 000
#0020
00011 LD 00000
00012 0R 20000
00013 ANDNOT TIM001
00014 OUT 20000
00015 LD 20000
00016 ANDNOT 00000
00017 TIM 001
#0020
00018 LD 25313
00019 OUT 01002
00020 FUN 01 Page 6 of 23
5.1.2 MATERIAL HANDLING SYSTEM (PORT SORTING)
OPERATION:
1. In this application, effective
products are detected and
rejected those being carried on
the conveyor.
2. Photoelectric sensor (PH1)
serves as the data input to the
shift register. The signal output
from this sensor turns ON when
a defective product has been
detected, otherwise it remains
OFF.
3. Photoelectric sensor (PH2) is used as a clock generator that serves as the
close input to the shift register. It generates one pulse each time the
product spaced at a fixed interval from each other, has traveled a
predetermined distance.
4. From the moment a defective product is detected by PH1, it is traced by the
shift register until the product arrives at the predetermined position on the
conveyor where it is ejected by the magnetic valve (MV).
3. Ladder diagram
4. Mnemonic Code
5.1.3 PACKAGE CONTROL SYSTEM
OPERATION:
1. When Start Push Button (PB1) is pressed, the box conveyor moves.
2. Upon detection of box present (SE2), the box conveyor stops and the apple
conveyor starts.
3. Part sensor (SE1) will count 10 apples.
4. Apple conveyor stops and box conveyor start again.
5. Counter will reset and operation repeats until Stop Push Button (PB2) is
pressed.
1. Operation Sequence:
PB1 : ON ; M2 : ON
SE2 : ON ; M2 : OFF, M1 : ON
SE1 : ON ; CNT000 : ACTIVATE, #0010
CNT000 : ON ; M2 : ON, M1 : OFF
2. I/O table:
Input Device
00000 Push Button ( PB1 )
00001 Stop Button ( PB2 )
00002 Part Sensor ( SE1 )
00003 Box Sensor ( SE2 )
Output Device
01000 Apple Conveyor (M1)
01001 Box Conveyor (M2)
3. Ladder diagram: 4. Mnemonic Code:
00000 LD 00000
00001 OR 20000
00002 ANDNOT 00001
00003 OUT 20000
00004 LD 20000
00005 OR 01001
00006 ANDNOT 01000
00007 OUT 01001
00008 LD 00003
00009 ANDNOT CNT000
00010 OUT 01000
00011 LD 01000
00012 AND 00002
00013 LD 00003
00014 CNT 000
#0010
00015 FUN(01)
5.1.4 SIMPLE TRAFFIC LIGHT CONTROL
PROGRAM
OPERATION:
1. Figure above show a traffic light system that install in under renovation 2
way roadway
2. 2 traffic light were install in both side of the road in opposite direction to
control the traffic.
3. The traffic light will operate alternately. When L1 goes GREEN, L2 will goes
RED and vice versa.
4. Each light will ON for 30 second.
1. Operation Sequence: 2. I/O Table:
OUTPUT DESCRIPTION
01000 TrafficLight2(G2)
01001 TrafficLight2(R2)
01002 TrafficLight1(G1)
01003 TrafficLight1(R1)
3. Ladder Diagram: 4. Mnemonic Code:
00000 LDNOT TIM001

00001 TIM 000
#0300
00002 LD TIM000
00003 TIM 001
#0600
00004 LDNOT TIM000
00005 OUT 01000
00006 LDNOT 01000
00007 OUT 01001
00008 LD 01001
00009 TIM 002
#0150
00010 LD TIM002
00011 TIM 003
#0300
00012 LD TIM002
00013 ANDNOT TIM003
00014 OUT 01002
00015 LDNOT 01002
00016 OUT 01003
00017 FUN(01)
5.1.5 LOADING & UNLOADING
OPERATION:
1. As the push button (PB1) is
pressed, MV1 open and the
water will begins to fill the tank.
At the same time, the stirring
motor (M) starts operations.
2. When the water passes Lower
level sensor (TLB2) and
reaches Upper level sensor
(TLB1), the MV1 valve will
close and the stirring motor will
stop.
3. Next, MV2 valve will opens and start draining the water. When the
water levels drops below TLB2, MV2 valve closes.
4. When the cycle of operations has repeated four (4) times, the
operation END indicator (LI) illuminates and the filling and draining
operation will not restart even if PB1 is pressed.
1. Operation Sequence: 2. I/O table:
PB1 : ON ; MV1 : ON Input Device

M : ON 00000 Push Button ( PB1 )
TLB1 : ON ; MV1 : OFF 00001 Stop Button ( PB2 )
TLB2 : ON M : OFF
00005 Upper Tank Limit (TLB1)
MV2 : ON
TLB2 : OFF ; MV2 : OFF 00006 Lower Tank Limit (TLB2)
CNT047 : Output Device
ACTIVATE 01000 Input Motor Valve (MV1)
#0004
01001 Output Motor Valve (MV2)
CNT047 : ON ; ALL STOP
PL : ON 01002 Stirring Motor (M)
PB2 : ON ; ALL STOP / 01004 Level Indicator (PL)
RESET
3. Ladder Diagram: 4. Mnemonic Code:
00000 LD 00000
00001 OR 01000
00002 ANDNOT 01004
00003 ANDNOT 01001
00004 OUT 01000
00005 LD 01000
00006 OUT 01002
00007 LD 01000
00008 AND 00005
00009 OR 01001
00010 AND 00006
00011 OUT 01001
00012 LD 01001
00013 LD 00001
00014 CNT 047
#0004
00015 LD CNT047
00016 OUT 01004
00017 FUN(01)
5.1.6 OTHERS RELATED EXAMPLES
Sample of how PLCs are being used in industry.
AUTOMOTIVE
i- Monitoring Automotive Production Machines:
The system monitors total parts, rejected parts, parts produced,

machine cycle time, and machine efficiency. Statistical data is available
to the operator anytime or after each shift.
ii- Power Steering Valve Assembly and Testing:
The PLC system controls a machine to ensure proper balance of the

valves and to maximize left and right turning ratios.
CHEMICAL AND PETROCHEMICAL
i- Dyes:
PLCs monitor and control the dye processing used in the textile
industry. They match and blend colors to predetermined values.
ii- Chemical Batching:

The PLC controls the batching ratio of two or more materials in a
continuous process. The system determines the rate of discharge of
each material and keeps inventory records. Several batch recipes can
be logged and retrieved automatically or on command from the
operator.
iii- Fan Control:

PLCs control fans based on levels of toxic gases in a chemical
production environment. This system effectively removes gases when
a preset level of contamination is reached. The PLC controls the fan
start/stop, cycling, and speeds, so that safety levels are maintained
while energy consumption is minimized.
GLASS PROCESSING
i- Glass Batching:
PLCs control the batch weighing system according to stored glass
formulas. The system also controls the electromagnetic feeders for in
feed to and out feed from the weigh hoppers, manual shut-off gates,
and other equipment.
ii- Batch Transport:

PLCs control the batch transport system, including reversible belt
conveyors, transfer conveyors to the cullet house, holding hoppers,
shuttle conveyors, and magnetic separators. The controller takes action
after the discharge from the mixer and transfers the mixed batch to the
furnace shuttle, where it is discharged to the full length of the furnace
feed hopper.
MANUFACTURING/MACHINING
i- Production Machines:
The PLC controls and monitors automatic production machines at high
efficiency rates. It also monitors piece-count production and machine
status. Corrective action can be taken immediately if the PLC detects a
failure.
ii- Transfer Line Machines:

PLCs monitor and control all transfer line machining station
operations and the interlocking between each station. The system
receives inputs from the operator to check the operating conditions
on the line-mounted controls and reports any malfunctions. This
arrangement provides greater machine efficiency, higher quality
products, and lower scrap levels.
MANUFACTURING/MACHINING
iii- Wire Machine. The controller monitors the time and ON/OFF
cycles of a wiredrawing machine. The system provides ramping
control and synchronization of electric motor drives. All cycles are
recorded and reported on demand to obtain the machine's efficiency
as calculated by the PLC.
iv- Paint Spraying. PLCs control the painting sequences in auto

manufacturing. The operator or a host computer enters style and color
information and tracks the part through the conveyor until it reaches
the spray booth. The controller decodes the part information and then
controls the spray guns to paint the part. The spray gun movement is
optimized to conserve paint and increase part throughput.
THANK YOU
&
GOOD LUCK
6.0 SELECTING, INSTALLING,
MAINTENANCE &
TROUBLESHOOTING PLC SYSTEM
INTRODUCTION
After the planning phase of the design, the equipment can be ordered. This decision
is usually based upon the required inputs, outputs and functions of the controller. The
first decision is the type of controller; rack, mini, micro, or software based. This
decision will depend upon the basic criteria listed below.
Number of logical inputs and outputs.

Memory - Often 1K and up. Need is dictated by size of ladder logic program. A ladder
element will take only a few bytes, and will be specified in manufacturers documentation.
Number of special I/O modules - When doing some exotic applications, a large number of
special add-on cards maybe required.
Scan Time - Big programs or faster processes will require shorter scan times. And, the
shorter the scan time, the higher the cost. Typical values for this are 1 microsecond per
simple ladder instruction
Communications - Serial and networked connections allow the PLC to be programmed
and talk to other PLCs. The needs are determined by the application.
Software - Availability of programming software and other tools determines the
programming and debugging ease.
INTRODUCTION
The process of selecting a PLC can Support while troubleshooting
be broken into the steps listed below. Shipping times for emergency
replacements
1. Understand the process to be Training
controlled The track record for the company
List the number and types of inputs Business practices (billing,
and outputs. upgrades/obsolete products, etc.)
Determine how the process is to be
controlled. 3. Plan the ladder logic for the
Determine special needs such as controls.
distance between parts of the
process. 4. Count the program instructions
and enter the values into the
2. If not already specified, a single sheets. Use the instruction times
vendor should be selected. Factors and memory requirements for each
that might be considered are : instruction to determine if the PLC
Manuals and documentation has sufficient memory, and if the
Support while developing programs response time will be adequate for
The range of products available the process.
INTRODUCTION
6.1 EXPLAIN PLC SELECTION PROCEDURE
6.1.1 Define input/output capacity:
The number of connection terminal at PLC I/O unit
Including local expansion & I/O network.
The total of Discrete vs Analog
Input / Output Unit Specifications
INPUT UNIT
TYPES NO. MODEL CAPASITY
CQM1-ID211 8 points
DC Input CQM1-ID212 16 points
CQM1-ID213 32 points
AC Input CQM1- IA121 8 points
CQM1-IA221 8 points
OUTPUT UNIT
TYPES NO.MODEL CAPASITY
Relay Output CQM1-OC211 8 points
Units CQM1-OC222 16 points
Transistor Output CQM1-OD211 8 points
Units CQM1-OD212 16 points
CQM1-OD213 32 points
CQM1-OD214 16 points
CQM1-OD215 8 points
Page 5 of 61
AC Output Unit CQM1-OD221 8 points
6.1.2 Define types of input / output:
Every programmable logic controller must have some
means of receiving and interpreting signals from real-world
sensors such as switches, and encoders, and also be able
to effect control over real-world control elements such as
solenoids, valves, and motors.
This is generally known as input/output
To select the I/O, must know;
Types of supply connected? AC/DC
Switching technique? Relay(normal
condition)/Transistor(fast condition)/ AC(High voltage)
The I/O Unit has two type;
i- Discrete I/O:
ii- Analog I/O http://modul2poli.blogspot.com/ Page 6 of 61
i- Discrete I/O:
A discrete data point is one with only two states on & off.
Digital I/O modules have digital I/O circuits that interface

to on/off sensors such as push-button and limit switches
and on/off actuators such as motor starters & pilot lights
Digital I/O modules cover electrical ranges from 5 to 276 V

AC or DC, and relay contact output modules are available
for ranges from 0 to 276 V AC or 0 to 175 V DC.
ii- Analog I/O
Analog I/O modules perform the required A/D and D/A
conversions using up to 16-bit resolution.
A range of analog signal levels can be accommodated,

including standard analog inputs and outputs and direct
thermocouple and RTD temperature inputs
Analog I/O is commonly available for modular PLCs for

many different analog signal types, including:
Voltage (0 to 10 volt, 0 to 5 volt)
Current (0 to 20 mA, 4 to 20 mA)
Thermocouple (mV)
RTD (mV)
Strain gauge (mV) http://modul2poli.blogspot.com/ Page 8 of 61
6.1.3 Define memory size:
The ability to store a program in the PLC.

1K, 6K, 8K, 12K, 14K
No. Model Memory size

CQM1-CPU11-E 3.2 K-word Program Memory
CQM1-CPU21-E 1K-word Data Memory
CQM1-CPU41-E
CQM1-CPU42-E 7.2 K-word Program Memory
CQM1-CPU43-E 6K-word Data Memory
CQM1-CPU44-E
CPU unit specifications
6.1.4 Describe types of software language:
Ladder diagram most popular
Instruction list
Structured text
Sequential function chart
Function block diagram
6.1.5 Describe future system expansion:
Today, the industry control system having a transformation
from traditional control method to automation control
system.
Most popular automation system:

Flexible Manufacturing System (FMS)
Computer Integrated Manufacturing (CIM).
PLC become the main agent for the automation system.
6.1.6 Describe support & backup:

Industrial automation control system need support &
backup units to carry out the existing control system in
case of damage.
PLC is the most convenient control system for backup.
PLC system is fast & easy to be install.
6.2 EXPLAIN INSTALLATION TECHNIQUE
6.2.1 Define site installation condition consideration:
- The PLC is resistance to harsh conditions & highly reliable,
but installing the PLC in a favorable site will maximize its
reliability & operating lifetime.
- Avoid installing the PLC in a site with any of the following

conditions:
- direct sunlight
- the ambient temperature exceeds the 0C to 55C range.
- the relative humidity exceeds the 10% to 90% RH range.
- consideration occurs due to sudden temperature changes.
- A site with corrosive gases, flammable gasses/ salt.
- A site with water, oil, @ chemical sprays.
- A site subjected to direct vibration @ shock.
6.2.2 Define panel/ cabinet heaters, transformers, or large
installation: resistors.
Install a cooling fan or system
Consider PLC operation,
when the ambient temperature
maintenance, and surrounding exceeds 55C
conditions when installing the
PLC in a panel or cabinet.
The operating temperature
range for the PLC is 0C to
55C.
Be sure that there is adequate
ventilation for cooling. The small PLC in panel
Allow enough space for air The big PLC in panel
circulation.
Do not install the PLC above
equipment that generates a
large amount of heat, such as
2. Installing the CPU Unit & I/O Do not install the small PLC in either of
Unit the following
positions.
The small PLC must be installed in
the position shown below to ensure
adequate cooling.
See the picture below;
The small PLC can be installed on Lower the small PLC so that the
a horizontal surface or on a DIN notch on the back of the PLC
track. catches the top of the DIN Track.
Push the PC forward until the lock
See the picture below ; snaps into place.
See the picture below ;
The Backplane is a simple device having
For the big PLC before installing, two functions. The first is to provide
the Units have to compiled one physical support for the Units to be
by one. There is no single Unit mounted to it.
that can be said to constitute a
Rack PLC. To build a Rack PLC, The second is to provide the connectors
we start with a Backplane. The and electrical pathways necessary for
Backplane for the Omron PLC is connecting the Units mounted to it. The
shown below. core of the PLC is the CPU.
The CPU contains the program consisting

of the series of steps necessary for the
control task. The CPU has a built-in power
supply, and fits into the rightmost position
of the Backplane.
The CPU of the big PLC has no I/O points
built in. So, in order to complete the PLC
we need to mount one or more I/O Units to
the Backplane.
Mount the I/O Unit to the Backplane by

locking the top of the I/O Unit into the slot
on the Backplane and rotating the I/O Unit
downwards as shown in the following
diagram.
Press down on the yellow tab at the bottom

of the slot, press the I/O Unit firmly into
position, and then release the yellow tab.
The figure below shows one I/O Unit mounted directly to the left of the CPU.
I/O Units are where the control connections are made from the PLC to all the
various input devices and output devices. As you can see from the figure
above, there is still some space available on the left side of the Backplane.
This space is for any additional I/O Units that may be required. The figure
below shows a total of eight I/O Units mounted to the Backplane.
After the big PLC compiled in the backplane then the big PLC can be
installed on the DIN Rail.
The DIN Rail Mounting Bracket shown below is necessary for mounting
the PLC to the DIN Rail.
The following diagram is a view of the back of the Backplane. Attach one
Mounting Bracket to the left and right sides of the Backplane as shown
below.
Loosen the screws attaching the
Mount the Backplane to the DIN Rail Mounting Brackets to the
so that the claws on the Mounting Backplane. Slide the Backplane
Brackets fit into the upper portion of upward as shown below so that the
the DIN Rail as shown below. Mounting Bracket and Backplane
clamp securely onto the DIN Rail.
Tighten the screws.
6.2.3 Define precautions for wiring:
I/O Lines Noise
Power lines & high-voltage equipment Ensure that the PLC can be
can cause electrical noise in the PLC ; accessed for normal operation and
maintenance;
Do not install the PLC in a panel or
cabinet with high-voltage equipment Provide a clear path to the PLC for
operation and maintenance. High-
Do not run CPM1A I/O lines in the voltage equipment or power lines
same duct @ conduit as power lines. could be dangerous if they are in the
way during routine operations.
Allow at least 200 mm between the
PLC and nearby power lines The PLC will be easiest to access if
the panel or cabinet is installed about
See the picture below; 3 to 5 feet above the floor
Installing I/O devices
I/O devices are attached at the place have been determined in the work
plan and wiring diagram. For switches are usually attached at the panel
while the sensor, selenoid and motor is usually placed at the machine to be
controlled.
Wiring and connections

Duct Work
Hanging Ducts If power cables carrying more
than 10 A 400 V, or 20 A 220 V must be run
along side the I/O wiring (that is, in parallel with it),
at least 300 mm must be left between the
power cables and the I/O wiring as shown below.
Floor Ducts
If the I/O wiring and power cables must be placed in the same duct (for
example, where they are connected to the equipment), they must be shielded
from each other using grounded metal plates.
Conduits
if Separating the PLC I/O lines, power and control lines, and power cables, as
shown in the following diagram.
I/O connections
Connect the I/O Devices to the I/O Units. Use 1.25-mm2 cables or larger The
terminals have screws with 3.5-mm diameter heads and self-raising pressure
plates. Connect the lead wires to the terminals as shown below. Tighten the
screws with a torque of 0.8 N _ m.
If you wish to attach solderless type terminals to the ends of the lead wires,
use terminals having the dimensions shown below.
The following diagrams show The following diagrams show the
the input configurations. output configurations.
This input configuration depend on This output configuration depend on
specification of the Input Unit will specification of the Output Unit will be
be used. used.
**See the specification before **See the specification before install.
install.
Power supply wiring (100 to 240 VAC)
-Wire a separate circuit for the CPM*As power supply circuit so that there isnt a
voltage drop from the inrush current that flows when other equipment is turned
on.
-When several CPM*A PLCs are being used, it is recommended to wire the PCs
on separate circuits to prevent a voltage drop from the inrush current @ incorrect
operation of the circuit breaker.
-Use twisted power supply wires to prevent noise from the power supply lines.
Adding 1:1 isolation transformer may reduce electrical noise even further.
-The following example show the proper way to connect the power source to the
PLC.
-Use 1.25-mm2 cables or larger. The terminal blocks have screws with 3.5-mm
diameter heads and self-raising pressure plates.
-For connecting to the terminal blocks, use round crimp terminals for 3.5-mm
diameter heads. Directly connecting stranded wires to the terminal blocks may
cause a short-circuit.
Grounding
This PLC has sufficient protection against noise, so it can be used without grounding
except for special much noise.
However, when grounding it should be done conforming to below items:
- Ground the PLC as independently as possible.

- Class 3 grounding should be used (grounding resistance 100 or less).
- When independent grounding is impossible, use the joint grounding method as
shown in the figure below (B).
- Use thicker grounding wire. Make sure the cable used for grounding at least 2mm2.
- Grounding site and the green cable must be terminated at the cable lug. Cable lug
must be tightened and soldered
- Grounding point should be as near as possible to the PLC to minimize the distance
of grounding cable.
Expansion unit
- The Expansion Unit or Expansion I/O Unit are usually attached when
amount of I/O devices to be controlled increase
- its amount over than capacities of the existing I/O Unit or attached
when needed to a special need like temperature sensor.
- The following shown the example of Expansion Units.
Expansion Unit of the big PLC
For the small PLC, use the following Insert the Expansion I/O Units connecting cable into
procedure when connecting an Expansion Unit the CPU Units or the Expansion I/O Units expansion
or Expansion I/O Unit; connector.
-Remove the cover from the CPU Units or the

Expansion I/O Units expansion connector.
-Use a flat-blade screwdriver to remove the

cover from the Expansion I/O Connector.
Replace the cover on the CPU Units or the Expansion

I/O Units expansion connector.
For the big PLC use the following picture when connecting an
Expansion Unit or Expansion I/O Unit;
6.2.4 Define technique to solve instable voltage &
voltage spike problems:
Voltage spike: A sudden, short surge in voltage. Voltage

spikes can be caused by lightning, power outages, short
circuits, or power transitions in large equipment on the same
power line.
To avoid voltage spike (suppression of Inductive Loads):
Install a snubber circuit, typically a resistor/capacitor network (RC).
Install metal oxide varistor (MOV).
Its may limit the voltage spike as well as control the rate of
current change through the inductor.
6.3 EXPLAIN PLC MAINTENANCE &
TROUBLESHOOTING METHODS
6.3.1 Determine PLC external faults:
1. Input & Output faults ( sensor & actuator)
60% - 80% of the automation system faults is because of the
input & output equipment (sensor & actuator).
Root cause:
The sensor position change.
The internal contact of the sensor disconnected.
The motor winding @ solenoid valve @ sensor become short circuit
(overload).
2. Wiring faults
Root cause:
Conductor in the cable disconnected.
Loose in terminal @ equipment connector.
The conductor become oxidize
3. Communication faults
Root cause:
Conductor in communication cable disconnected.
Connection pin damage.
Loose in terminal connection.
Interference in communication connection cable
(motor, coil, high voltage, etc)
Short circuit.
3. Power supply interruption

If the supply voltage reduce less that 85%, PLC will
automatically stop.
6.3.2 Determine PLC internal faults:
Internal damage may happened because;
Short circuit in transistor at output module.
Optocoupler in input module malfunction.
Short circuit (fuse, microprocessor, RAM, ROM).
Backup batteries malfunction.
PLC Maintenance
1. Applying the safety procedure
During execution of the work, the safety procedure must be executed

truly so that the risk of the work accident can be avoided.
Example of applying the safety procedure;
Use the safety equipment

Follow the instruction of safety procedure
Comprehending fringe of writing on the wall or emergency
2. Checking the installation and power supply
To do the maintenance and reparation of the PLC system, one of the

important matter that must be done is perform the inspection to the PLC
installation as according to the manual instruction, for example;
3. Maintain and repair the PLC
The maintenance and reparation of the PLC is all activity which

intentionally be done to the PLC by following a systematic procedure
with target so that the PLC which we own always can be used in the
best condition, fluent, peaceful and technically has along live.
6.3.5 Execute preventive maintenance methods:
Preventive maintenance
The main system components of a PLC system are semiconductors, and

it contains few components with limited lifetimes. Poor environmental
conditions, however, can lead to deterioration of the electrical components,
the harsher the environment, the more frequent the maintenance
necessary.
Preventive maintenance of programming controller systems includes only

a few basic procedures which will greatly reduce the failure rate of system
components.
The standard period for maintenance checks is 6 months to 1 year, but

more frequent checks are required if the PLC is operated in more
demanding conditions. When inspecting one or two times per six
months, check the following items.
Types of preventive maintenance should be done on the PLC:
Periodically clean @ replace any filters that have been installed in

enclosures at frequency dependent on the amount of dust in the area.
Do not allow dirt and dust to accumulate on the PLCs components;
the central processing unit and I/O system are not designed to be dust
proof.
Periodically check the connections to the I/O modules to ensure that
all plugs, sockets, terminal strips, and modules have good
connections. Also, check that the module is securely installed.
Ensure that heavy, noise-generating equipment is not located too
close to the PLC.
Make sure that unnecessary items are kept away from the equipment
inside the enclosure.
If the PLC system enclosure is in an environment that exhibits
vibration, install a vibration detector that can interface with the PLC as
a preventive measure. http://modul2poli.blogspot.com/ Page 42 of 61
Preventive maintenance consisted of several activity below;
Pre maintenance
Pre maintenance is a preparation activity, matters which require
to be prepared for example;
Prepare the maintenance equipment
Prepare the maintenance material especially weared routinely,

for example; cleanser material, Lubricant material, corrosion
preventative material, etc.
Prepare the maintenance documentation
Prepare the power supply and air compressor
Daily maintenance
The following table shows the inspection and items which are
to be checked daily.
Periodic maintenance
Check the following items once or twice every six months, and
perform the needed corrective actions.
Several example of the maintenance
activity on the Omron PLC is shown
below;
CPU and Power Supply Fuses
To replace a fuse, follow the steps below:
Turn OFF the power to the PLC.

Remove the fuse holder by turning it
approximately 50/ counterclockwise with a
standard screwdriver.
Remove the fuse from the holder.
Insert a new fuse.
Reattach the fuse holder by turning it
approximately 50/ clockwise with a
standard screwdriver.
Output Unit Fuses
To replace a fuse, follow the steps below. Use only UL/CSA certified
replacement fuses.
Remove the screw from the top
Turn OFF the power to the PLC. of the Unit (Phillips screwdriver).
Detach the terminal block by Detach the case from the Unit
unlocking the lock levers at the top and (flat-blade screwdriver).
bottom of the terminal block.
While pushing down the lock lever on
the Backplane with a screwdriver as
shown below, remove the Output Unit.
Pull out the printed circuit board.

Insert a new fuse. A spare fuse
is provided inside the rear of the
case when the Unit is delivered.
Reassemble in reverse order of
assembly. Page 48 of 61
Output Unit Relays
To replace a Relay, follow the steps

below:
Turn OFF the power to the PLC.
Detach the terminal block by

unlocking the lock levers at the top
and bottom of the terminal block.
While pushing down the lock lever

on the Backplane with a screwdriver
as shown below, remove the Output
Unit.
Remove the screw from Pull out the printed circuit board. The
the top of the Unit Relays are placed on the PLC boards
(Phillips screwdriver). of individual Units as shown in the
figures below :
Detach the case from the
Unit (flat-blade
screwdriver).
A Relay puller is provided inside the rear of the case when the
Unit is delivered. Use the Relay puller to pull out the Relay as
shown below. Insert a new Relay.
Reassemble in reverse order of assembly.
Batteries
Some RAM Packs use a battery. When the battery is nearly

discharged, the ALARM indicator blinks and the message BATT
FAIL appears on the Programming Console. When this occurs,
replace the battery within one week to avoid loss of data. The battery
comes together with its connector as a set. To replace the Battery
Set, follow the steps below. The entire replacement must be
completed within five minutes to ensure that the
data will not be lost.
If you are using model C200H-CPU11-E as the CPU, the battery is

installed in the Unit upon delivery.
Turn OFF the power to the PLC. (If the power was not already ON,
turn the power ON for at least one minute before turning the power
OFF.)
Remove the cover from the battery compartment of the RAM Pack.
Remove the old Battery Set.
Install the new Battery Set as shown in the following diagram.
Replace the cover of the battery compartment.
Press CLR, FUN, MONTR, MONTR or just turn the power to the
PC OFF and then ON again to clear the error message on the
Programming Console.
6.3.6 Execute steps for troubleshooting PLC systems:
1. Main Check
The following example
explains the procedure
for determining the
cause of troubles as well
as the errors and
corrective actions to the
Omron PLC.
Use the following
flowcharts to
troubleshoot errors that
occur during operation.
2. Fatal Error Check
3. Non- Fatal Error Check
4. I/O Check
The I/O check flowchart is based on the following ladder diagram

section.
5. Environmental Conditions Check
6. Memory Error Check

.

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PROGRAMMABLE LOGIC

CONTROLLER (PLC) AND

1. Understand automation system

2. Understand relays, contactors, electromechanical

Automation therefore is the mechanism for

Automation is a set of technologies

Whereas mechanization provided human operators with machinery

Type of Automation system :

By automating a given operation, and transferring the

Automation helps to reduce the elapsed time between

Replacing humans in tasks done in dangerous

Performing tasks that are beyond human capabilities of

A relay is usually an electromechanical device that is actuated by an electrical

Relays are used in a wide variety of applications throughout industry, such as in

In the home, relays are used in refrigerators, washing machines and

Normally-open (NO) contacts connect the circuit when the relay is

Normally-closed (NC) contacts disconnect the circuit when the relay is

Double-throw (DT), contacts control two circuits: one normally-open

On/Off Control: Example: Air conditioning control, used to

Limit Control: Example: Motor Speed Control, used to

Logic Operation: Example: Test Equipment, used to connect

When the applied current or voltage exceeds a threshold value,

When a power is supplied to the coil, it generates a magnetic

When no voltage is applied to pin 1, there is no current flow

This is a Single Pole Single Throw (SPST) relay.

This is a Double Pole Single Throw (DPST) relay. When the

This relay is a Double Pole Double Throw

This is a 4 Pole Double Throw (4PDT) relay. It

Single Pole relay have 1 common

Figure : Wiring of relay

contactor is controlled by a circuit which has a much

Contactors are used to control electric motors, lighting,

In the following illustration the circuit is

The contacts are shown in their normally

When the relay is energized, the

The contacts have been highlighted to

Normally Close Contact

In the following illustration the contacts

A complete path of current exists and

When the relay is energized, the

3-PHASE MOTOR STARTER - DOL

Start/stop station controlling magnetic starter

Start/stop station controlling two magnetic starter with

Start/stop station with pilot light indicate device deactivation .

Electromechanical timers are used to start or stop a machine or

They consist of both electrical and mechanical components,

They typically accept electric or electronic inputs to operate a

Contact symbols determine the time of timer action:-

Electromechanical counters are used to detect, totalize, and

They typically accept electric or electronic inputs to operate

These devices may count UP and/or DOWN, support multiple

Sensors allow a PLC to detect the state of a process.

Logical sensors can only detect a state that is either true

inductive proximity - is a metal object nearby?

A proximity sensor is a sensor able to detect the presence of

A proximity sensor often emits an electromagnetic field or a

The maximum distance that this sensor can detect is

The emitter and detector are positioned so that an

In the figure the light beam is generated on the left,

At the detector side the beam is focused on the detector

If the beam is broken the detector will indicate an object

The oscillating light wave is used so that the sensor can

3. Photo Optics/ Through Beam Sensor

The frequency of oscillation is in the KHz range, and too