PLC

AND SCADA SYATEMS PRACTICAL

PLC INTRODUCTION
A programmable logic controller (PLC) or programmable
controller is an industrial digital computer that has
been ruggedized and adapted for the control of manufacturing
processes, such as assembly lines, robotic devices, or any
activity that requires high reliability, ease of programming, and
process fault diagnosis. A PLCs were invented by Dick Morley
in 1964. Since then PLC has revolutionized the industrial and
manufacturing sectors. There is a wide range of PLC functions
like timing, counting, calculating, comparing, and processing
various analog signals. The main advantage of PLC over a
“hard-wired” control system is that you can go back and change
a PLC after you’ve programmed it, at little cost (just the cost of
the programmer’s time). In a hard-wired control system, you’re
essentially having to rip out wires and start from scratch (which
is more expensive and takes longer). Let’s look at an example to
better understand this advantage. Imagine you have a light
connected to a switch. In general, the light operates under two
conditions – ON and OFF. Now you are given a task that when
you turn ON the switch, the light should glow only after 30
seconds. With this hard-wired setup – we’re stuck. The only way
to achieve this is to completely rewire our circuit to add a timing
relay. That’s a lot of hassle for a minor change.
Advantages of plc
• It has very faster scan time.
• It has capable to communication with computer in plant.
• It has great computational capabilities.
• It has shorter training time required.
• A wide range of control application.
• It Have interfacing for inputs and outputs already inside the
controller.
• It is easily programmed and has an easily understood programming
language.
• It has project cost can be accurately calculated.
• It has supervisory control capability.
• It has small physical size.
• It has flexibility in programming and reprogramming.
• Troubleshooting is easier and faster.
• It has high speed counters.
• It has shorter project implementation time.
It has reliability in operation.
Architecture:
• The heart of the PLC system is the CPU (Central Processing Unit).
It is made up of a control unit and processor. The CPU control unit
manages the interaction between the various PLC hardware
components while the CPU processor handles all the number
crunching and program (ladder logic) execution
• Data flow is from the input devices, through the CPU processor
and then to the output devices. The CPU processor also exchanges
data with the program and data memory. Once all the data is
gathered the program (ladder logic) is processed in a cyclic
fashion. The resulting data flows to the output interface for
conditioning and execution of the output devices.
• The CPU also controls and exchanges data with the
communication interface and devices.
 • An addressing system is used for data organization that is shared
between the various hardware components.
• A programming terminal is used to formulate the PLC program
( ladder logic), load the program into the controller and
monitor/control the PLC and its program.
• The power supply is responsible for supplying and managing the
power requirements of the various PLC hardware components
Types:

Types of plc programming language:

SCADA
(Supervisory Control and Data Acquisition)
Introduction
Supervisory Control and Data Acquisition (SCADA) systems are used
for remote monitoring and control in the delivery of essential services
products such as electricity, natural gas, water, waste treatment and
transportation. This blog will introduce SCADA fundamentals that will
help analyze security considerations in the subsequent blog post. Electric
utilities use SCADA systems to detect current flow and line voltage, to
monitor the operation of circuit breakers and to take sections of the
power grid online or offline. A typical water SCADA application would
be used to monitor water levels at various water sources like reservoirs
and tanks. When the water level exceeds a preset threshold, the
application activates the system of pumps to move water to tanks with
low tank levels. Transit authorities use SCADA to regulate electricity to
subways, trams and trolleys and to automate traffic signals for rail
systems, to track and locate trains and to control railroad crossing gates
Basic principles of SCADA:
– Data Acquisition
– Data Conversion
– Data Communication
– Data Presentation and Control
SCADA network architecture
 Programs
Program 1: washing machine
1. INPUT CONDITION
1.1.a.
If plc input 003 turn on then internal relay 1000 turn on else internal
relay 1000 turn off.
1.1.b.
If internal relay 1105 turn on and plc output 0501 turn off then internal
relay 1000 turn on else internal relay 1000 turn off.
1.2.
If plc input 003 turn off and plc output 0502 turn off and plc output 0500
turn off then internal relay 1001 turn on else internal relay 1001 turn off.
1.3.
If plc input 0001 turn on then internal relay 1002 turn on else internal
relay 1002 turn off.
1.4.
If plc input 0000 turn on then internal relay 1003 turn on and hold turn
on.
1.5.
If plc input 0003 turn on then internal relay 1003 turn off.
3. OUTPUT CONDITION
3.1.
If internal relay 1104 turn on and plc output 0500 turn off then Timer
T001 active, after 5 x100ms = 500ms(millisecond) timer T001 turn on.
This timer for TurnTable STOP stability and Time can be set according
to need.
3.2.
If internal relay 1107 turn on and plc output 0502 turn on then Timer
T002 active, after 5 x100ms = 500ms(millisecond) timer T002 turn on.
This timer for water spray on delay and Time can be set according to
need.
3.3.
If internal relay 1108 turn on and plc output 0502 turn off then Timer
T003 active, after 5 x100ms = 500ms(millisecond) timer T003 turn on.
This timer for water spray off delay and Time can be set according to
need.
3.4.a.
If internal relay 1100 turn off and internal relay 1101 turn on and
internal relay 1104 turn off then plc output 0500 turn on and hold turn
on.
3.4.b.
If internal relay 1100 or 1104 turn on then plc output 0500 turn off.
3.5.
If plc input 0002 turn on then plc output 0501 turn on else plc output
0501 turn off.
3.6.a.
If internal relay 1100 turn off and internal relay 1106 turn on and
internal relay 1108 turn off then plc output 0502 turn on and hold turn
on.
3.6.b.
If internal relay 1100 or 1108 turn on then plc output 0502 turn off.
4.1.
If internal relay 1100 to 1108 turn off then internal relay 1005 turn on
else internal relay 1005 turn off.
4.2.
If internal relay 1005 turn on and counter C000 not equal 0 then counter
C000 reset turn on or current value of counter C000 filled with 0.
4.3.
If special relay 2002 always on then counter C000 activated. Input
counter use internal relay 1004 and maximum 1000 counting.
4.4.
If internal relay 1000 turn on then counter C000 reset turn on or current
value of counter C000 filled with 0.
f special relay 2002 always on and read data from counter C000 and
compare with value 0 to 8.Result compare used for turn on/off internal
relay. The following are the conditions of the comparison :
• If counter C000 equal 0 then internal relay 1100 turn on else internal
relay 1100 turn off.
• If counter C000 equal 1 then internal relay 1101 turn on else internal
relay 1101 turn off.
• If counter C000 equal 2 then internal relay 1102 turn on else internal
relay 1102 turn off.
• If counter C000 equal 3 then internal relay 1103 turn on else internal
relay 1103 turn off.
• If counter C000 equal 4 then internal relay 1104 turn on else internal
relay 1104 turn off.
• If counter C000 equal 5 then internal relay 1105 turn on else internal
relay 1105 turn off.
• If counter C000 equal 6 then internal relay 1106 turn on else internal
relay 1106 turn off.
• If counter C000 equal 7 then internal relay 1107 turn on else internal
relay 1107 turn off.
• If counter C000 equal 8 then internal relay 1108 turn on else internal
relay 1108 turn off.
Here is the description for rotary bottle washing machine:
1. Waiting All Origin and Waiting Start 1 Cycle or Auto Cycle.
2. TurnTable RUN to next point position.
3. Check proximity sensor: Check ON condition.
4. Check proximity sensor: Check OFF condition.
5. TurnTable STOP and waiting stability timer.
6. Check Jet Pump Motor (Water Spray) : If jet pump motor turn off
then goto waiting start 1 cycle or auto cycle (no.1) else goto solenoid
valve turn on (no.7).
7. Solenoid Valve turn on.
8. Delay for Solenoid Valve turn on.
9. Solenoid Valve turn off and Delay.
Program: filling machine
INPUT PLC :
0000 ; Push Button Start
0001 ; Push Button Stop
0002 ; Selector Switch 1
0003 ; Selector Switch 2
0004 ; Selector Switch 3
0005 ; Selector Switch 4
0006 ; Sensor Bottle 1
0007 ; Sensor Bottle 2
0008 ; Sensor Bottle 3
0009 ; Sensor Bottle 4
0010 ; Digital Flow Switch 1
0011 ; Digital Flow Switch 2
012 ; Digital Flow Switch 3
0013 ; Digital Flow Switch 4
0014 ; Proximity for Count Revolution
0015 ; Fluid Sensor
0100 ; Motor Feedback Alarm for Screw Conveyor
0101 ; Limit Switch (LS) Nozzle Down
0102 ; Limit Switch (LS) Nozzle Up
OUTPUT PLC:
0500 ; Motor ( Motor Running ) for Screw Conveyor
0501 ; Solenoid for Cylinder Nozzle Up
0502 ; Solenoid for Cylinder Nozzle Down
0503 ; Single Solenoid for Drain Nozzle 1
0504 ; Single Solenoid for Drain Nozzle 2
0505 ; Single Solenoid for Drain Nozzle 3
0506 ; Single Solenoid for Drain Nozzle 4
0507 ; Single Solenoid for Filling Nozzle 1
0508 ; Single Solenoid for Filling Nozzle 2
0509 ; Single Solenoid for Filling Nozzle 3
0510; Single Solenoid for Filling Nozzle 4
0511; Single Solenoid for Pneumatic Pump 1
0512; Single Solenoid for Pneumatic Pump 1
0513; Single Solenoid for Pneumatic Pump 1
0514; Single Solenoid for Pneumatic Pump 1
Reading Ladder PLC Programming for Filling Machine :
Step 1:
a.If 0000 = ON And 0001 = OFF And 0015 = ON And 0100 = ON Then
1200 = ON And 1201 = Momentary ON ( Diff. Up).
b.1201 For Return To Origin Signal
c.If 1200 = ON Then ALL System Ready (Master Control = ON).
Step 2 :
For Pump ON and Drain Process for 1 Nozzle, Example Nozzle 1
a. If 0002 = ON And 1300 = OFF Then 1000 = ON.
b. If 0511 = ON And 0507 = OFF Then 1004 = ON.
c. If 0511 = ON And 0503 = ON And 0010 = OFF Then T000 Activated
(Can be Setting for Stability).
d. If T000 = ON Then SET 1300 = Hold ON.
e. If 0002 = OFF Then RES 1300 = OFF.
See Picture for Setting Stability Flow Switch OF
Step 3:
Filling Process
a. If (0511 = ON And 0006 = ON) Or (0512 = ON And 0007= ON) Or
(0513 = ON And 0008= ON) Or (0514= ON And 0009= ON) Then 1008
= ON.
b. If 1008 = ON And 0102 = ON And 0500 = OFF And 1109 = OFF
Then 1009 = ON (Latching ON) And 1010 = Momentary ON (Diff. Up).
c. If 1010 = ON And 1106 = OFF And 1009 = ON Then 1011 = ON
(Latching ON).
d. If 1011 = ON And 0101 = ON And 1106 = OFF And 1009 = ON
Then 1012 = ON (Latching ON).
e. If 1012 = ON And 0511 = ON And 0006 = ON And 1101 = OFF
Then 1013 = ON And T004 Activated (Can be Setting for Liquid
Volume).
f. If 1012 = ON And T004 = ON Then SET 1101 = Hold ON (Bottle 1 =
FULL).
g. If 1101 = ON And 1102 = ON And 1103 = ON And 1104 = ON Then
1105 = ON (ALL Bottle = FULL).
Step 4:
Nozzle Up
a. If 1010 = ON Or 1106 = ON Then 1101 = OFF And 1102 = OFF And
1103 = OFF And 1104 = OFF.
b. If 1012 = ON And 1105 = ON And 1107 = OFF Then 1106 = ON
(Latching ON).
Step 5:
Running Screw Conveyor
a. If (1106 = ON Or 1111 = ON) And 0102 = ON And 1108 = OFF
Then 1107 = ON (Latching ON).
b. If 0500 = ON Then C010 Activated Count Up to 4 (Not Set).
c. If C010 = ON Then 1107 = OFF.
d. Continue To Step 3
Step 6 :
Return to Origin
a. If 1201 = ON And 0102 = OFF Or (0006 = OFF And 0007 = OFF
And 0008 = OFF And 0009 = OFF ) Then 1109 = ON (Latching ON).
b. Nozzle move to Up
c. If Bottle Empty Then Running Screw Conveyor

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