Professional Documents
Culture Documents
EXPERIMENT 3
PROGRAMMABLE LOGIC CONTROLLER (PLC) - LG
OBJECTIVE
Understand automation process in the industrial field is essential for an engineer. Should
engineer student used to work and practice likely in this environment, so when it comes to
real system they are not surprised. In this experiment, we will use PLC LG that shows basic
automation command clearly and easy to understand.
.
REFERENCE
Anonymous, User’s Manual LG Programmable Logic Controller : Instruction and
Programming, LG Industrial Systems.
David W. Pessen, Industrial Automation:Circuit Design and Components, 2008.
EQUIPMENTS REQUIRED
PLC LG Chungpa 1 piece
Red Short Cable (40 cm) 10 piece
Red Long Cable (110 cm) 10 piece
Black Short Cable (40 cm) 10 piece
Black Long Cable (110 cm) 10 piece
Power Cable 2 piece
RS-232 and USB to Serial cable 1 piece
PRE-EXPERIMENT TASK
1. What industries used to applied PLC to their system ? Why is that ?
2. What is the company that produces the PLC ?
INTRODUCTION
Automation System is a system that makes human life easier. It has so many advantages,
because it can work effectively and efficiently in case of time, energy, and cost needed. So
that we can achieve it all, many industries use PLC. A PLC is an industrial computer control
system that continuously monitors the state of input devices and makes decisions based upon
a custom program to control the state of output devices. Almost any production line, machine
function, or process can be greatly enhanced using this type of control system. However, the
biggest benefit in using a PLC is the ability to change and replicate the operation or process
while collecting and communicating vital information.
There is two type of PLC, that is Compact and Modular PLC. Compact PLCs are used in
automation as replacements of relays. A PLC does not cost more than a handful of relays and
the programming is as flexible as wiring. The weak points of this type PLC are low memory
for the program and data, low processor performance, low number of PLC timers and
counters, and missing data types (like floating point, string). On the other hand, today’s more
expensive compact PLCs have the same functionalities as other PLC types, the only flaw is
the fixed number of I/Os. Examples of compact PLC are Festo FEC PLC, Siemens Logo and
S7-200 PLC.
A modular PLC contains several different modules that can be coupled together to build a
customized controller. Typically, a base module contains core functions such as electrical
1
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
power regulation, the computer processor, and input connections. Additional modules,
including analog to digital signal converters or additional outputs, can be added to this core
unit as needed. This modular design allows a PLC to be customized and changed easily. The
Allen Bradley Micrologix 1200 is a commonly used example of the modular PLC type. This
unit is able to handle between 23 and 40 inputs and outputs. The actual number of
connections can be expanded easily by adding modules. This provides a wide range of
flexibility and is typical of a modular PLC. While Ladder Logic is the most commonly used
PLC programming language, it is not the only one. There are five programming language
used to put in use :
Ladder Diagram (LD)
Traditional ladder logic is graphical programming language. Initially programmed
with simple contacts that simulated the opening and closing of relays, Ladder Logic
programming has been expanded to include such functions as counters, timers, shift
registers, and math operations.
Function Block Diagram (FBD)
A graphical language for depicting signal and data flows through re-usable function
blocks. FBD is very useful for expressing the interconnection of control system
algorithms and logic.
Structured Text (ST)
A high level text language that encourages structured programming. It has a language
structure (syntax) that strongly resembles PASCAL and supports a wide range of
standard functions and operators.
Instruction List (IL)
A low level “assembler like” language that is based on similar instructions list
languages found in a wide range of today’s PLCs.
Sequential Function Chart (SFC)
A method of programming complex control systems at a more highly structured level.
A SFC program is an overview of the control system, in which the basic building
blocks are entire program files. Each program file is created using one of the other
types of programming languages. The SFC approach coordinates large, complicated
programming tasks into smaller, more manageable tasks.
We will use PLC LG and GMWIN 4.0 for its software. PLC LG has many types that were
GLOFA GM1, GM2, GM3, GM4, GM5, GM6, and GM7. In this experiment, we will use
GLOFA GM4 that is shown in Figure 1.
2
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
In this experiment we will use software for PLC LG named GMWIN 4.0. There are two ways
to Addressing in GMWIN : one is to give a name to a data element using an
identifier(Variable by Identifier) and the other is to directly assign a memory address
(DirecVariable).
Variable by Identifier
A variable by identifier should be unique within its program area where the variable
was declared in order to distinguish it from other variables. Example of addressing by
Variable Identifier is shown in Figure 2 :
Direct Variable
A direct variable is expressed as one, which starts with the percent sign (%) followed
by a prefix of the data size and more than one unsigned integer numbers divided by a
period(.). Example of addressing by Direct Variable is shown in Figure 3:
3
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
Every PLC have their way to addressing. In PLC LG, there were some functions and symbol
of basic instruction.
1. Contacts and Coils
‘Contact’ transmits a value to the right horizontal line, which is the result of logical AND
operation of these: the state of left horizontal connection line. Coil stores the state of the
left connection line or the processing result of state transition in the associated BOOL
variable.
Description : The value of NO Instruction will be “1” when it active and will be “0”
when it does not.
Description : The value of NC Instruction will be “0” when it active and will be “1”
when it does not.
Description : When the value of RLO is “1” then NO coil will be “1” and when RLO
“0” then NO coil will be “0”.
Description : When the value of RLO is “1” then NO coil will be “0” and when RLO
“0” then NO coil will be “1”.
2. Timer
a. TOF (Timer-Off Delay)
Time off delay is a condition when the coil active if the contact have been pressed and
inactive after the period time.
4
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
Description : When input value of IN is “1” then output Q is “1” and when IN is “0”
then timer will count until PT value. After the count end then output Q will be “0”.
Remember to write the time, fill in the ‘PT’ by click once and write T#....S.
b. TON(Timer-On Delay)
Time on delay is a condition when the coil active if the contact have been pressed for a
period of time.
Description : When input value of IN is “0” then output Q is “0” and when IN is “1”
then timer will count until PT value. After the count end then output Q will be
“1”. Remember to write the time, fill in the ‘PT’ by click once and write T#....S
3. Counter
a. Counter Up
Counter Up is a function that could counting from zero to a value that have assigned.
Description : When input CU changed from “0” to “1” then CV will increased by 1.
Output of Q will be “1” when CV=PV. Value of Q is “1” until input R is “1”. When R
is “1” then CV is reset to “0”. Remember to count, fill in the ‘PV’ by click once and
write ....(Numerical Value)
b. Counter Down
Counter Down is a function that could counting from value that have assigned to zero.
Description : When input LD is “1” then CV will be the same with PV. When CD
changed from “0” to “1” then CV decreased by 1. Output Q will be “1” when CV=0.
Value of Q will be ”1” until LD is “1” again. Remember to count, fill in the ‘PV’ by
click once and write ....(Numerical Value)
5
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
Electrical module is provided to make an electrical circuit, activate contact and coil, timer,
counter and many function which needed an electrical supply.
1. Power Supply Module
Electric module that have function as voltage supplier. Red Port (Top) as +24 volt supply
and Black Port (Bottom) as ground (0 V). It is shown in Figure 4.
2. Switch Module
Electric module that have function as manual input. Red Port (Top) as + 24 volt supply,
Black Port (Bottom) as Ground (0 V), Yellow Port as Com (Reference), Blue Port as
Normally Close Contact, Green Port as Normally Open Contact. It is shown in Figure 5.
6
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
EXPERIMENT
3. Open GMWIN 4.0, choose menu Project Option Connection Option. Set RS.232C
on method connection, (com 1 ~ 10) on communication port, and local on depth of
connection. They are shown in Figure 9.
7
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
4. Make a new project. In the Project New project then rename. In the Select PLC type,
choose GM4 shown in Figure 10.
Figure 10. Menu display to give project name and choosing PLC type
5. In the final step, choose programming language LD (ladder) then click Finish. It is
shown in Figure 11.
8
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
6. After make the program, choose Online Connect+Write+Run. If offline word in the
status bar changed to GM4 stop, so the PLC have connected with PC.
Figure 12. Ladder Diagram of Contacts and Coils Circuit Experiment(NO and NC Coil)
5. Configure Ladder Diagram for AND circuit as shown in Figure 13. Do not forget to
make the circuit in electrical module.
6.Place two NO contact consecutively with a NO coil. Place both of them in same row with
NO coil.
7.Write condition of lamp/buzzer when it is depressed and released.
8. Configure Ladder Diagram for OR circuit as shown in Figure 14. Do not forget to
make the circuit in electrical module.
9. Place two NO contact consecutively with a NO coil. Place one of them in same row with
NO coil and the other one in second row, connected vertically with first row.
10. Write condition of lamp/buzzer when it is depressed and released.
B. Experimental Data
All of condition, experience and image that you observe after Contacts and Coils experiment,
9
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
can be written in Table b. Hence, for AND & OR circuit experiment can be written in Table
c.
Lamp Condition
Normally Open Normally Close
Condition Depress
Contact
Release
Table b. Contact and Coils Experimental Data
Contact State
Lamp Condition
Normally Open Normally Open 2
0 0
0 1
AND
1 0
1 1
0 0
0 1
OR
1 0
1 1
Table c. AND & OR circuit experiment
Information : 0 = Released
1 = Depressed
10
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
B. Experimental Data
All of condition, experience and image that you observe after Self Holding circuit
experiment, can be written in Table d.
Lamp Condition
Normally Open Normally Close
Depress
Condition
Contact
Release
5. Configure Ladder Diagram for Counter Up as shown in Figure 18. Do not forget to
make the circuit in electrical module.
6. Write condition of lamp/buzzer in table!
7. Configure Ladder Diagram for Counter Down as shown in Figure 19. Do not forget
to make the circuit in electrical module.
8. Write condition of lamp/buzzer in table!
11
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
B. Experimental Data
All of condition, experience and image that you observe after Timer On Delay experiment
can be written in Table e and Timer Off-Delay experiment in Table f. Hence for Counter Up
experiment can be written in Table g and Counter Down experiment in Table h.
0
Contact
(NO/NC) 5
0
Contact
(NO/NC) 5
0
Contact
(NO/NC) 5
12
Laboratorium Teknik Pengaturan
Departemen Teknik Elektro
Fakultas Teknologi Elektro
Institut Teknologi Sepuluh Nopember
0
Contact
(NO/NC) 5
13