Workshop and Tooling Lab CP, UET Taxila

Experiment 02
Introduction to PLCs and Ladder Logic
Objective: To get familiar with FATEK PLCs and ladder logic programming.

Activity Time Boxing:

Task No. Activity Name Activity Time

1 Lecture 10 ” 15 min

2 Performing Experiment 120 125 min

3 Results and Evaluation 30 ” 40 min

Total Time: 180 min

Background:

PROGRAMMABLE LOGIC CONTROLLER (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. A PLC has a microcontroller or a microprocessor-
based control inside with special interface circuits to operate in a harsh environment of an
industry. To work with a microprocessor or a microcontroller one has to be familiar with the
programing language of a particular device. Normally electrical or electronic engineers can work
with microprocessors and microcontrollers. In contrast to program a PLC only logical approach is
required to work with LADDER logic. An industrial computer that can be programmed with
LADDER, FBD or STL language is to be categorized as PLC.

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PLC Architecture:

The main components of a PLC consist of a central processing unit (CPU), power supply,
programming device, and input and output (I/O) modules.
CPU
The CPU is the brain of the PLC and carries out programmed operations. These operations or outputs
are executed based on signals and data provided from connected inputs.
I/O Modules
PLC input modules connect various external devices, such as sensors, switches, and push buttons
to the PLC to read various digital and analog parameters, such as temperature, pressure, flow,
speed, etc. Output modules convert signals from the CPU into digital or analog values to
control output devices.
Power Supply
The power supply provides power to the PLC by converting the available incoming AC power to
the DC power required by the CPU and I/O modules to operate properly.
Inputs and Outputs of a PLC:
Inputs and outputs signal to a control system can be divided in to two groups i.e. Digital and
Analog. A digital signal has only two states I.e. 0 or 1. Where 0 and 1 corresponds to voltage
levels and can have different potential levels for 1, for example status 1 could be 3.3V DC, 5V
DC in case of microcontroller based system or 12V DC for CMOS digital system. For a PLC control
system status 1 corresponds to 24V DC. These voltage levels are true for both input and output
signals.

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An analog signal can have many values between minimum and maximum value of input or
output signal. for example, minimum and maximum voltage level as analog input or output could
be + 3.3V, 15V in case of microcontroller-based system. For a PLC control system minimum and
maximum level for an analog signal could be + 100mV, +10V or 120mA. These voltage levels are
true for both input and output signals.
FBS PLC is Single-Unit system which is built only by a single FBs-PLC and its expansion
unit/modules and communication boards/modules. Such system has a limited capability
(refer), beyond that capability can incorporate CPU communication via LINK function for
expansions. The figure below shows the block diagram of the Single-Unit system of FBs-PLC,
where, besides the available main units, the available communication peripherals resources and
l/O expansion resources are depicted on the left and the right respectively.

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Software
The PLC manufacturer typically determines PLC development software. Allen Bradley, Siemens,
and GE each have their own software development platforms for programming their PLC models.
Once the platform is determined, the actual programming of the PLC logic can be done in a few
different methods. The most common methods of PLC programming include Ladder Logic,
Function Block, and structured text. Platform used for FATEK PLCs is Winproladder.
Ladder Logic Programming:

The Automotive Industry was a major early adopter of programmable logic controllers (PLC).
They wanted a programming method that could be easily understood by their existing controls
engineers and technicians. The result of this desire was a programming language called Relay
Ladder Logic (or “ladder logic”).
Ladder logic is a programming language that creates and represents a program through
ladder diagrams that are based on circuit diagrams. It is mainly used in developing programs or
software for programmable logic controllers (PLCs), which are used in industrial applications. The
language evolved from originally being a method for documenting the design and construction of
relay racks used in manufacturing and process control, with each relay rack represented by a
symbol on the ladder diagram that has connections to devices below them that look like
vertical rails. The relay symbols themselves look like rungs in a ladder.

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Structured Text
Structured text is a text-based PLC programming language and is similar to Python, Visual Basic,
or C coding languages. Programming with structured text has multiple advantages, such as the program
requiring less space due to being text based instead of graphic based. Additionally, the
structured text can be combined with other programming languages, such as creating
function blocks containing functions written in structured text.
Function Block
Function block PLC programs are represented in the form of graphical blocks. Signals or data
flow into the function block from inputs connected to the PLC. When the incoming signals or data
triggers the function block's pre-programmed function, the PLC executes one or more outputs.
Function blocks can have standard functions such as timers, counters, calculating min and
max values, obtaining averages, and more.
Winproladder:
Winproladder uses a project-oriented approach, presenting your software development content
visually in a ladder diagram display, facilitating the clear and simple display of the content. All
project content, be it for software development or for program maintenance, can be viewed and
worked on in an intuitive and straight-forward manner. Powerful diagnostic functions including
SIMULATOR, BIT forcing and STATUS monitoring. Includes ON-LINE EDITING feature for fast
development in a machinery or continuous production application.

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Function Toolbar

The functions toolbar is the collection of functions included in the applications software,
presented in different categories. When the user selects any of the categories in the above
function toolbar, a list of additional selectable functions will be displayed for the user to select.

Tools bar

In the process of the design of a project, it is often convenient to provide a toolbar with the
most commonly used functions included in it for the user to directly select, which can prove to
be much faster and more convenient that having to find the function through the function
toolbar.

Component Tray

We provide a component tray which allows the user to easily select the components and
command functions that they need to use without having to search for what they want through
the functions toolbar, which is faster and more convenient.

Status Bar

The status bar displays information on the status of the current application, such as whether
the application is connected, whether it is in execution or has been disconnected, and the
current location of the cursor, etc., allowing the user to know the status of the current
application at all times.
Creating a Project:
Step 1: Execute the WinProIad.exe program.
Step 2: Select [File]4 [New Project] from the function toolbar using your mouse, or press “Ctrl”
+ “N” on your keyboard, and the [New Project] window will appear, as is shown below:

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Step 3: Enter “Test example” into the [Project Name] field.

Step 4: Click on the “Edit” button to enter the PLC model type selection screen.

Project Information !

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Description !

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Step 5: Select the corresponding model type according to the actual testing machine.

Step 6: Click the “OK” button, and the following screen will appear:

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Using Your Mouse to Input and Edit the Example Program:

Step 1: Now you can begin to input the ladder diagram program, first move your cursor to the
upper left-hand corner of the ladder diagram window and click on it, you should then see a
flashing blue square at that same location.
Step 2: Move your cursor to where the component tray is, there should be an icon that looks
like the following:

Step 3: Left click on the button and a B normal close contact cursor should appear, move
this cursor to the location of the blue square and perform a left click. The following dialog window
should appear:

Step 4: Input “TO” and then press “Enter” to input TO with a normal close contact.

Step 5: move your cursor to the in the component tray and click on it, now a cursor in the
shape of a T should appear. Left click on your mouse and the following dialog box window should
appear.

Step 6: After you input “0”, use your mouse or the “Down” arrow key to move the cursor to
the [PV] field and input “100” and then press “Enter” or click on the “OK” button using your
mouse, now you have completed the input of the TO timer function.

Step 7: Now input the TO normal open contact ( ) using the same method as the TO

normal close contact ( ), except you click the function toolbar icon

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Step 8: After inputting the TO normal open contact you should then input SHFL (Fun51), use

your mouse to click on , then you should see a cursor in the shape of an F, move this
cursor behind the TO normal open contact and click it, then you should see the following window
appear:

Input “SHFL” or function code “51” in the Function Name field, if you are not familiar with
function names or function codes, you can also move your cursor to the [Class] field and click
on “Shift/Rotate”, and all of the instructions related to this category will be listed, after you
select “SHFL”, it will appear in the [Function Name] field, now if you press the “Enter” key or
click on the “OK” button, the following window will appear:

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Input "WMO" and "1" into the [D] and [N] fields, respectively, because most function block
instructions have flexible pulse trigger and 32 bit operand can now be selected using a mouse or
a keyboard. If you use your keyboard, use the "Alt" + "D" combination for [32 bits]; use the "Alt"
+ "P" combination to control the [Pulse], the [Pulse] function must be selected for this example.

Step 9: Move your mouse cursor to the in the component tray and click on it, a cursor with
a horizontal short circuit icon should appear, move it at specified location and continue to fill in
the horizontal short contact.

Step 10: We are now intentionally skipping the MOV instruction network, and we will revisit the
following portion later on.

Lab Task:

Use Winproladder to design AND, OR, NAND, NOR, XAND and XOR gates.

Output:

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Discussion:

Conclusion

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