Lab Designation1

PLC Based Motor Control Panel
Implementation of a PLC program
by
Malik Khalid Salim Ghawas
A PROJECT REPORT
Submitted to the
SALALAH VOCATIONAL COLLEGE
in partial fulfillment of the requirements
for the award of the degree
of
Vocational Educational Diploma Program
in
Electrical Engineering (Industrial Electricity)
June, 2018
Salalah Vocational College – Department of Electrical Engineering 2
PLC Based Motor Control Panel “Implementation of a PLC Program”
ABSTRACT
This report can be considered as a supplement for the “PLC based motor control panel”, as
it treats the software side of this project. The first one has talked about the wiring diagrams and
connections performed to achieve this graduation project, in addition to the required mechanical
works.
We should remind that this project consists in the conception of a control panel based on a
Programmable Logic Controller that will be used to control a three-phase squirrel cage
asynchronous motor in different ways:
 Direct START
 Reverse START
 Direct star/delta START
 Reverse star/delta START
Page | 2
Acknowledgment
In the name of Allah the Most Gracious, the Most Merciful…

Thanks to Allah the All Mighty, All Sovereign and All Supreme for giving us good and health to finish
our project.
First, we wish to extend our appreciation and thanks to our supervisor, Mr. Mehrez Mongi Saafi, for
his supervision and various advice on how to complete this project.
We would like, also, to thank all our teachers for their kind help during this achieved period within
Salalah Vocational College.
In particular, we wish to acknowledge the support given from our family who are always there on
our ups and down and pray for us.
Lastly, thanks to all our friends for their suggestion and help to excellent in all aspect of our project.
And for those who give us support direct and indirectly to finish our final year project, thank you very
much. May Allah bless all of you.
Page | 3
Contents
Content 4
List of Figures 5
List of tables 6
Introduction 7
Chapter 1 : Conceptual Framework 8
Chapter 2 : Development strategy 15
Conclusions and Future work 21
References 22
Annexes 23
Page | 4
List of Figures
Fig.1 Hardware and software required to implement the program 8
Fig.2 LOGO! Inputs and outputs 10
Fig.3 Example of OR Block 11
Fig.4 View of the LOGO! display 11
Fig.5 Assignment of a block number 12
Fig.6 Motor control wiring diagram 17
Fig.7 Connection label 18
Fig.8 Designation of program blocks 19
Fig.9 Final program to implement 20
Page | 5
List of Tables
Tab.1 LOGO! Connector types 10
Tab.2 Technological choices 15-16
Tab.3 PLC I/O addressing 16
Page | 6
Introduction
Programs for microprocessor-based systems have to be loaded into them in machine code,
this being a sequence of binary code numbers to represent the program instructions. However,
assembly language based on the use of mnemonics can be used; for example, LD is used to indicate
the operation required to load the data that follows the LD, and a computer program called an
assembler is used to translate the mnemonics into machine code. Programming can be made even
easier by the use of the so-called high-level languages, such as C, BASIC, PASCAL, FORTRAN,
COBOL. These use pre-packaged functions, represented by simple words or symbols descriptive
of the function concerned. For example, with C language the symbol & is used for the logic AND
operation. However, the use of these methods to write programs requires some skill in programming
and PLCs are intended to be used by engineers without any great knowledge of programming. As
a consequence, ladder programming was developed. This is a means of writing programs which
can then be converted into machine code by some software for use by the PLC microprocessor.
This method of writing programs became adopted by most PLC manufacturers, however
each tended to have developed their own versions and so an international standard has been
adopted for ladder programming and indeed all the methods used for programming PLCs. The
standard, published in 1993, is IEC 1131-3 (International Electrotechnical Commission). The IEC
1131-3 programming languages are ladder diagrams (LAD), instruction list (IL), sequential function
charts (SFC), structured text (ST), and function block diagrams (FBD).
This chapter is an introduction to the programming of a PLC using ladder diagrams and
functional block diagrams, with discussion of the other techniques in the next chapter. Here we are
concerned with the basic techniques involved in developing ladder and function block programs to
represent basic switching operations, involving the logic functions of AND, OR, Exclusive OR, NAND
and NOR, and latching.
Page | 7
Chapter1: Conceptual Framework
This chapter will give a description about the main functions of the LOGO! logic module in
this module.
Typical tasks are explained by using a sample task and processed in a project in the following steps:
 Creating a program for the LOGO! logic module
 Testing the task in LOGO! RUN mode
 Setting the IP address
 Programming the task with the LOGO! software
 Simulating the task with the LOGO! software
 Test the task with the LOGO! software.
1- Hardware and software needed:
In order to implement a program on the PLC, we need the following components:

 PC as of Pentium III, operating system as of Windows 7 Home, network card
 LOGO!Soft Comfort Version 7.1 software (LOGO! 0BA8 requires Version 8.0)
 LOGO! logic module 0BA0 – 0BA6 (alternatively)
 LOGO! PC cable (alternatively)
 LOGO! logic module 0BA7 – 0BA8 with Ethernet interface (alternatively)
 Ethernet cable (alternatively)
Fig.1: Hardware and software required to implement the program
Page | 8
2- Features and advantages of PLC LOGO!:

LOGO! integrates the controller with operator control and display unit. LOGO! operator
control and display unit can be used to create programs, edit and execute system functions.
Moreover, we can use an interface or a PC cable from the LOGO! SOFT programming software to
read in an external program from a program module. In addition to creating a program, LOGO! SOFT
has the ability to simulate your circuit on the computer or print out overview diagrams.
Depending on the device type, the LOGO! logic modules already include ready-to-use basic
functions, such as delayed ON, delayed OFF and current impulse relay, time switch, binary bit
memory, as well as inputs and outputs.
LOGO!:can be used to solve multiple tasks:
- in home and installation technology (e.g. stairway lighting, outside lighting, awnings, shutters, show
window lighting and much more),
- in control cabinet installation and machine and apparatus design (e.g. gate controls, ventilation
systems, industrial water pumps and much more).
LOGO! can also be used for special controllers for signal pre-processing.
By connecting the LOGO! module to the AS–Interface, it can be used as I/O with its own intelligence
to control machines and processes on-site. This means we can execute control tasks in the LOGO!
logic module and reduce the load on the master controller by doing so.
There are special versions without operating unit for serial applications in small machine and
apparatus engineering, in control cabinet installation and the installation area. These must be
downloaded afterwards by means of a program module or with the LOGO! SOFT PC software.
3- General description of PLC LOGO!:
In this part, we will give a brief description of the main parts of the PLC LOGO!.
3.1- Connectors:
LOGO! has inputs and outputs. The inputs are specified with the letter I and a number. When
you look at LOGO! from the front, you can see the connectors for the inputs at the top. Only with
analog modules LOGO! AM2 and AM2 PT100 are the analog inputs on the bottom. The outputs are
specified with the letter Q and a number. The connectors of the outputs can be seen at the bottom
in next figure2.
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Outputs Analog Inputs
Fig.2: LOGO! Inputs and outputs.

We refer to all connections and states used in LOGO! as connectors. The inputs and outputs
can have the status '0' or the status '1'. Status '0' means that there is no voltage at the input; status
'1' means that voltage is present. Connectors hi, lo and x have been introduced in order to make it
easier to input the program. 'hi' (high) has the fixed status '1'. 'lo' (low) has the fixed status '0'.
Sometimes, when we do not want to activate an input of a block, we use the connector 'x'. All kind
of connectors are summarized in table 1 below.
DM AM AM2AQ
Connectors
LOGO! 0BA6 LOGO!0BA7
LOGO! 230RCE Two groups: I9 to I24 AI1 to none
LOGO! 230RC/RCo I1 to I4 and I5 to I8 AI8
LOGO! 24RC/RCo
Inputs LOGO! 12/24RCE I1, I2, I3-I6, I7, I8 I9 to I24 AI5 to
LOGO! 12/24RC/RCo AI3, AI4 ... AI1, AI2 Al8
LOGO! 24/24o LOGO!
24C/24Co
Q1 to Q4 Q5 to none AQ1,
Outputs Q16 AQ2
lo Logical '0' signals (off)
hi Logical '1' signals (on)
X An existing connection that is not used
Digital flags: M1 to M27
Analog flags:
Flags
AM1 to AM6 (0BA6)
AM1 to AM 16 (0BA7)
S1 to S8 (0BA6) S1.1
Shift register bits
to S4.8 (0BA7)
Network inputs 1) NI1 to NI64 (0BA7 only)
NAI1 to NAI32 (0BA7 only)
Network analog inputs 1)
Network outputs 1) NQ1 to NQ64 (0BA7 only)

Network analog outputs 1) NAQ1 to NAQ16 (0BA7 only)
Tab.1: LOGO! Connector types.
Page | 10
3.2- Blocks and block numbers:

In this part, we will show how to use the LOGO! elements to create comprehensive circuits
and how we can link the blocks with each other and with the inputs and outputs.
3.2.1- Blocks:
In LOGO! a block is a function that converts the input information into output information. In
the past, we had to wire the individual elements in the control cabinet or the terminal box. For
programming, we connect the connectors with blocks. We simply select the required connector from
the Co menu. The Co menu is named for the English term "connector".
3.2.2- Logical operations:
The simplest blocks are logical operations (e.g., AND, OR).
Here the inputs I1 and I2 are connected to the OR block. The last two inputs of the block are not
used and therefore occupied with x.
The special functions are much more powerful (e.g., current impulse relay counters timers)
Fig.3: Example of OR Block
3.2.3- Display of blocks in LOGO! display:

The figure below shows a typical LOGO! display. Only one block can be displayed at the
time. This is why block numbers have been introduced to help control the circuit structure.
Block number –
Another block is assigned by LOGO!
connected at this point
Input
This connector is not
Block
Fig.4: View of the LOGO! display

3.2.4- Assignment of a block number:
Every time we insert a block into a program, LOGO! assigns a block number to this block.
LOGO! uses the block number to show the interconnection between blocks. The block numbers are
initially only as an orientation in the circuit program.
Page | 11
Block numbers
These blocks are

interconnected
Fig.5: Assignment of a block number

The overview screen shows the three LOGO! displays that together make up the circuit
program. As it can be viewed, LOGO! interconnects the blocks with each other by using the block
numbers.
3.3- Important rules of LOGO! operation:
 Rule 1 - Changing the operating mode
We create the circuit program in the Programming mode. After a Power on and "No Program
/ Press ESC" on the display, we press ESC to enter Programming mode. We can change the time
values and parameter values of an existing circuit program in the Parameter assignment and
Programming modes.
LOGO! is in RUN mode during parameter assignment, which means the circuit program is
still being processed. We must stop the processing of the circuit program for programming with the
"Stop" command. We get to RUN mode with the menu item 'Start' in the main menu. Press ESC in
RUN mode to return to the Parameter assignment mode. If we are in Parameter assignment mode
and want to return to Programming mode, run the "Stop" command in the parameter assignment
menu and answer with "Yes" for "Stop Prg" by moving the cursor to "Yes" and pressing OK.
 Rule 2 - Outputs and inputs
We always enter a circuit from the output to the input. We can connect an output with several
inputs but not connect several outputs to one input. We cannot connect an output with a preceding
input within a program path. We need to interconnect bit memories or outputs for such internal
feedback.
 Rule 3 - Cursor and cursor movement
The following applies when entering a circuit:
We can move the cursor when it is shown as underscore.
Page | 12
 we move the cursor in the circuit with the , ,  or  keys

 we change to "Select connector/block" with OK
 we exit entering the circuit with ESC
If the cursor is displayed as solid block, we must select a connector/block.
 we select a connector/block with the  or  keys
 we apply the selection with OK
 we go back one step with ESC
 Rule 4 – Planning
Before we enter a circuit, we plan it completely on paper or program LOGO! directly with
LOGO!Soft or LOGO!Soft Comfort. LOGO! can only save complete programs. If a circuit has not
been entered completely, LOGO! cannot exit the Programming mode.
3.4- Overview of LOGO! menus
 Programming mode:
Page | 13
 Parameter assignment mode:
Page | 14
Chapter2: Development strategy
This chapter will describe the different steps done to implement the program in the
programmable logic controller.
1- Main task:
The objective of this graduation project is to concept a PLC based control panel used to
control a three-phase squirrel cage asynchronous motor with regards to the following specifications:
 Start the motor in different ways: Forward start, reverse start, forward star/delta start and reverse
star/delta start
 Stop the motor manually, or in case of an emergency or when overload occurs.
 Display the state of the motor (forward running, reverse running, star connection, delta connection
and overloaded).
2- Technological choices:
The following table 2 shows the technological choices used for the control of the motor.
Technological choices
Element Designation Function
STOP STOP Button Stop the motor
FW Forward START Button Run the motor in the forward direction
RV Reverse START Button Run the motor in the reverse direction
Forward Star/Delta START
FWYD Direct star/delta Starter
Button
Reverse Star/Delta START
RVYD Reverse star/delta Starter
Button
ES Emergency STOP Button Stop the motor (case of an emergency)
K1 Magnetic Contactor Supply the motor (Positive sequence)
K2 Magnetic Contactor Supply the motor (Negative sequence)
Ky Magnetic Contactor Star connection
Kd Magnetic Contactor Delta connection
F Thermal Overload Relay Protection against overload
Page | 15
MCB Miniature Circuit Breaker Protection against short-circuits

F1 Fuse Protection against short-circuits
H1 Signal lamp Forward running
H2 Signal lamp Reverse running
H3 Signal lamp Motor windings connected in star
H4 Signal lamp Motor windings connected in delta
H5 Signal lamp Motor overloaded
Tab.2: Technological choices
3- PLC I/O addressing:

Table 3 below describes the PLC I/O addressing.
PLC I/O addressing

Element Type PLC addressing
STOP Input I1
RVYD Input I2
FWYD Input I3
RV Input I4
FW Input I5
ES Input I6
F Input I7
K1, H1 Output Q1
K2, H2 Output Q2
Ky, H3 Output Q3
Kd, H4 Output Q4
Tab.3: PLC I/O addressing

4- Motor control panel wiring with LOGO! 24RC:
Figure 6 on page 17 shows the wiring method according to technological choices and PLC
I/O addressing.
Page | 16
Figure 6: Motor control wiring diagram
Page | 17
5- Problem solution:
The main problem in this program is how to isolate the effect of each inputs (especially push
buttons for motor running), so we can activate only one push button and only one at a time. At that
moment, if one push button of those one (FW, RV, FWYD and RVYD) is activated, the effect of
others will be eliminated until the motor is switched off.
This problem can be solved by using to special blocks:
 NOR block:
This logic functions gives 0 when at least one input is set to 1.
 Latching Relay:
This function memorizes the state of the SET (S) input until it is erased by the RESET (R)
input.
In the following, we will give the held solution: PLC connection label, the required blocks and
the complete program.
Figure 7: Connection label
Page | 18
Fig.8: Designation of program blocks
Page | 19
Fig.9: Final program to implement
Page | 20
Conclusions and Future work
PLC or Programmable logic controllers are in the end controller better suited and specifically
made for automation industry. The following reason can be cited for PLCs success over
microcontroller or microprocessor-based costume solutions.
 Large capacity - The PLC nowadays have a capacity of 3000+ I/Os that is analog and digital
combined. This is maintained through a central engineering station for ease of control.
 Modular Design - The PLC capacity and design can easily modified to suite customer need
post implementation stage. This is not feasible with relays or microcontroller-based solutions.
 Distributed architecture - For large application a distributed system can be implement with
communication between various PLC using protools like Modbus or profibus etc.
 Industrial Grade - PLCs are designed with tolerance to withstand various hazardous condition
for Industries such as Electromagnetic interference, high temperature, power fluctuation etc.
 Safety - PLCs manufacturers also provide safety features such are SIL certification as per
customer requirement for Protection/Emergency Shutdown System.
 Utility - PLCs can interface with a large no of drives and actuators ranging from analog and
digital to special type such as speed measurement and RTD/thermocouples etc. These can be done
easily by changing the I/Os modules and configuring them.
 Easy Maintenance and Spares - Due to modular design the trouble shooting is easier and the
no of spares requirement is reduced and easily manageable.
 Inbuilt Function and Algorithms - There are inbuilt functions like PIDs, Feedforward, State
observer etc in the PLC logic software that can be used for logic design.
 Diagnostic features - PLC have inbuilt diagnostics for LAN failure, power failure, logic issues,
Disconnection of I/Os and alarms.
In this report, we try to give a global description of a program that should be implemented for
controlling a three-phase squirrel cage asynchronous motor in different starting methods. This
program has taken into account all the required specifications, in addition to the mandatory safety
precautions.
Page | 21
References
Siemens AG, "LOGO! Siemens" Manual Edition, June 2003.

[1] http://w3.siemens.com/mcms/programmable-logic-controller/en/logic-module-
logo/Pages/Default.aspx
[2] R.W. Lewis, “Programming industrial control systems using IEC 1131-3”
W.A. Halang & K.M. Sacha, “Programmable Logic Controllers, in Real Time Systems,
[3] Implementation of Industrial Computerised Process Automation”, World Scientific,
pages 291-313, Chapter 15
IEC International standard 1131-3, “Programmable controllers, Part 3: Programming

[4]
languages” ,1993
S. Anderson and D. Tourlas, “Diagrams and Programming Languages for

[5]
Programmable Controllers”, The University of Edinburgh, 1997
http://w3.siemens.com/mcms/programmable-logic-controller/en/logic-module-
[6]
logo/overview/Pages/default.aspx
Page | 22
Annexes
ANNEXE 1
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PLC Based Motor Control Panel

Implementation of a PLC program

Malik Khalid Salim Ghawas

SALALAH VOCATIONAL COLLEGE

in partial fulfillment of the requirements

for the award of the degree

Vocational Educational Diploma Program

Electrical Engineering (Industrial Electricity)

In the name of Allah the Most Gracious, the Most Merciful…

Chapter 1 : Conceptual Framework 8

Chapter 2 : Development strategy 15

Conclusions and Future work 21

Fig.1 Hardware and software required to implement the program 8

Fig.2 LOGO! Inputs and outputs 10

Fig.3 Example of OR Block 11

Fig.4 View of the LOGO! display 11

Fig.5 Assignment of a block number 12

Fig.6 Motor control wiring diagram 17

Fig.7 Connection label 18

Fig.8 Designation of program blocks 19

Fig.9 Final program to implement 20

Tab.1 LOGO! Connector types 10

Tab.2 Technological choices 15-16

Tab.3 PLC I/O addressing 16

Chapter1: Conceptual Framework

In order to implement a program on the PLC, we need the following components:

Fig.1: Hardware and software required to implement the program

2- Features and advantages of PLC LOGO!:

Outputs Analog Inputs

Fig.2: LOGO! Inputs and outputs.

Network outputs 1) NQ1 to NQ64 (0BA7 only)

Tab.1: LOGO! Connector types.

3.2- Blocks and block numbers:

Fig.3: Example of OR Block

3.2.3- Display of blocks in LOGO! display:

Fig.4: View of the LOGO! display

These blocks are

Fig.5: Assignment of a block number

 we move the cursor in the circuit with the , ,  or  keys

 Parameter assignment mode:

Chapter2: Development strategy

MCB Miniature Circuit Breaker Protection against short-circuits

Tab.2: Technological choices

3- PLC I/O addressing:

PLC I/O addressing

Tab.3: PLC I/O addressing

Figure 6: Motor control wiring diagram

Figure 7: Connection label

Fig.8: Designation of program blocks

Fig.9: Final program to implement

Conclusions and Future work

Siemens AG, "LOGO! Siemens" Manual Edition, June 2003.

IEC International standard 1131-3, “Programmable controllers, Part 3: Programming

S. Anderson and D. Tourlas, “Diagrams and Programming Languages for

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