PLC TRAINER KIT 1

INTRODUCTION TO MECHATRONICS

Mechatronics is a branch of engineering that deals with the study and design of the
products whose function relies an interdisciplinary branches of engineering namely –
mechanical, electrical, electronics and control system.

Control
systems

Mechanical Electronics
Mechatronics
systems systems

Computer
systems

Mechatronics systems : The integration of microprocessor control system,

electrical system and mechanical system is termed as Mechatronics system.

Mechatronics system includes :

 Measurement and actuation module.

 Communication module.

 Central processing unit (CPU).

 Output signal conditioning module.

 Feedback module.

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IMPORTANCE OF MECHATRONICS

There have been rapid changes and improvements in the fields of electronics, computer
and control systems over the last years. As a result of this, computer controlled systems
have been in increase in almost every field. The number of only mechanically operating
systems is very few. The applications of artificial intelligence techniques have been put
into use in design, production and maintenance. Therefore, the design, production and
maintenance of advanced products are no longer a single subject. It has become a must to
use mechanics, electrics and electronics, hydraulics and pneumatic and computer
technologies together. This made Mechatronics emerge as a new discipline. What
Mechatronics covers ranges from home technologies to advanced medical devices and
from computer controlled benches to robots.

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The application fields of Mechatronics can be illustrated as

follows:

 Control Systems (position, level, pressure and heat control system)

 Robots (transport and welding robots)
 Industrial Automation (barcode systems and production belts)
 Building Automation (security systems, automatic air conditioning and automatic
door systems)
 Home appliances (washing machines and dish washers)
 Automotive (air bag, antilock braking system)
 Defense Industry (mine detection robots, automatically guided vehicles)
 Medical Applications (magnetic resonance, arthroscopic devices, ultrasonic
probes etc.)
 Aeronautical Engineering (automatic pilots, unmanned aerial vehicles)
 Image and Sound Processing (automatic focusing devices, sound-operated
devices)
 Production (Computerized Numerical Control -CNC, Numerical Control -NC)
 Laser optical systems (barcode)
 Intelligent measuring devices (calibration devices, testing and measuring sensors.

Advantages of Mechatronics.

1) Versatility

Having touch with both Mechanical engineering and Electrical engineering, it opens us to
a wide field of industries that you can enter. You can do hands on mechanical work,
wiring and programming, key core skills that would be highly appreciated and especially
since you are good at them.s

2) Robotics & Automation Specialty

Mechatronics are dedicated to the study and learning of Robotics and Automation which
is definitely going to be key growth during years ahead. One who acquires the knowledge
in the field of mechatronics has great scope in the modern robotics and automation
industries.

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3) Growth Potential

At present Mechatronics is still a relatively small group compared to other fields despite
how important we are in manufacturing and automation. Therefore upcoming years this
field has got a great growth potential.

4) Simplified mechanical design.

5) Rapid machine setup.

6) Cost-effectiveness.

7) Rapid development trials.

8) Possibilities for adaptation during commissioning.

9) Optimized performance, productivity, reliability.

10) Guaranteed quality of the products

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INTRODUCTION TO PROGRAMMABLE LOGIC CONTROLLER

A programmable logic controller (PLC), or programmable controller is an

industrial digital computer which has been adapted for the control of manufacturing
processes, such as assembly lines, robotic devices or any activity that requires high
reliability control and ease of programming and process fault diagnosis.

Need for PLC.

1. Hard wired panels were time consuming to wire, debug and change.
2. Easy to modify input and output devices.
3. Easily programmed and maintained.
4. Be able to function in industrial faculty efficiently.
5. It should be programmable, reusable, and reliable.
6. It should be in a solid state and no moving parts

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TECHNICAL STUDY OF PLC

PLC Operation Steps:
This type of machine uses four steps to operate and control the associated machine.
These work in a repeating loop to keep the right level of control. All machines use the
same loop, starting with the input scan and ending with housekeeping.

Step Process

Input Scan Detects input device state

Connects to PLC

Program Scan Carries out program logic made by user

Output Scan De-energizes or energizes output devices

Connects to PLC

Housekeeping Communicates with internal diagnostic

Communicates with programming terminals

All four steps are straightforward and allow for seamless control operation. How long
each step takes depends on the machine a person is using. However, all PLC machines
work significantly faster than manual controls.

Program Scan

When a PLC executes a program, it must know in real time when external devices
controlling a process are changing. During each operating cycle, the processor reads all
the inputs, takes these values, and energizes or de-energizes the outputs according to the
user program. This process is known as a program scan cycle. Illustrates a single PLC
operating cycle consisting of the input scan, program scan and output scan.

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Special features of PLC

1. Programming in PLC is easier than wiring the physical components.

2. The PLC can be reprogrammed using user – friendly programming software.
3. Installation and maintenance of PLCs is easier.
4. PLCs take up much less space.
5. The PLC can be connected to distributed plant automation system, supervised and
monitored.
6. PLCs are armored for severe conditions (such as dust, moisture, heat, cold), and
have the facility for extensive input/output (I/O) arrangements.
7. PLCs operate electric motors, pneumatic or hydraulic cylinders,
magnetic relays, solenoids, or analog outputs.
8. PLC may have external I/O modules attached to a computer network that plugs
into the PLC.

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Advantages of PLC.

1. Rugged and designed to withstand vibrations, temperature, humidity, and noise.

2. Have interfacing for inputs and outputs already inside the controller.
3. PLCs are easily programmed and have an easily understood programming language.
4. Troubleshooting is Easier and Faster..
5. Easy to develop Programs by offline simulation
6. Less amount of Space Needed
7. Less Maintenance
8. Easy to Monitor Inputs and Outputs by HMI devices....and from PC's

ARCHITECTURE OF PLC

Internal Architecture

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Above Figure shows the basic internal architecture of a PLC. It consists of a central
processing unit (CPU) containing the system microprocessor, memory, and input/output
circuitry. The CPU controls and processes all the operations within the PLC. It is
supplied with a clock that has a frequency of typically between 1 and 8 MHz. This
frequency determines the operating speed of the PLC and provides the timing and
synchronization for all elements in the system. The information within the PLC is carried
by means of digital signals. The internal paths along which digital signals flow are called
buses. In the physical sense, a bus is just a number of conductors along which electrical
signals can flow. It might be tracks on a printed circuit board or wires in a ribbon cable.
The CPU uses the data bus for sending data between the constituent elements, the address
bus to send the addresses of locations for accessing stored data, and the control bus for
signals relating to internal control actions. The system bus is used for communications
between the input/output ports and the input/output unit.

The CPU:

The internal structure of the CPU depends on the microprocessor concerned. In general,
CPUs have the following:

An arithmetic and logic unit (ALU) that is responsible for data manipulation and carrying
out arithmetic operations of addition and subtraction and logic operations of AND, OR,
NOT, and EXCLUSIVE-OR.

Memory, termed registers, located within the microprocessor and used to store
information involved in program execution.

A control unit that is used to control the timing of operations.

The Buses:

The buses are the paths used for communication within the PLC. The information is
transmitted in binary form, that is, as a group of bits, with a bit being a binary digit of 1
or 0, indicating on/off states. The term word is used for the group of bits constituting
some information.

Thus an 8-bit word might be the binary number 00100110. Each of the bits is
communicated simultaneously along its own parallel wire. The system has four buses:

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The data bus carries the data used in the processing done by the CPU. A microprocessor
termed as being 8-bit has an internal data bus that can handle 8-bit numbers. It can thus
perform operations between 8-bit numbers and deliver results as 8-bit values. The address
bus is used to carry the addresses of memory locations. So that each word can be located
in memory, every memory location is given a unique address. Just like houses in a town
are each given a distinct address so that they can be located, so each word location is
given an address so that data stored at a particular location can be accessed by the CPU,
either to read data located there or put, that is, write, data there. It is the address bus that
carries the information indicating which address is to be accessed. If the address bus
consists of eight lines, the number of 8-bit words, and hence number of distinct
addresses, is 28 ¼ 256. With 16 address lines, 65,536 addresses are possible.

The control bus carries the signals used by the CPU for control, such as to inform
memory devices whether they are to receive data from an input or output data and to
carry timing signals used to synchronize actions. The system bus is used for
communications between the input/output ports and the input/ output unit.

Memory:

To operate the PLC system there is a need for it to access the data to be processed and
instructions, that is, the program, which informs it how the data is to be processed. Both
are stored in the PLC memory for access during processing. There are several memory
elements in a PLC system:

System read-only-memory (ROM) gives permanent storage for the operating system and
fixed data used by the CPU.

Random-access memory (RAM) is used for the user’s program. Random-access memory
(RAM) is used for data. This is where information is stored on the status of input and
output devices and the values of timers and counters and other internal devices.

The data RAM is sometimes referred to as a data table or register table. Part of this
memory, that is, a block of addresses, will be set aside for input and output addresses and
the states of those inputs and outputs. Part will be set aside for preset data and part for
storing counter values, timer values, and the like.

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Possibly, as a bolt-on extra module, erasable and programmable read-only-memory

(EPROM) is used to store programs permanently.

The PLC processor: It stores the control program and data in its memory. Reads the
status of connected input devices. Executes the control program. Commands connected
outputs to change state based on program execution For example: Turn a light on, start a
fan, adjust a speed, or temperature and Comes in various physical forms.
I/O Modules: They Physically connect to field devices. Input modules convert electrical
signals coming in from input field devices such as pushbuttons, to electrical signals that
the PLC can understand. Output modules take information coming from the PLC and
convert it to electrical signals the output field devices can understand, such as a motor
starter, or a hydraulic solenoid valve. I/O comes in various forms.

A module in PLC.

Programmable Logic Controllers (PLCs) are computers designed to automate

electromechanical processes. They are used in a wide range of applications including
assembly lines, food processing, transportation, injection molding and water treatment.

Interface Module

Interface Modules are small terminals most often used to activate adjacent systems.

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User Interface:
PLCs may need to interact with people for the purpose of configuration, alarm reporting
or everyday control. A Human-Machine Interface (HMI) is employed for this purpose.
HMI's are also referred to as MMI's (Man Machine Interface) and GUI (Graphical User
Interface).A simple system may use buttons and lights to interact with the user. Text
displays are available as well as graphical touch screens. Most modern PLCs can
communicate over a network to some other system, such as a computer running a
SCADA (Supervisory Control And Data Acquisition) system or web browser.

Selection criteria of PLC:

* System (task) requirements.
* Application requirements.
* What input/output capacity is required
* What type of inputs/outputs are required
* What size of memory is required
* What speed is required of the CPU
* Electrical requirements.
* Speed of operation.
* Communication requirements.
* Software.
* Operator interface.
* Physical environments.

System requirements:
* The starting point in determining any solution must be to understand what is to be
achieved.
* The program design starts with breaking down the task into a number of simple
understandable elements, each of which can be easily
described.

Application requirements:

* Input and output device requirements. After determining the operation of the system,
the next step is to determine what input and output devices the system requires.

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* List the function required and identify a specific type of device.

* The need for special operations in addition to discrete (On/Off) logic.
* List the advanced functions required beside simple discrete logic.

Electrical Requirements:
The electrical requirements for inputs, outputs, and system power; When determining the
electrical requirements of a system, consider three items:

 Incoming power (power for the control system);

 Input device voltage; and
 Output voltage and current.

Speed of Operation:
How fast the control system must operate (speed of operation).
When determining speed of operation, consider these points:
1. How fast does the process occur or machine operate

2. Are there “time critical” operations or events that must be detected

3. In what time frame must the fastest action occur (input device detection to output
device activation)
4. Does the control system need to count pulses from an encoder or flow-meter and
respond quickly

Communication: If the application requires sharing data outside the process, i.e.
communication. Communication involves sharing application data or status with another
electronic device, such as a computer or a monitor in an operator’s station.
Communication can take place locally through a twisted-pair wire, or remotely via
telephone or radio modem.

Operator Interface:
If the system needs operator control or interaction. In order to convey information about
machine or process status, or to allow an operator to input data, many applications require
operator interfaces. Traditional operator interfaces include pushbuttons, pilot lights and
LED numeric display. Electronic operator interface devices display messages about

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machine status in descriptive text, display part count and track alarms. Also, they can be
used for data input.

Physical Environment
The physical environment in which the control system will be located. Consider the
environment where the control system will be located. In harsh environments, house the
control system in an appropriate IP-rated enclosure. Remember to consider accessibility
for maintenance, troubleshooting or reprogramming

Programming Languages
A program loaded into PLC systems in machine code, a sequence of binary code numbers
to represent the program instructions. Assembly language based on the use of mnemonics
can be used, and a computer program called an assembler is used to translate the
mnemonics into machine code.
High level Languages (C, BASIC, etc.) can be used.

Programming Devices
1. programming console
2. Hand programmer
3. computer system

PLC Languages

The following is a list of programming languages specified by this standard:

 Ladder diagram (LD)
 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)

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.

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Ladder Logic:

Ladder logic is the main programming method used for PLC's. As mentioned before,
ladder logic has been developed to mimic relay logic. The decision to use the relay logic
diagrams was a strategic one.

By selecting ladder logic as the main programming method, the amount of retraining
needed for engineers and trades people was greatly reduced.

The first PLC was programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers
how to program - so this programming method has stuck and it is the most common
technique for programming in today's PLC.

Mnemonic Instruction

There are other methods to program PLCs. One of the earliest techniques involved
mnemonic instructions. These instructions can be derived directly from the ladder logic
diagrams and entered into the PLC through a simple programming terminal.

Sequential Function Charts (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.

Structured Text (ST)

Programming has been developed as a more modern programming language. It is quite

similar to languages such as BASIC and Pascal. Structured Text (ST) is a high level
textual language that is a Pascal like language. It is very flexible and intuitive for writing
control algorithms.

Function Block Diagram (FBD)

FBD is another graphical programming language. The main concept is the data flow that
start from inputs and passes in block(s) and generate the output.

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INTRODUCTION TO LADDER LOGIC

LADDER LOGIC
Ladder Logic, or Ladder Diagrams is the most common programming language used to program a PLC.

Ladder logic was one of the first programming approaches used in PLCs because it
borrowed heavily from the Relay Diagrams that plant electricians already knew. The symbols used
in Relay Ladder Logic consist of a power rail to the left, a second power rail to the right,
and individual circuits that connect the left power rail to the right. The logic
of each circuit (or rung) is solved from left to right. The symbols of these diagrams
look like a ladder - with two side rails and circuits that resemble rungs on a ladder. The picture
above has a single circuit or "rung" of ladder.
• If Input1 is ON (or true) - power (logic) completes the circuit from the left
rail to the right rail - andOutput1 turns ON (or true).
• If Output1 is OFF (or false) - then the circuit is not completed and logic
does not flow to the right – and Output 1 is OFF. There are many logic symbols

CONTACTS AND COILS

With just the Normally Open Contact and Normally Open Coil - a surprising array of
basic logical conditions can be represented.

Normally Open Contact.

Normally Open Coil

This can be used to represent any discrete output from the control logic .When "solved" if the logic
to the left of the coil is TRUE, the referenced output is ON (logical 1).

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Below figure shows an example of a single rung ladder.

TIMERS AND COUNTERS

Many times we will want to take action in a control

program based on more than the states of discrete inputs
and outputs. Sometimes, we will want to turn something on
after a delay, or count the number of times a switch is hit. To do
these simple tasks, we will need Timers & Counters.

Simple Timers (TIM)

A timer is simply a control block that takes an input and changes an output
based on time. There are two basic timer types we will deal with
initially (there are other advanced timers, but we will start with the
basics first) - On-Delay Timer and the Off-Delay Timer.

On-Delay Timer
This timer takes an input, waits a specific amount of time, then turns ON an
output (or allows logic to flow after the delay).

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Off-Delay Timer
this timer takes turns ON an output (or allows logic to flow) and keeps that output ON
until the set amount of time has passed, then turns it OFF (hence off-delay)

Simple Counter (CNT)

A counter simply counts the number of events that occur on an input. There are two basic
types of counters- Up counter and a Down counter.

Up Counter
As its name implies, whenever a triggering event occurs, an up counter
increments the counter.

Down Counter
Whenever a triggering event occurs, a down counter decrements the counter

Ladder programs
Ladder programs process inputs at the beginning of a scan and outputs at the end of a
scan, as illustrated in. For each rung executed, the PLC processor will perform the
following steps: The first step is to update the input image table by sensing the voltage of
the input terminals. Based on the absence or presence of a voltage, a 0 or a 1 is stored
into the memory bit location designated for a particular input terminal. The second step is
to solve the ladder logic in order to determine logical continuity. The processor scans the
ladder program and evaluates the logical continuity of each rung by referring to the input
image table to see if the input conditions are met. If the conditions controlling an output
are met, the processor immediately writes a 1 in its memory location, indicating that the
output will be turned ON; conversely, if the conditions are not met a 0 indicating that the
device will be turned OFF is written into its memory location.

And the final step of the scan process is to update the actual states of the output devices
by transferring the output table results to the output module, thereby switching the
connected output devices ON (1) or OFF (0).

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INTRODUCTION TO INTRODUCTION
TO ABB AC31GRAF PLC SOFTWARE

USER MANUAL FOR ABB AC31GRAF PLC:

Install the ABB software from the CD. After the completion of installation go for Start
menu on the desktop and select on ABB AC31GRAF option as shown and follow the
given steps

1. Project Management Window is opened

2. Click on New button for creating new project

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3. Enter the name for the project in the name text box, select the language from the
language option. Select Quick LD(Ladder diagram) & click on OK button.

4. Programming window is opened as shown below.

Considering a simple example, click on F2 key button for inserting Contact on Left.
Rung instructions are explained later.

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Double click on the NC contact for entering the input address

Click on the button to select the address.

Select 162.00 for input & O62.00 for output.

5. For verifying the code go for FileVerify option, verify window is seen,

click on verify and Build.

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6. Go for Options and Link Configuration

Select the COM port name from the options listed, click on OK.

7. PLC Communication is to be done, go for FilePLC Communication

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On click of PLC Communication option, control panel window is opened as shown

below.

Click on Download option send program

click on yes

Click on yes, It asks for updating the EPROM, click on yes

finally EPROM Updated window is seen

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8. Check for the desired output through the PLC Interface.

Initially keep the PLC kit in Program mode (off), after downloading the program change
the PLC to Run Mode to verify the output on PLC Panel.

As discussed above quick LD language is selected to build ladder programs as per the
given applications.

Using the quick LD editor

The LD Language enables the graphic representation of Boolean expressions. Boolean

AND, OR, NOT, operators are explicitly represented by the diagram topology. Boolean
input variables are attached to graphic coils. The AC31GRAF Quick LD editor provides
diagram entering using either keyboard or mouse. Elements are automatically linked and
arranged on rungs by the Quick LD editor. No connection is drawn manually by the user.

The Quick LD Editor also arranges rungs in the diagram so that the space filled by the
diagram is always optimized.

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A Contact modifies the Boolean data flow, according to the state of a Boolean variable.
The name of the variable is displayed upon the contact symbol . The following types of
contacts are supported by AC31GRAF Quick LD Editor.

A Coil represents an action. The rung state is used to force a Boolean variable. The name
of the other variable is displayed upon the coil symbol. The following types of coils are
supported by AC31GRAF.

A block in an LD Diagram can represent a function, a function block, a sub programmer

or an operator. Its first input and output parameters are always connected to rung. Other
inputs and output parameters are literally written outside of the block rectangle.

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A jump symbol always refers to a rung label, id. The name of a rung defined somewhere
in the same LD diagram. It is placed at the end of a rung. When the rung state is true, the
execution of the diagram directly jumps to this target rung. Note that backward jumps are
dangerous as they may lead to a blocking of the PLC Loop in some cases.

On Some operators, functions or function blocks , the first input does not have Boolean
data type. As the first input must always be connected to the rung, another input is
automatically inserted at the first position, called ‘EN’. The block is executed only if the
EN input is TRUE. Below is the example of a comparison Operator, and the equivalent
expression.

On some operators, functions or function blocks , the first output does not have Boolean
data type. As the first output must always be connected to the rung, another output is
automatically inserted at the first position called ‘ENO’. The ENO output always takes
the same state as the first input of the block. On some cases , both EN and ENO are

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required. Below is an example with an arithmetic operator, and the equivalent code
expressed in pseudo language.

This does not allow to continue a rung (insert other contacts or coils) on the right of a
coil. If several outputs have to be made on the same rung, the corresponding coils must
be drawn in parallel.

The editing grid

The LD diagram is entered in a logical matrix. Each cell of the matrix may contain up to
one LD symbol. Use the arrows of the keyboard, or click on a cell to move the current
selection. The selected cell is marked in

reverse. For some cut/copy/paste operations, it is possible to select several cells. To do

that with the mouse, just drag the mouse cursor in the diagram. With keyboard, use arrow
keys with SHIFT key pressed.

Starting a new rung

To add a new rung to a diagram, move the selection after the last existing rung and insert
a contact (hit F2 or press the corresponding button in the LD toolbar). A new rung with
one contact and one coil is created.

Entering the rung comment

Each rung may be documented with up to two lines of text. To enter a rung comment
text, move the selection on the cell upon the rung and hit ENTER key, or double click on
this cell with the mouse:

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Entering the rung label

Each rung may be identified by a name. This name can be used as a target label for jump
operations. To enter or change the label of a rung, move the selection on rung head and
hit ENTER key, or double click on this cell with the mouse:

The AC31GRAF Quick LD editor keeps the memory of the rung labels you already
entered, whether it has been specified for a rung name or a jump operation. The
"Jump/Label"' dialog box gives you the possibility either to enter a new label, or to select
an existing one.

If you enter a new name, it will automatically be added to the list. The "Remove" button
is used to remove the selected name from the list. It does not remove the label on the rung
you selected in the diagram. To do this, just press OK when the edit box is empty.

Inserting symbols on a rung

The insertion of symbols (contacts, coils, blocks...) on an existing rung is always made
according to the current selection. You have to select a valid cell position within the rung
and hit one of the following function keys to insert:

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F2 a contact before the selected symbol (on the left)

F3 a contact after the selected symbol (on the right)

F4 a contact in parallel with the selected symbol

F6 a block before the selected symbol (on the left)

F7 a block after the selected symbol (on the right)

F8 a block in parallel with the selected symbol

The following commands are valid when the selection is on the rung output (coil):

F5 add a coil in parallel with the selected one

F9 add a "Jump" symbol in parallel with the selected one

Shift + F9 add a "Return" symbol in parallel with the selected one

For parallel insertion (F4/F8), if several contacts of a rung are selected together, the
symbol is inserted in parallel with the group of selected elements. Below is an example:

To insert symbols in the diagram, you can also use the commands of the "Insert" menu.
With the mouse, you can click on the LD toolbar, on the type of symbol you want to
insert:

Entering symbols

To associate a variable symbol to a contact or a coil, select it and hit ENTER. With the
mouse, double click on the contact or coil. A variable selection box appears. Refer to

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chapter "More about program editors" in this document for further information about how
to use this box. To associate a function, function block or operator to a block, hit ENTER
when the selection is on the inside its rectangle. To associate a variable symbol to an
input or output block parameter the selection must be on the corresponding location,
outside the rectangle of the block.

Dialog boxes including variable or block selection lists are normally used for text input.
If the "Manual keyboard input" mode is checked in the "Options" menu, variable symbols
and block names are entered directly in a single text edit box. Enter new text and hit
"Enter" key to validate it, or hit "Esc" key to exit modification and close the text edit box.
The text edit box used in "Manual keyboard input" mode cannot be closed with the
mouse. For a variable, if the symbol does not exist, the variables list appears once the
"Enter" key is hit.

Changing the type of contacts and coils

The "Edit / Change coil/contact type" changes the type of the selected contact or coil. A
contact may be direct, negated, with positive or negative edge detection. A coil may be
direct, negated, set or reset, with positive or negative edge detection. Hitting the SPACE
bar has the same effect.

Inserting a rung in a diagram

The "Edit / Insert rung" command inserts a new rung in the diagram, before the selected
one. The rung is initiated with one contact and one coil.

Correcting a diagram

The DEL key can be used to remove the selected elements. It is not possible to remove a
coils, a jump or return symbol when it is the only output of a rung. Use "Edit / Undo"
command to restore elements after a DEL command. The DEL command can also be

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applied to a group of elements selected in the diagram. The DEL command can be used
when selection is on the rung comment text to reset it. The DEL command, used when
the selection is on the rung head, remove the entire rung.

Copying symbols

The "Cut", "Copy", "Paste" commands of the "Edit" menu are used to move or copy
selected elements. These commands do not act on rung comments. The "Edit / Paste
special" command gives you the choice to

insert the pasted elements:

· before the selected element (on the left)

· after the selected element (on the right)

· in parallel with the selected element

Verifying (compiling) the program

The "File / Verify" command runs the AC31GRAF code generator to verify the
programming syntax of the currently edited program. In case of SFC language, both level
1 and 2 are checked. When syntax verification is complete, the code generator window
must be closed to continue work on the program. If there is only one program in the
application (the edited one) the application code is generated if no syntax error is
detected.

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PLC TRAINER KIT

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 PLC TRAINER KIT 33

INTRODUCTION TO PLC TRAINER KIT

The above figure shows the PLC trainer kit. This trainer kit has 8 number of inputs and 6
outputs, in addition to this it has ground and main connections. For the indication of the
output LED switches are provided. Basically PLC trainer kit provides an interface
between the ladder programs built using the respective software in the system and the
actual working models. From the figure following operations can be performed using this
trainer kit, which are as follows:

1) Motor on/off control.

2) Piston extension and retraction control.
3) Motor and pump control.
4) Water level controller.
5) Washing machine control.

Apart from these operations for applications in industries where PLC’s play a vital role in
beverage, food production etc, in these industries conveyor system used can be controlled
by using PLC trainer kit as an interface.
We can perform all the above functions in the PLC trainer kit itself without using any
actual equipment.

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SAILENT FEATURES :

 Various Static application dependent programs to be interfaced with PLC

STATIC APPLICATION PANELS (SAP):

Switching of Lights

Water level Control

Traffic Light Control

Counting pulses from source and checking for pre-determined values.

Conveyor control

Lift Control

Washing Machine

Timing Circuits

 Learning and Troubleshooting Skills through front panel

 Study of Ladder Diagram
 Dynamic Ladder display on Personal Computer
 Light weight study panel

SPECIFICATION OF PLC :
Make VASUNDHARA TECHNOLOGIES
DI 8 Built in
DO 6 Built in
PC Interface RS 232 Cable

Sufficient Courseware: Literature for Various Static application dependent programs

Instructor’s Guide, Technical Reference.

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 PLC TRAINER KIT 35

Motor on/off control:

(* *)
INPUT ESV MOTOR
T_0 Q

TIMER ZD

As discussed above this operation can be performed using PLC trainer kit. To perform
this the above figure shows the ladder diagram built using ABB AC31GRAF PLC
software. In this diagram there is an input, on-delay timer and an output (motor). When
input is given the on-delay timer which is set for a particular time, switches on the motor
after the specified time. When the input is turned off the motor stops running.

Piston extension and retraction control:

INPUT SWITCH PISTON MOVEMENT

As discussed above this operation can be performed using PLC trainer kit. To perform
this the above figure shows the ladder diagram built using ABB AC31GRAF PLC
software. In this diagram there is an input and an output. When the input is given the
piston extends and when the input is turned off the piston retracts back to its original
position, which is indicated by the LED’s on the trainer kit.

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Water level controller:

(* *)
%M000.01 TE MOFF

%M000.02 TF

SE

(* *)
TF ESV %M000.01 MON
T_0 Q
%M000.02 TE
T2 ZD
SF

(* *)
MON ESV %M000.01
T_0 Q
%M000.02
T1 ZD

In this Liquid Level Set-up, we are having two tanks namely SUMP & TANK. Sump is
used to store the water. Whenever the motor is on water is pumped to the tank from the
sump to the Tank in which the level of water is maintained.
In this setup we are having three types of probes. Extreme left probe is the REFERENCE
probe, which will always be immersed in water in sump. Middle one is the LOWER
LEVEL probe. Right side is the UPPER LEVEL probe in tank.
PUMP will be ON or OFF, depending on the logic what we have implemented in the
Ladder Logic program. O62:00 gives necessary signal to the motor either to turn ON or
OFF. And all the above operations are indicated by the LED’s on the PLC trainer kit.

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MOTOR PUMP ON/OFF CONTROL

The above diagram shows the ladder logic of MOTOR PUMP control Build using ABB
AC31GRAF PLC software. In this diagram when input I62.00 is switched on then the
motor switches on after a delay of 5000millisecs and then switches off. Then later pump
switches on after a delay of 10000millisecs.

(* *)
%I62.00 ESV MOTOR
T_0 Q

%KD000.01 ZD

(* *)
%I62.00 ESV PUMP
T_0 Q

%KD000.01 ZD

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CONCLUSION:

In many mass production industries where automation is required to complete the given
tasks in time the PLC’s can be used. PLC’s are one of the effective ways for automation.
for the very automation the ladder programs which are required can be prepared in the
computer systems using sophisticated PLC softwares. These programs need to be
transferred to the working equipments which can be achieved by using the PLC trainer kit
which acts as an interface module between the computer systems and the actual working
equipments. The above model prepared can be used to simulate the operations in the
trainer kit itself and also to operate the actual working equipments. The advance version
of this model can be built and used in industries for practical applications.

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BIBILOGRAPHY

MECHATRONICS BOOK BY – BOLTEN

https://en.wikipedia.org/wiki/Programmable_logic_controller

https://www.engineersgarage.com/articles/plc-programmable-logic-controller

http://new.abb.com/plc.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING