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Level1 (Bigener) PDF
Level1 (Bigener) PDF
Training center
Pre-requisites : None
Duration : 6 days two hours per day
Description : Basics of PLC Operation and programming
Technology :
• LG K7M/MK-120S
• PC
• KGL and other appropriate Software
Target audience : All person that are required to deal with PLC
circuits and PLC programming.
contents : Lesson 1:
• Digital signal
• Digital input device
• Digital output device
• PLC architecture "PLC inside view"
• PLC circuit wiring and interface
Lesson 2:
• Ladder logic
• Memory map
• KGL programming software
Lesson 3:
• Timers
1. On delay timer
2. Off delay timer
3. Mono stable timer
• Examples
• using master controller tool
Lesson 4:
• Counters
• Examples
Lesson 5:
• Step controller "sequence controller"
and its' applications
Lesson 6:
• How to choose suitable PLC for your
application
• General notes
Main points
Digital Signal
Hardware wiring
Inputs for a PLC come in a few basic varieties, the simplest are AC
and DC inputs.
Sourcing and sinking inputs are also popular. Instead, the device
only switches current on or off, like a simple switch.
FEATURES:
In the sensor the area of the plates and distance between them is
fixed. But, the dielectric constant of the space around them will
vary as different materials are brought near the sensor. An
illustration of a capacitive sensor is shown in Figure. an oscillating
field is used to determine the capacitance of the plates. When this
changes beyond a selected sensitivity the sensor output is
activated.
NOTE:
For this sensor the proximity of any material near the electrodes
will increase the capacitance. This will vary the magnitude of the
oscillating signal and the detector will decide when this is great
enough to determine proximity.
These sensors work well for insulators (such as plastics) that tend
to have high dielectric coefficients, thus increasing the capacitance.
But, they also work well for metals because the conductive
materials in the target appear as larger electrodes, thus increasing
the capacitance as shown in Figure. In total the capacitance
changes are normally in the order of pFard
Electro Hydraulic Automation (EHA)
℡ (+202)4941760-499377 Fax.(+202)49192896
- 10 -
Dielectrics and Metals Increase the Capacitance
The sensors are normally made with rings (not plates) in the
configuration shown in Figure. In the figure the two inner metal
rings are the capacitor electrodes, but a third outer ring is added to
compensate for variations.
Without the compensator ring the sensor would be very sensitive to
dirt, oil and other contaminants that might stick to the sensor.
FEATURES:
Size: 18mm or 30 mm
3-wire DC or 2-wire AC models
normally open or normally closed
3-wire DC available NPN or PNP
Adjustable sensitivity
Detecting distance to 15mm
LED indication of output status
2 meter cable
IP66 (18mm) or IP65 (30mm)
SOLENOIDS
VALVES
The flow of fluids and air can be controlled with solenoid controlled
valves. An example of a solenoid controlled valve is shown in Figure
the solenoid is mounted on the side. When actuated it will drive the
central spool left. The top of the valve body has two ports that will
be connected to a device such as a hydraulic cylinder. The bottom
of the valve body has a single pressure line in the center with two
exhausts to the side. In the top drawing the power flows in through
the center to the right hand cylinder port. The left hand cylinder
port is allowed to exit through an exhaust port. In the bottom
drawing the solenoid is in a new position and the pressure is now
applied to the left hand port on the Top and the right hand port can
exhaust. The symbols to the left of the figure show the schematic
equivalent of the actual valve positions. Valves are also available
that allow the valves to be blocked when unused.
Finally the PLC updates the status of the outputs. It updates the outputs based on
which inputs were on during the first step and the results of executing your program
during the second step. Based on the example in step 2 it would now turn on the first
output because the first input was on and your program said to turn on the first output
when this condition is true. After the third step the PLC goes back to step one and
repeats the steps continuously. One scan time is defined as the time it takes to execute
the 3 steps listed above.
Input wiring
Dc 24v
Output wiring
• Re-check the input voltage for the input part. If a voltage over the
maximum switching capacity (24V) is applied, it can cause faults,
destruction or fire.
• During drilling or wiring, do not allow any wire scraps to enter the
PLC. It can cause malfunction and fault.
• Wiring I/O wires with high voltage cable or power supply line can
cause malfunction or disorder.
• Be sure that any wire does not pass across during input LED (I/O
status will not be clearly identified).
• Be cautious that strong shock does not applied to the I/O part.
Main points
Ladder Logic
Memory Map
Example1:
Now let's compare a simple ladder diagram with its real world
external physically connected relay circuit and see the differences.
Figure (1.6)
P0
COM
K 24VDC
P1
P40
K
COM
24VDC
M
220VAC
To study PLC you must know the memory mapping of the data
memory of this PLC, the PLC data memory is divided into several
parts , every part have a name & special specifications , these parts
called devices .
1- P area
2- M area
3- K area
This device for real input and real outputs only, you can change
these device status (write in these bits) using hardware, if you put
24v on p0 input, and the bit of p0 get high (on)
Example:
This device for not real input and not real outputs, you can only
write in these bits using software instructions.
Example:
M0 Æ internal imagine input or output in plc.
Note:
No. of points (mxx) limited to plc software point
For example for master k120s from m000 to
m191f (191*16= 3056 marker)
This device the same like m device but it can keep its value even if
power off and on again.
Example:
Note:
No. of points (kxx) limited to plc software point
For example for master k120s from k00 to k31f
(31*16= 496) Keep relay.
(I.e. if power off while k0 was on, when power turn on again we
Will find k0 on)
Example:
Note:
You can get list of flags by click f3 from the keyboard then select
flags
Main points
Timers
Examples
Let's now see how a timer works. What is a timer? It's exactly what
the word says…….. It is an instruction that waits a set amount of
time before doing something. Sounds simple doesn't it.
On-Delay timer
This type of timer simply "delays turning on". In other words, after
our sensor (input) turns on we wait x seconds before activating a
solenoid valve (output). This is the most common timer. It is often
called TON (timer on delay)
Off-Delay timer
Let's now see how to use them. We typically need to know 2 things:
When the instructions before the timer symbol are true the timer
starts "ticking". When the time elapses the timer will automatically
close its contacts. When the program is running on the plc the
program typically displays the elapsed or "accumulated" time for us
so we can see the current value. Typically timers can tick from 0 to
65535 times.
This timer is the on-delay type and is named T0. When the enable
input is on the timer starts to tick. When it ticks 10 (the preset
value) times, it will turn on its contacts that we will use later in the
program. Remember that the duration of a tick (increment) varies
with the time base used. (I.e. in MK 120s I can set some timers the
time base 100msec, others to the time base 10msec ...)
In this diagram we wait for input P0 to turn on. When it does, timer
T000 (a100ms increment timer) starts ticking. It will tick 100 times.
Each tick (increment) is 100ms so the timer will be a 10000ms (i.e.
10 second) timer. 100ticks X 100ms = 10,000ms. When 10 seconds
have elapsed, the T000 contacts close and P40 turns on. When
input P0 turns off (false) the timer T000 will reset back to 0 causing
its contacts to turn off (become false) thereby making output P40
turn back off.
To get help on timers just click F10 (dialogue box will appear) Î
then SELECT TON FROM the LIST Î THEN CLICK help
Example
To put on delay timer with 100sec delay do the following Click F10--
--write Ton Tn 1000 as n any number from 0-255
Hint:
Hint:
Every timer has a bit or contact take the same name of the timer
for example t10 is contact of the timer T10 this bit condition depend
on its timer condition.
1-TON Example
When push the button P0 get on the contact T0 get on, when
release the button P0 get off T0 will keep on for 20 sec then get off
Example1:
OBJECT:
SOLUTION:
When start p.b (P0) pushed motor run in forward direction so Till
certain time (T144) then motor stop running at forward direction
(P40 off ) and reverse direction Begin till certain time (T145) then
motor stop running at backward direction (P41 off ) and run
forward again and so on.
Let's now look at what are called master controls. Master controls
can be thought of as "emergency stop switches".
Note:
Main points
Counters
Examples
OBJECT:
Store with maximum capacity 200 car, has two gates each one
has sensor make a program to output signal when store empty
and other one when full
Solution:
By up down counter, up enable (P0) from entrance gate and down
enable from exit Gate and compare counter value if less than 1 out
EMPTY signal (P40) and if
Greater Than 200 out FULL signal (P41)
Next Scan
After 100 scans, NO P0 turns off (becomes false, user release the
push button connected P0). The logic remains in the same state as
"next scan" shown above. (D doesn't react therefore the logic
stays the same on rungs 2 and 3)
When P0 get on m10 get on for one scan cycle, when P0 get
off m12 get on for one scan cycle
OBJECT:
Great knife driven by motor, make a program to operate this knife
through selector and when Overload occur knife sops and never
run again before make the selector off and ON again
Solution:
Main points
STEP CONTROLLER
For example:
For ladder S00.00 (it varies from S00.00 to S00.99) Step S00.00
ON firstly and if any step come (like S00.07) S00.00 OFF.
For this method we can move from any step to the other one
without any condition, but we must remember that only one step
will be ON
1- The previous step was ON before trying to SET this step (for
example to SET S00.02 S00.01 must be ON first)
Notes:
Only the first step (for example S00.00 for ladder S00) can come at
any time (i.e. If we SET S00.00 for ladder S00 at any time S00.00
will be ON)
Main points
General notes
after determine these data you can found more than plc
type match with these data , you will found that mk10s1
the most cheapest type , after that mk80S ,after that
mk120s, after that mk200s , after that mk300s