28-08-2014, 03:07 PM
This report has been prepared as a textbook to give an insight to Programmable Logic Controllers (PLC) based automation which is emerged out of the latest technological advancements in computers and communication, that guides the Modern industrial environment. Programmable Logic Controllers (PLC) is the conglomeration these two areas. PLC based automation forms the lifeline of modern automated Industries. With the advent of versatile networking techniques, PLCs are used in a complicated networked environment to enhance the efficiency of industries. This gives rise to a growing need for PLC training. Presented in a lucid language, the report helps the reader to understand the subject step-by-step. This book is divided into seven chapters and provides a comprehensive treatment of Programmable Logic Controllers. Throughout the preparation of the report, the authors have kept all the valuable details about the various training modules of PLC.
ACKNOWLEDGEMENT Before we get into thick of the things I would like to add a few heart- felt words for the people who were par of this study in numerous way, people who gave unending support right from the very beginning of this report. Their support cannot be acknowledged in words. I want to thank all those people who made my study possible and wish that my feelings of gratitude reached their hearts. First of all, I would like to thank the supreme powers, the Almighty God for his blessings showered on me that I’m able to complete this project work in this topic relevant to the present time. I also thank my beloved parents who supported me emotionally & financially to prepare this training report. Their motivation is unmatchable. I pay my deep gratitude to Mr. Harish Jindal, Head of the Department (ECE), Gulzar Group Of Engg. And Technology, Khanna for his motivation and supervision. I am also highly indebted to Ms. Amandeep Kaur and Ms. Rosy Kaplesh , Training Coordinator, Automation Systems (Schneider Electric), Ludhiana for their invaluable guidance throughout the work & this training report became realistic with her assistance. I am also grateful to my friends whose contribution cannot be described in words. And finally heartfelt appreciation to all those people who helped me to reach the completion of this report. Thanks. RAGHAV SHARMA PREFACE This report has been prepared as a textbook to give an insight to Programmable Logic Controllers (PLC) based automation which is emerged out of the latest technological advancements in computers and communication, that guides the Modern industrial environment. Programmable Logic Controllers (PLC) is the conglomeration these two areas. PLC based automation forms the lifeline of modern automated Industries. With the advent of versatile networking techniques, PLCs are used in a complicated networked environment to enhance the efficiency of industries. This gives rise to a growing need for PLC training. Presented in a lucid language, the report helps the reader to understand the subject step-by-step. This book is divided into seven chapters and provides a comprehensive treatment of Programmable Logic Controllers. Throughout the preparation of the report, the authors have kept all the valuable details about the various training modules of PLC. CONTENTS LIST OF FIGURES………………………………………….7 LIST OF TABLES…………………………………………...8 COMPANY PROFILE About Automation System………………………………………...9 Schneider All Over India – Service and Sales Network………….10 Key Milestone…………………………………………………...11 Vision……………………………………………………………..11 Activities………………………………………………………...12 Associations………………………………………………………12 Recent References………………………………………………...12 Training Module………………………………………………..13 1. AUTOMOTIVE DESCRIPTION 1.1 Automation and Automation Device…………………………14 1.2 Need of Automation…………………………………………..14 1.3 Program and Programmable Controller………………………14 1.4 Basics Before studying PLC………………………………...15 2. INTRODUCTION TO PLC 2.1 Definition and History of PLC……………………………..19 2.2 Manufacturing and Assembly Processes……………………...20 2.3 Overall PLC System…………………………………………..20 2.4 Programming a PLC…………………………………………...23 2.5 Advantages and Disadvantages……………………………..25 2.6 Leading brands of PLC 3. INTRODUCTION TO ZELIO LOGIC 3.1 Introduction…………………………………………………...26 3.2 Description of Serial Number………………………………...27 3.3 Diagrammatic Startup with Zeliosoft V 2.0…………………..28 3.4 Programming Language……………………………………..29 3.5 Elements Of Ladder Language……………………………….30 3.6 Programming Using ZELIOSOFT V 2.0……………………..37 3.7 Advantages and Disadvantages……………………………….38 4. TWIDO PLC 4.1 Introduction of Twido………………………………………...40 4.2 Types of Twido PLC………………………………………….40 4.3 Description of Serial Number…………………………………42 4.4 Communication Overview…………………………………….43 4.5 Expansion I/O Module to Base………………………………..45 4.6 Special Features of Twido Soft………………………………..46 4.7 Twido-Programming Software………………………………...50 4.8 Advantages…………………………………………………….50 4.9 Disadvantages………………………………………………….50 5. MODICON M340 PLC 5.1 General Information……………………………………………51 5.2 Power Supply…………………………………………………..52 5.3 Memory Card…………………………………………………..52 5.4 Digital Input/Output……………………………………………53 5.5 Programming Software-Unity Pro V4.0……………………….53 5.6 Project Browser………………………………………………...54 5.7 Start New Project………………………………………………55 5.8 Methodology to Develop New Program……………………….55 6. INTRODUCTION TO M218 PLC 6.1 Introduction…………………………………………………….57 6.2 M218 System Architecture…………………………………….58 6.3 M218 System Expansion Architecture………………………...59 6.4 SoMachine V3.0 Software……………………………………..60 6.5 Creation Of Project……………………………………………64 7. HUMAN MACHINE INTERFACE 7.1 Introduction To HMI………………………………………….66 7.2 STU Series Touch HMI………………………………………..67 7.3 Creation Of Project…………………………………………….68 7.4 XBTr400- HMI Using Keypad………………………………...70 7.5 Application Of HMI…………………………………………..71 8. SCADA 8.1 Introduction…………………………………………………….72 8.2 Architecture Of SCADA……………………………………….73 8.3 System Concept………………………………………………...74 8.4 Trends In SCADA……………………………………………...76 8.5 Application Of SCADA………………………………………...77 9. AUTOMATION OF BOTTLING INDUSTRY 9.1 Statement……………………………………………………..78 9.2 Inputs/Outputs………………………………………………..78 9.3 Procedure……………………………………………………..79 9.4 Program………………………………………………………..80 10. INDUSTRY APPLICATION OF PLC 81 CONCLUSION……………………………………………..81 BIBLIOGRAPHY…………………………………………..81 LIST OF FIGURES: 1.4.4 Types Of Switches…………………………………………………………...16 2.1.2 History Of PLC………………………………………………………………19 2.3.1 Operation Of PLC…………………………………………………………….20 2.3.2 PLC And Their Units………………………………………………………….21 3.2.1 Serial Numbers………………………………………………………………...27 3.3 Diagrammatical Startup with Zelio Soft v2.0..………………………………….28 3.4 Programming Language…………………………………………………………29 3.5.7 Clock…………………………………………………………………………..35 3.6 Programming with Zelio Soft v2.0………………………...……………………37 4.7 Twido Programming Software………………………………………………….50 5. Modicon M340 PLC……………………………………………………………...51 5.5 Programming Software Unity Pro v40………………………………………….53 5.6 Project Browser…………………………………………………………………54 5.7 Start New Project………………………………………………………………..55 5.8 Methodology To Develop New Project…………………………………………56 6.1 Introduction To M218 PLC……………………………………………………..57 6.2 M218 System Architecture……………………………………………………...58 6.3 M218 System Expansion………………………………………………………..59 6.4 So-Machine v3.0 Software……………………………………………………...60 6.4.3.1 Overview…………………………………………………………………….61 6.5 Creation Of Project……………………………………………………………...64 7.2 STU Series Touch HMI…………………………………………………………67 7.3 Creation Of Project……………………………………………………………...68 7.4 XBTr400-HMI Using Keypad…………………………………………………..70 8.2 Architecture Of SCADA………………………………………………………..73 8.3 System Concept…………………………………………………………………75 8.4 Trends In SCADA………………………………………………………………76 9.4 Program.…………………………………………………………………………80 List of Tables: 1.4.1 Number System……………………………………………………………..15 1.4.2 Brief Description Of The Logic Gates……………………………………….15 1.4.5 Input Devices………………………………………………………………...18 1.4.6 Output Devices……………………………………………………………….18 2.4.4 Basic Instructions……………………………………………………………..24 3.2.5 Power Supply………………………………………………………………..27 3.5.1 Graphical Elements…………………………………………………………...30 3.5.3 Discrete Outputs……………………………………………………………...32 3.5.5 Counters……………………………………………………………………..33 3.5.7 Clock………………………………………………………………………….35 3.5.8.2 Timing Diagram…………………………………………………………….36 4.5 Assembling An Expansion I/O Module To Base……………………………….45 4.6.1.4 Special Cases………………………………………………………………..46 4.6.4.2 Animation Table…………………………………………………………...48 4.6.5 Counters……………………………………………………………………...49 5.3 Memory Card…………………………………………………………………..52 7.4.1 Characterstics………………………………………………………………...70 8.5 Application Of SCADA……………………………………………………...71 9.2 Inputs/Ouputs………………………………………………………………..78 9.3 Procedure……………………………………………………………………..79 COMPANY PROFILE ABOUT AUTOMATION SYSYTEM Automation System was founded in 1995 and starting from scratch, got built it into a viable entity with annual sales of INR 30 million with small PLC, drives and SCADA system and grew into a company of repute in the industrial automation market in India. Appointed as the System Integrator of Schneider Electric in 1996, The Company got a bandwidth of products connecting sensors to boardrooms. The company has a staff of 20 engineers specialized in PLC systems; AC and DC drive applications and SCADA implementations. It has built long lasting relationships with corporate clients and is one of Schneider Electric’s top performing System Integrators. Marketing, system conceptualization, strategy and personnel motivation/training are the main areas of operation although being a small concern. Specialized in PLC’s, drives and other automation components for implementation of Automation schemes for a broad range of industries (Paper, Steel, Wire and Cable, Rubber, Automobile mfg etc.). Some of the projects handled are as follows: Designed & commissioned control system for complete biscuit plant using PLC, Drives and HMI on Unitelway network for an OEM of Punjab and commissioned the system in Kenya (Africa) and completed similar job for a plant to be commissioned in Nigeria Worked as a consultant to M/s Ralson Industries Ltd., one of the leading bicycle tyre manufacturers in India and helped them to buy complete second hand machinery from Germany and Holland, dismantled the complete machinery and then successfully commissioned the plant in Bhopal (Central India) using PLC, Drives, SCADA, and HMI on MODBUS plus Network Designed & Commissioned Automatic Tyre curing line of 28 barometric presses using PLC, SCADA on MODBUS Plus Network for M/s Continental of Germany installed at M/s Metro Tyres. Partnered Schneider Electric in commissioning, execution and after sales support for OSP SCADA project of Reliance Infocomm Ltd., one of the biggest projects of Transparent Factory in World with over 426 Telemecanique Micros. Schneider All Over India - Service and Sales Network Schneider Electric is a French global company. It was founded in 1836 by two Schneider brothers. From 1836 to today, Schneider Electric has transformed itself into the global specialist in energy management. Starting from its roots in the iron and steel industry, heavy machinery, and ship building, it moved into electricity and automation management. After 170 years of history, Schneider Electric has become today the solution provider that will help you make the most of your energy. It is among the fortune 500 companies which deal in electrical only. In 1981-1997 Schneider Group continued to focus on the electrical industry by separating from its non-strategic activities. This policy was given concrete form through strategic acquisitions by Schneider Group: Telemecanique in 1988, Square D in 1991 and Merlin Gerin in 1992 and it came to India in 1995. Schneider All Over India SERVICE NETWORK SALES NETWORK KEY MILESTONE VISION To bring innovation in the automation solution provided, and adding values in every stakeholder's life by providing the Right product/services, at Right time & at Right price. We wish to be universally admired & benchmarked as an organization for customer care, employee satisfaction & business operations of the highest integrity, forging an enduring and profitable relationship with stakeholders. ACTIVITIES Automation Systems takes prides in three specialized sectors; Industrial Automation Building Automation Home Automation. ASSOCIATIONS Schneider Electric India Pvt. Ltd. for Telemechanique AC Frequency Drives Telemechanique Modicon PLCs Lexium Servo motors & drives Magelis Display Units VijeoCitec SCADA Phaseo Power Supplies Clipsal products for Building & Home Automation RECENT REFERNCES Ralson Industries Metro Tyres Ltd. ,Ludhiana Mangal Engineers, Patiala Vardhman Spinning, Ludhiana Rollcon Engg. Mohali Haldiram Hindustan Hydraulic, Jalandhar Reliance Info com Dunn Food, Baddi Crown Cap (Coca Cola), Amritsar G.S. Auto, Ludhiana Hind Products and many more. TRAINING MODULE SR. CONTENTS DESCRIPTION 1. Basics • Basic Control System • Implementation of Digital logics in Industry • Need of Automation • Industrial Sensors • Basics and architecture of PLC 2. Zelio PLC (Schneider) • Complete Software knowledge with Ladder Programming • Hardware wiring and on board Simulation • Software development of Industrial projects 3. Twido PLC (Schneider) • Complete Software knowledge including usage of functional blocks like Timers, Counters, etc. • Implementation of mathematical functions. • Usage of compare and operate blocks with Ladder Logic • Transfer of program from Computer/ Laptop to Module and online Simulation 4. Micro PLC (Schneider) • Complete Software knowledge of all functional blocks • Implementation of mathematical functions. • Usage of compare and operate blocks • Online Programming and use of runtime screens 5. AC Drives (Schneider) • Basics of AC Motors • Full knowledge of Drive internal parameter settings 6. HMI (Schneider) • Creating application pages • Creating alarm pages • Interfacing through PLC 7. SCADA • Creating Display and Graphical User Interfaces which correspond to Automated plant • Animating Displays by assigning different properties like orientation, position, action, etc. to the images 1. AUTOMOTIVE DESCRIPTION 1.1 AUTOMATION AND AUTOMATION DEVICE 1.1.1 AUTOMATION To analyze and control all the process parameters in the plant by the help of automation devices. 1.1.2 AUTOMATION DEVICE Automation device is a system, which on the basis of information fed in it, performs predefined actions with a bearing on its environment. 1.2 NEED OF AUTOMATION 1. To save energy 2. Bulk production 3. Less cost of production 4. Less human error that is high accuracy 5. High speed of operation 6. Simplification of the circuits 7. Easy faultfinding and troubleshooting 8. Lesser down timing of process / control 1.3 PROGRAM AND PROGRAMMABLE CONTROLER 1.3.1 PROGRAM A program is the series of instruction that can be executed one after the other and can be easily written and modified using a programming terminal. 1.3.2 PROGRAMMABLE CONTROLLER In an automated system, the programmable controller constitutes the data proceeding system. It’s the brain of the installation OR programmable controller is a real computer, which is also capable of receiving data via its inputs their sending command by its outputs.The bus enables all the parts of the system to communicate with each other. It is the internal dialogue tool of the PLC. 1.4 BASICS BEFORE STUDYING PLC 1.4.1 NUMBER SYSTEM Number system is ordered set of digits, which are used to perform the arithmetic operations. There are different types of number systems: Sr. Number System Base Symbols Used Examples 1 Binary 2 0 &1 1101.01 2 Octal 8 0,1,2,3,4,5,6,7 3761.62 3 Decimal 10 0,1,2,3,4,5,6,7,8,9 9540.57 4 Hexadecimal 16 0,1,2,3,4,5,6,7,8,9,A,B,C,D,E,F 3F6A.F9 1.4.2 BRIEF DESCRIPTION OF THE LOGIC GATES Sr. Gate’s name and its symbol Circuit Diagram Ladder Diagram Truth Table 1. Or Gate I 1 I 2 I 1 Q 1 I 2 I 1 I 2 Or 0 0 0 0 1 1 1 0 1 1 1 1 2. And Gate I 1 I 2 I 1 I 2 Q 1 I 1 I 2 And 0 0 0 0 1 0 1 0 0 1 1 1 3. Not Gate I 1 I 1 Q 1 I 1 Not 0 1 1 0 4. Nand Gate I 1 I 2 Q 1 I 1 I 2 I 1 I 2 Nand 0 0 1 0 1 1 1 0 1 1 1 0 5. Nor Gate I 1 I 2 I 1 I 2 Q 1 I 1 I 2 Nor 0 0 1 0 1 0 1 0 0 1 1 0 6. Xor Gate I 1 I 2 Q 1 I 1 I 2 I 2 I 1 I 1 I 2 Xor 0 0 0 0 1 1 1 0 1 1 1 0 1.4.3 SWITCH An electrical switch is any device used to interrupt the flow of electrons in a circuit. Switches are essentially binary devices: they are either completely on ("closed") or completely off ("open"). The schematic symbology for switches vary according to the switch's purpose and actuation. A normally-open switch contact is drawn in such a way as to signify an open connection, ready to close when actuated. Conversely, a normally-closed switch is drawn as a closed connection which will be opened when actuated. Any kind of switch contact can be designed so that the contacts "close" (establish continuity) when actuated, or "open" (interrupt continuity) when actuated. For switches that have a spring-return mechanism in them, the direction that the spring returns it to with no applied force is called the normal position. Therefore, contacts that are open in this position are called normally open and contacts that are closed in this position are called normally closed. 1.4.4 Types Of Switches 1.4.4.1 Toggle switch Toggle switches are actuated by a lever angled in one of two or more positions. The common light switch used in household wiring is an example of a toggle switch. Most toggle switches will come to rest in any of their lever positions, while others have an internal spring mechanism returning the lever to a certain normal position, allowing for what is called "momentary" operation. 1.4.4.2 Pressure switch Gas or liquid pressure can be used to actuate a switch mechanism if that pressure is applied to a piston, diaphragm, or bellows, which converts pressure to mechanical force. 1.4.4.3 Selector switch Selector switches are actuated with a rotary knob or lever of some sort to select one of two or more positions. Like the toggle switch, selector switches can either rest in any of their positions or contain spring-return mechanisms for momentary operation. 1.4.4.4 Pushbutton switch A switch that is open when un-actuated is called normally-open. A switch that is closed when un-actuated is called normally-closed. Sometimes the terms "normally-open" and "normally-closed" are abbreviated N.O. and N.C., respectively 1.4.4.5 Limit switch Some switches are specifically designed to be operated by the motion of a machine rather than by the hand of a human operator. These motion-operated switches are commonly called limit switches. 1.4.4.6 Proximity switch Proximity switches sense the approach of a metallic machine part either by a magnetic or high-frequency electromagnetic field. Simple proximity switches use a permanent magnet to actuate a sealed switch mechanism whenever the machine part gets close (typically 1 inch or less). 1.4.5 Input Devices DIGITAL ANALOG Pushbuttons Transducers/Transmitters Selector Switches Encoders Proximity Sensors Level Transducers Limit Switches Pressure/Temperature Photoelectric Sensors Potentiometers Relay Contacts Motor Starter Contacts 1.4.6 Output Devices DISCRETE ANALOG Valves Analog Meters Motor Starters Electric motor drives Solenoids Electric valves Control Relays Alarms, Lights, Fan, Led Display 2. INTRODUCTION TO PLC 2.1 DEFINATION AND HISTORY OF PLC 2.1.1 DEFINATION OF PLC For a lay man programmable logic controller is magic box/black box which senses some conditions from the field devices and activates the devices as per requirement of the system. For a Technical person a programmable logic controller is an industrial computer that accepts inputs from switches and sensors, evaluates these in accordance with a stored program, and generates outputs to control machines and processes. 2.1.2 HISTORY OF PLC PLC were first created to serve the automobile industry, and the first PLC project was developed in 1968 for general motors to replace hard wired relay systems by Dick Morley. 2.2 MANUFACTURING AND ASSEMBLY PROCESSES In an industrial setting, PLC’s are used to automate manufacturing and assembly processes. By “process” we mean a step-by-step procedure whereby a product is manufactured and assembled. It is the responsibility of the product-engineering (PE) department to plan for the manufacture of new or modified products.According to Rehg and Kraebber, in their book, Computer- Integrated Manufacturing, 2nd ed., the PE plan has seven elements: 1. Process planning 2. Production machine programming 3. Tool and fixture engineering 4. Work and production standards 5. Plant engineering 6. Analysis for manufacturability and assembly 7. Manufacturing cost estimating 2.3 OVERALL PLC SYSTEM 2.3.1 OPERATION OF PLC The operation of the PLC system is simple and straightforward. The Process or CPU completes three processes: (1) scans, or reads, from the input devices (2) executes or “solves” the program logic, and (3) updates, or writes, to the output devices. 2.3.2 PLC and Their UNITS A PLC (Programmable Logic Controller) is a real computer, which is also capable of receiving data via its inputs their sending command by its outputs. Sensors Actuators Controller The major units of the PLC system are:- 2.3.2.1 Central Processing Unit: It is the brain of the system or the installation. The CPU, or processor, constitutes the motor or the "master of ceremonies" of the Controller. It works as in the following pattern: • Reads the sensors value. • Executes the program with the data contained in memory. • Writes the output connected to the actuators. 2.3.2.2 Memory: The Controller memory contains the program to be executed, but also the data used by the program (timer values, monostable values, counter values, etc.). This is where all the data contained in the Controller is stored. The Controller cannot operate without memory. 2.3.2.3 I/O Modules: The input module has terminals into which outside process electric signals, generated by sensors or transducers, are entered. The output module has terminals to which output signals are sent to activate relays, solenoids, various solid-state switching devices, motors, and displays. An electronic system for connecting I/O modules to remote locations can be added if needed. The actual operating process under PLC control can be thousands of feet from the CPU and its I/O modules. 2.3.2.4 Power Supply: The electrical supply that converts alternating current (AC) line voltage to various operational DC values is used as power supply. In the process, the power supply filters and regulates the DC voltages to ensure proper computer operation. Bus enables all parts of the system to communicate with each other. It is the internal dialogue tool of the programmable controller. The communication module transfers the data from computer to controller or controller to computer. 2.3.2.5 Sensors: Sensors are basic input elements through which the controller senses an input signal. There are various types of sensors used in the field but basic are mentioned below: • Level Sensor • Temperature Sensor (Thermometer) • Motion Sensor (Techno meter, Auto meter), etc. E.g. to detect an automobile at a highway toll booth, photoelectric sensor is used. 2.3.2.6 Actuator: It allows actions to be performed in the system. In other words we can say it is an output terminal through the operation is seen to be performed. These are: • Pumps • Cylinder • Engines, etc. 2.4 Programming a PLC 2.4.1 PROGRAMMING DEVICES (PROGRAMMERS) A programming device is needed to enter, modify and troubleshoot the PLC program, or to check the condition of the processor. Once the program has been and the PLC is running, the programming device may be disconnected. Three types of programmers are generally used: 1. Hand held (Smaller, cheaper, portable but limited display capability & few functions) 2. Dedicated desktop (User-friendly, designed for industrial use, portable but costly, limited PLC’s can be programmed, limited documentation and limited graphics capability). 3. Personal computer: With software available for all major brands of PLC’s, the PC today is the most common programming device. It can store program on floppy disk / hard disk. If for some reason the program is lost the restoration of the program is simple. When the s/w is updated by the manufacturer to provide additional features, the update is easily accomplished by loading the new s/w program onto the PC hard disk by way of the floppy disk drive. 2.4.2 Program A Program is a user developed series of instructions or commands that directs the PLC to execute actions. 2.4.3 Programming Language A Programming Language provides rules for combining the instructions so that they produce the desired actions. The most commonly used Programming Language is ‘LADDER LOGIC’ Other Languages occasionally used to program the PLC’s include: Functional Block Diagram (FBD) Statement/Instruction List. (IL) Grafcet. Structured Text (ST) 2.4.3.1 LADDER LOGIC Ladder language is a graphic language composed of contacts, coils and links between these elements The Ladder logic programming language is an adaptation of an electrical relay wiring diagram, also known as ladder diagram. Ladder Logic is a graphical system of symbols and terms even those not familiar with relay wiring diagram can easily learn it. 2.4.4 BASIC INSTRUCTIONS Sr. Instruction Description Symbol 1. LD (Load) Begins the logic operation with normally open contact. 2. LDN (Load Not) Begins the logic operation with normally close contact. 3. AND Adds the normally open contact serially 4. OR Adds the normally open contact in parallel way. 5. OUT Output 2.5 PLC ADVANTAGES AND DISADVANTAGES 2.5.1 ADVANTAGES 1. Flexibility 2. Implementing Changes and Correcting Errors 3. Large Quantity of Contacts 4. Lower Cost 5. Pilot Running 6. Visual Observation 7. Speed of Operation 8. Ladder or Boolean Programming Method 9. Reliability and Maintainability 10. Simplicity of Ordering Control System Components 11. Documentation 12. Security 13. Ease of Changes by Reprogramming 2.5.2 DISADVANTAGES 1. Newer Technology 2. Fixed Program Applications 3. Environmental Considerations 4. Fail-Safe Operation 5. Fixed-Circuit Operation 2.6 Leading Brands of PLC 2.6.1 AMERICAN 2.6.2 EUROPEAN 2.6.3 JAPANESE 1. Allen Bradley 1. Siemens 1. Toshiba 2. Gould Modicon 2. Klockner and Mouller 2. Omron 3. Texas Instruments 3. Festo 3. Fanuc 4. General Electric 4. Telemechmanique 4. Mitsubishi 5. Westinghouse 6. Cutter Hammer 7. Square D 3.INTRODUCTION TO ZELIO LOGIC 3.1 INTRODUCTION Zelio logic is an automated system module, programmable and completely autonomous and easy to install. It is the most basic PLC used in the field of automation. Zelio logic is the only logic programming language which is familiar to both ELECTRICIAN – Wiring diagram and AUTOMATION SYSTEMS ENGINEER – Ladder or Contact language. This application program consists of several diagram lines. Each line consists of: five contacts at the most function blocks and compulsory a coil. Zelio Logic (Smart Relay) is of two types: 3.1.1 Compact module – non expandable. 3.1.2 Modular module – expandable. 3.1.1 Compact module: It is a non expandable version of Zelio logic (Smart Relay). Various models under this category are: - a. 10 I/O Logic Module – 6 inputs and 4 outputs. b. 12 I/O Logic Module – 8 inputs and 4 outputs. c. 20 I/O Logic Module – 12 inputs and 8 outputs. 3.1.2 Modular module: It is an expandable version of Zelio logic (Smart Relay). Various models under this category are: - a. 16 I/O Logic Module – 9 inputs and 7 outputs. b. 26 I/O Logic Module – 14 inputs and 12 outputs. Expandable models are: - a. 6 I/O Logic Module – 4 inputs and 2 outputs. b. 10 I/O Logic Module – 6 inputs and 4 outputs. c. 14 I/O Logic Module – 8 inputs and 6 outputs. 3.2 DESCRIPTION OF SERIAL NUMBER 3.2.1 Serial Number: SR 2 A 10 1 FU 3 B 2 BU D BD E JD Smart relay Module Type Inputs Power Supply Product type Output type 3.2.2 Module Type 2 means Compact Zelio Module 3 means Modular Zelio Module 3.2.3 Product Type Sr. Type Description 1. A With display without clock. 2. B With display with clock. 3. D Without display without clock. 4. E Without display with clock. 3.2.4 Output Type 1 means Relay output with current rating of 2.0 A & 1 lac switching operation. 2 means Transistor output with current rating 0.3 A & 10 lac switching operation. 3.2.5 Power Supply Sr. Type Description 1. FU 100 – 240 V A.C. 2. BU 24 V A.C. 3. BD 24 V D.C. 4. JD 12 V D.C. 3.3 DIAGRAMATICAL STARTUP WITH ZELIO v 2.0 3.3.1 Open Zelio Soft V2.0 , Create new program. 3.3.2 Select the module on which you want to perform action. 3.3.3 Write the ladder language program in edit mode. 3.4 Programming Language 3.5 LADDER LANGUAGE ELEMENTS 3.5.1 GRAPHICAL ELEMENTS 3.5.1.1 Contacts Graphic elements of the contacts are programmed in the test zone and take up one cell (one row high by one column wide). Sr. Name Ladder Symbol Electrical symbol Functions 1. Normally open contact Conducting contact when its controlling input is active. 2. Normally closed contact Conducting contact when its controlling input is inactive. 3.5.1.2 Linking Elements Linking graphic elements are used to connect test and action graphic elements. Sr. Name Graphic representation Functions 1. Horizontal connection Used to link test and action elements together between the two potential bars 2. Vertical connection Used to link test and action graphic elements in parallel. A horizontal connection represents a logical AND; it sends the state of the contact located immediately to its left to the contact located immediately to its right. A vertical connection represents the logical OR of the active states of the horizontal connections located to its left, i.e.: • Inactive if the states of all the horizontal contacts located to the left are inactive • Active if at least one of the horizontal contacts located to the left is active. 3.5.1.3 Coils The graphic elements of the coils are programmed in the action zone and take up one cell (one row high by one column wide). Sr. Name Ladder symbol Electrical symbol Functions 1. Direct Coil Coil energizes if the contacts to which it is connected are conducting (contact mode). 2. Impulse Coil Coil energizes if the contacts to which it is connected change state (impulse relay mode). 3. Set/ Latch Coil Coil energizes once the contacts to which it is connected are conducting, then stays triggered even if later the contacts are no longer conducting (SET mode). 4. Reset/ Unlatch Coil Coil is deactivated when the contacts to which it is connected are conducting. It remains inactive even if later the contacts are no longer conducting (RESET mode). 3.5.2 DISCRETE INPUTS ( ) The Discrete Inputs can be used exclusively as contacts in the program. These represent the status of the input for the smart relay connected to a sensor (push button, switch, sensor, etc.). The contact number corresponds to the number of terminals of the associated input: 1 to 9, then A to R (except for letters I, M and O) according to the smart relay and the possible extension. 3.5.2.1 Use as a Contact: This contact may use the direct state of the input (normally open mode) or its inverse state (mode normally closed). 3.5.3 DISCRETE OUTPUTS ( ) Discrete Outputs correspond to the smart relay output relay coils (connected to the actuators). These outputs are numbered from 1 to 9, then from A to G, according to the smart relay and any extensions. They can be used, in the program, indifferently either as a coil or a contact. 3.5.3.1 Use as a Coil: Sr. Mode Symbol Description Example 1. Contactor Mode [Q - Coil is energized if the contacts to which it is connected are conducting otherwise not. I1 --------- [Q1 2. Impulse Relay Mode ∫Q - Pulse energization, the coil changes state on each pulse it receives. I1 --------- ∫Q1 3. Latch Mode SQ - Coil is energized as soon as the contacts to which it is connected are conducting, and then stays set even if later the contacts are no longer conducting. I1 -------- SQ1 4. Unlatch Mode RQ - Coil gets deactivated when the contacts to which it is connected are conducting. It remains inactive even if later the contacts are no longer conducting. I1 -------- SQ1 I1 -------- RQ1 3.5.4 AUXILIARY RELAYS ( ) Auxiliary relays marked M behave in exactly the same way as Q Discrete outputs but do not have an electrical output contact. They can be used as internal variables.There are 31, numbered from 1 to 9 and from A to Y except for letters I, M, and O. All auxiliary relays can be used, in the program, indifferently either as a coil or contact. They can be used to latch a state to be used in the form of the associated contact. 3.5.5 COUNTERS ( ) The Counters function is used to up count or down count pulses. The smart relay has 16 timers, numbered from 1 to 9 then from A to G. It can be reset to zero or to the preset value during use. It may be used as a contact to find out whether: The preset value has been reached (up-counting mode TO). The counter has reached 0 (down-counting FROM). 3.5.5.1 Use of Coil: Sr. Mode Symbol Description Example 1. Counting Pulse CC- Every time the coil is energized, the counter is incremented or decremented by 1 according to the counting direction chosen I1 ------- CC1 2. Reset Initial Counter State RC- Reset the current count value to 0 if the count type is TO or to preset value if the count type is FROM Z1 ------ RC1 3. Counting Direction DC- Down counts if the coil is energized and up counts if not. I2 ------ DC1 Examples: Below three simple examples of the use of a counter (configured in up counting mode toward the preset value): Sr. Screen Description 1 Up counting and zero resetting: Counter is incremented each time input I1 is activated. Counter is reset each time input I2 is activated. 2 Down counting and Resetting: Counter is decremented each time input I1 is activated. Counter is reset each time the I2 input is activated 3 Up counting, Down counting and Resetting: Counter is incremented each time input I1 is activated. Counter is decremented each time the I3 input is activated. Counter is reset each time the input I2 is activated 3.5.6 COUNTER COMPARATOR ( ) This function is used to compare the current counting values of two counters or of a counter and a constant value