Industrial Automation

Unit – 5 Advanced PLC Functions & PLC applications

Mr. Santosh Madiwal

Assistant Professor
Department of Electrical Engineering
KIT’s College of Engineering (Autonomous), Kolhapur

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Outline
•Introduction,
•Types of PLC analog modules and systems,
•PLC analog signal processing,
•BCD or multibit data processing,
•PLC analog output application examples.
•Applications- Motor sequence control, Traffic light control, Speed control of AC
motor/ DC Motor

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Introduction
• With discrete PLC operation – input and output have only two states –
on/off.
• But in analog PLC operation –processes are controlled by variables.
• Many medium and large sized PLC can able to deal with analog signals.
• For analog operation- level of PLC input signal is sensed by analog input
module.
• Similarly, analog output signal (variable value) sent to different processes
through analog output module.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue..
• PLC analog input modules can be connected to –thermal indicators, pressure
transducers, electrical potentiometers, thermocouples, encoders, strain
gauges, displacement transducers and many other data input devices with
varying signal values.

• BCD PLC analog input and output ranges are divided into number of steps.
• BCD analog input devices are – thumbwheels, encoders, barcode readers..etc
• BCD analog output devices are – stepper motors, DC servos, AC servos,
seven segment displays.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue…
• Analog PLC ‘s allow many different actions based on single input signal.
1) E.g.- A process having 20 lamps to indicate water level in the tank. Thus
each lamp will indicate 5 % level. It is possible to display level with
increment of 5 % using only one analog sensor signal and one analog input
terminal on PLC module.
• Where as in discrete (or digital) it require – 20 on-off sensors & 20 inputs.
2) Similarly single analog output can control a valve in many different
positions.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Types of analog PLC Modules & systems
• Analog PLC systems are –
• BCD type (or multibit type) &
• Straight numerical type
• Operation of a thumbwheel input to an input BCD module.

Thumbwheel switch

Thumbwheel Switches have

circular parts with numbers
printed on them. The circular
parts can be rotated to select
numbers which then form a
combination of contact circuit
ON/OFF signals. Those switches
can convert the numbers to
binary, decimal,or hexadecimal
numbers and output them.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue…
• In BCD output module - BCD codes are fed from the output module to a
numerical indicating device (displays).
• BCD output devices include such things as digital number displays,
variable position actuators, and stepper motors.
• The other general PLC analog system is the straight numerical type.
• Some typical ranges of the modules available for these systems are-
• 2-10 mA
• 4-20 mA
• 10-50 mA
• 0 to +5 Volts DC
• 0 to +10 Volts DC
• ±2.5 Volts DC
• ±5 Volts DC
KIT ECDC | • ±10 Volts DC
Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue…
• The PLC straight numerical type of module is used for a large variety of
input devices, the most common of which is the electrical potentiometer.
• The potentiometer is used to input a linear varying electrical value to the
input module.
• The potentiometer can be a type that reads temperature, pressure, distance,
position, or electrical values.
• Other inputs include thermocouples, strain gauges, and straight electrical
signals.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue..
• Note that the PLC handles continuous analog systems in discrete
steps.
• The continuously varying input signal is not strictly continuous
when it reaches the PLC CPU.
• As we divide up the input signal into more steps, it more nearly
approaches the exact duplication of the input signal.
• As the number of input divisions goes up from 8 to 16, the digital
signal more nearly describes the actual input signal.
• Some normally used PLC divisions are 1024 (10 bit) and 4096 (12
bit) .
• As the number of divisions goes up, the PLC system cost also goes
up.
• You must have enough steps to control your process with precision
and/or accuracy, but not so many that cost becomes prohibitive
(Unaffordable).
KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 PLC Analog Signal Processing
• Sensor / signaling devices not having output of same electrical range.
• Its lower limit electrical values od sensor – matched with lower limit
electrical value of input module.
• Similarly upper limit electrical values of sensor – matched with upper limit
electrical value of input module.
• E.g – signal varies from 0 to 78 VAC, 0 percent is = 0, 100 percent is = 78
• You have input module of 0 – 5 VDC
• So you must convert 0-78 VAC into 0-5 VDC,
• Further – DC voltage signal can be easily converted into digital form.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 PLC Analog Signal Processing
• Input Signal Processing
• Consider - Input is converted into steps using 8-bit AD converter, so it will have 256 steps, and is
not perfectly linear when the CPU receives data.
• The accuracy of this system is 1/256 = 0.0039, or about 0.4 percent.
• Similarly,
• 2^10 = 1024 steps
• 2^12 = 4096 steps
• 10 and 12 bits can be obtained at higher cost if needed in application.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 PLC Analog Signal Processing
• Output Signal Processing

• it is assumed that the signal in below is multiplied by 2 in the CPU (depends on

o/p module ranges). The output ratio is then 0.794. This would be 203 on the
256-step scale. Assume that there is an output module feeding an op amp
device with a range of -10 V to +10 V.
• The math shown indicates that the output would have a value of 5.9 VDC.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 PLC Analog Signal Processing
E.g.-An Analog ADD application

17 v ac

42 v ac

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 PLC Analog Signal Processing
E.g.-An Analog ADD application
• An output meter is to indicate the sum of two analog inputs.
• The two input values go through conversion and then through the input module.
• The digital values end up in IROI and IR02, as shown.
• An ADD function adds the two values when the ADD function is enabled.
• The sum can be updated very quickly by rapid enabling of the ADD function.
• The sum is put into OR01.
• The sum is then sent to an output module and then to the indicating meter.
• For illustration, 17 V and 42 VAC are added and converted, giving an output of 7.8 V to the
meter.
• The meter full scale could be set at 2 times 78, or 156 VAC, to match input and output
scales.
• Figure 22-7 shows a block diagram of the conversion process, along with two numerical
examples. This module has 1024 steps, but it could have had 512, 4096, or some other
power of 2. These are typical values for the module's divisions.
KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 BCD or Multibit data processing
• BCD data is handled like analog data.
• The input and output devices are mathematically
matched directly by the input and output modules.
• No conversion of values is required because the input
and output devices are built to match the values directly.
• In this illustration, the input number is entered
directly from thumbwheels.
• The input data is scaled to half for the output indicator.
• The resulting half value is sent to the output
device like four-digit seven-segment display.
• Since the CPU does math in binary, appropriate BCD and binary conversions are carried out.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Analog output application examples
• Analog In / Discrete Out
• BCD In / Discrete Out
• Analog In / Analog or BCD out
• BCD In / BCD or analog out
• Two analog In / Two analog out
• Two BCD In / Two analog out

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Analog In / Discrete Out
• The example given in below figure is analog in and discrete out. The figure's values further
illustrate the example. The problem is to have one output go on when a certain level, 0.5 ampere, is
reached, and another output on when the ampere is between 0.8 and 1.1 amperes. To accomplish
this, use the input values with comparison functions. For the first output, use a GE function. Since
the second condition has two limits. needs two comparison functions-in this case, greater than and
less than.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continue…

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 BCD In / Discrete Out
• The input is a BCD thumbwheel that counts up to 9999. If the input is 3750 or above, output 6 is
to go on. If the input is between 6200 and 8542, output 7 is to go on. Assume that the input data is
received in register IR0006 in the CPU. As stated previously, therefore you must convert the
IR0006 value to binary. Register HR0045 will receive the converted value. Thereafter, the
comparison functions are the same.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Analog In / Analog or BCD out
• For this example an analog signal of 0 to 10 volts comes in through a converter to an input module. The
signal is to be scaled to 1/5 of its value by the CPU and then sent out through an output module. The
output is also to be sent to a BCD output display. Figure-B illustrates how the PLC can be programmed
internally to accomplish one or both output conditions. The analog signal goes out directly. The output
signal to the analog output is first converted to BCD and then sent to the BCD display.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 BCD In / BCD or analog out
• In this example a BCD input, 0 to 9999, is received by an input module, which places the value
received into register IR0004. A fixed value of 180 is to be subtracted from the value received, and
the result is to be sent out to a 0-9999 BCD output display. Additionally, the output value is to be
placed in a 0-20 milliampere analog output module. Figure-B illustrates the PLC programming
necessary to accomplish the transfer of the original input value, minus 180. Appropriate BCD-to-
binary conversions are included in the program.

IR0004

180

180

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Two analog In / Two analog out
The example shown in figure has two analog inputs whose values are manipulated in the CPU. For
illustration, the values are both added and subtracted. The sum is output to one analog output, and the
difference is sent out to another. The internal programming to perform the mathematical manipulations is also
shown.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Two BCD In / Two analog out
It has two BCD inputs and two numerical analog outputs. You could also mix and match analog and BCD
inputs and outputs with little difficulty. In example 22-6, the first output is the product of the inputs and the
second output is the sum, minus 155. The product is read on readout X and the sum, minus 155, on readout
Y. Again, the PLC program to perform the math functions is shown.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Applications- Motor sequence control, Traffic light
control, Speed control of AC motor/ DC Motor

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Applications- Motor sequence control

• In many industries, there are lots of motors are used. Sometimes

we need to start more than one motor in an application.
• Here we will consider one similar example where we START each
motor one by one.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Problem Solution
• In this case, we have to operate motors sequentially. There are
total 3 motors to be controlled in a sequence. so that
each motor will start sequentially, say Motor 1 will START then
after some delay then motor 2 will start and after some delay
motor 3 will start.
• So that whole operation will take 10 seconds to start all motors in
a sequence. By providing this delay we can avoid the problem of
taking large
current by motors during initial stat up.
• All motors will be operate in the sequence and 5 seconds time
delay is to be provided between operations of each motor.

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Continued…
• Inputs List

• Start PB : I0.0
• Stop PB: I0.1
• Outputs List

• Cycle on : Q0.0
• Motor 1: Q0.1
• Motor 2 : Q0.2
• Motor 3 : Q0.3

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Traffic light control
• Develop a ladder diagram to control a traffic light of one pole.

• Inputs –
• Start – X0
• Stop – X1

• Outputs –
• Red – Y0
• Green – Y1
• Yellow – Y2

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701
 Speed control of DC Motor
• Link

KIT ECDC | Department of Electrical Engineering | Course: Industrial Automation | Course Code: UELC0701