KV 16

PLC Manual
DIPLOMA IN ELECTRICAL & ELECTRONICS ENGG.

SITEC ELECTRONICS
#33/B, opposite to Florence School P & T colony, 2nd Block, R.T.Nagar, Bangalore-560032 Phone: 9180-23339222. Fax: 23335449 Email: sitec@vsnl.net http://www.chipmaxasia.com

INTRODUCTION PLC (Programmable Logic Controller): The PLC is a microcontroller based device with input/output circuitry that monitors the status of field connected sensor (inputs) and controls the attached (output) actuators (motor -starters, Solenoids, Speed drives, Valves etc.) according to a user created logic program stored in the memory. PLC Architecture:
PC

CPU (Microcontroller)

Input Points

MEMORY

Output Points

The above architecture is divided into three parts a. CPU : It is the brain of PLC system .It consists of the mcirocontroller,Memory IC and necessary circuit to store and retrieve information from the memory. The Job of CPU is to monitor status or state of input device, scan and solve the logic of a user program and control ON or OFF state of output device. b. Memory : The type of RAM (Random Access Memory) normally used is CMOS (Complementary Metal Oxide Semiconductor) to store the program. c. Input/Output : Input is the one through which signal is send and result is observed at the Output. Why a PLC ? The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control system. PLC have been gaining popularity ,because of the following advantages : Cost effective for controlling complex system.
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 Flexible and can be reapplied to control other system quickly and easily. Computational abilities allow more sophisticated control. Trouble shooting aids make programming easier and reduce downtime. Reliable components make these likely to operate for longer life. Ladder Logic : A graphical, problem oriented programming language which replicates electronic switching blueprints or circuits. Features of KV 16R : It is the worlds smallest PLC from KEYENCE, JAPAN and it is called KV-16 means Keyence Visual having 10- inputs and 6 Outputs. It is worlds smallest PLC. Variety of expansion option. Inbuilt simulator software to check the Output on PC without connecting to PLC. 20KHz clock pulse output. User friendly window ladder software.
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 It has built in one milliseconds timer. Memory capacity up to 3000 steps or lines. Serial communication function. Program is stored in EEPROM, to eliminating the need for battery back up.

DEPARTMENT OF TECHNICAL EDUCTION

DIPLOMA COURSE IN ELECTRICAL & ELECTRONICS ENGG.

MECHATRONICS LAB

Programming PLC and introduction to ladder diagrams and communication between PLC and Pc 1. Single motor ON /OFF control. 2. Interlock Control of two motors. 3. Water level control with three sensors. 4. Three speed control of a motor. 5. Timer ON delay/ OFF delay of a motor.

1. Single motor ON/OFF control.

Coding:
SL.No 1 2 3 4 5 6 7 8 Instruction LD LDB TMR LD TMR OUT END ENDH Operand 0000 T 000 001 #00100 T 001 000 #00100 500

Description: Output relay 500 (Motor) turns ON and OFF repeatedly while input relay 0000 is ON. Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board. 2. Interlock control of two motors.
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Coding:
SL.No 1 2 3 4 5 6 7 8 Instruction LD OUT LD TMR LD OUT END ENDH Operand 0000 503 503 000 #00100 T 000 504

Description: Output relay 503 (Motor 1) turns ON when input relay 0000 turns ON. Output relay 504 (Motor 2) turns ON after 10 seconds after 503 turns ON. Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board

3. Water level control with three sensors.

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Coding:
SL.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Instruction LD C LDB OUT LD OUT LD TMR LD OUT LD OUT LD OUT LDB OUT END ENDH Operand 0000 000 #00001 0008 C 000 503 0009 502 502 001 #00010 T 001 501 0008 500 500 504 503 504

Description:
0008 and 0009 relays are for upper and lower level respectively. Initially when both relay 0009 and 0008 is OFF i.e.( no water in the tank), output relay 0503 is ON that means, Pump is ON. Once if you press key 0009 in board the output relay 0502 is ON, when both keys are ON the output relay,504(Pump) is OFF means the tank is full. When you release the 0008 key 0504 is still in OFF condition (Pump is OFF).

Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board

4. Three speed control of a motor.

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Coding:
SL.No Instruction Operand

1 2 3 4 5 6 7 8 9 10 11 12 13 14

LD OUT LD TMR LD RES OUT LD TMR LD RES OUT END ENDH

0000 500 500 000 #00100 T 000 500 501 501 001 #00100 T 001 501 502

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Description: Initially when 0000 relay turns ON the motor (500) start rotating at the maximum speed. After a delay of 10 seconds the motor start rotating at medium speed. Again after a delay of 10 seconds the motor start rotating at minimum speed.

Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board

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5. Timer ON/OFF delay of motor.

A. ON time delay of a motor.

Coding:
SL.No Instruction Operand

1 2 3 4 5 6

LD TMR LD OUT END ENDH

0000 000 #00100 T 000 500

Description: Output relay 500 (Motor) turns ON in a specified time after input relay 0000 turns ON. When input relay 0000 turns OFF, Output relay 500 (Motor) also turns OFF. Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board
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B. OFF time delay of a motor.

Coding:
SL.No Instruction Operand

1 2 3 4 5 6

LD TMR LDB OUT END ENDH

0000 000 #00100 T 000 500

Description: When input relay 0000 turns ON, output relay 500 (Motor) turns ON. Output relay 500 (Motor) turns OFF in a specified time after 0000 turns OFF. Connection: 1. Make the connection between External Connector (C4) on PLC board to experimental module. 2. To see Output on module change switch to EXT. on PLC board and observe the output on LED. 3. Connect the power supply (24V) to PLC board
BASIC INSTRUCTION SET:
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Mnemonic

Instruction

Function

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LD LDB AND ANB OR ORB SET LDA CMP RES TMR TMH TMS C JMP STG END ENDH CALL

LOAD LOAD BAR AND AND BAR OR OR BAR SET LOAD A COMPARE RESET 0.1 Second 0.001 Second 1 millisecond

Counter Jump Stage END ENDHI Subroutine Call RET Subroutine Represent the end of subroutine Return N.O - Normally Open Switch/Relay N.C - Normally Closed Switch/Relay T - Timer C - Counter # - Decimal R - Relay

Connects N.O* contact relay or switch Connects N.C^ contact relay or switch Connects N.O contact in series with previous contact Connects N.C contact in series with previous contact Connects N.O contact in parallel with previous contact Connects N.C contact in parallel with previous contact Forces relay ON and holds this status when input is ON Loads input data to internal register. Compares the value specified by the operand. Forces relay/counter/timer OFF, when input is ON It is 16-bit count down timer with 0.1 sec. decrements It is 16-bit count down timer with 0.01 sec. decrements It is 16-bit count down timer with 1milli sec. decrements Sets 16- bit counter. Jumps to the specified stage Executes instruction in STG i.e. step by step execution Indicates end of each routine of program Indicates end of entire program. Executes subroutine specified by operand

Special Utility Relay List Relay No. Function 2002 Always ON 2003 Always OFF 2005 0.1 Second clock pulse. 2007 Remains OFF during first scan after startup 2008 Remains ON during first scan after startup 2009 Turns ON when result of arithmetic operation is negative or when an overflow is generated 2010 Turns ON when result of arithmetic operation is 0 2011 Turns ON when result of arithmetic operation is positive 2012 Turns ON when an arithmetic operation generates an error

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