DASAR DIGITAL CONTROL SYSTEM

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

[email protected]

Logic and Relay

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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Logic and Relay

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Electromagnetic Control Relays

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Electromagnetic Relay Operation

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Relay Symbol

Coil
CR1
CR1-1 CR1-2

Normally open Normally closed

(NO) contact (NC) contact

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Relay Circuit Operation

L1 L2
S
CR1
With switch S open:
CR1-1  coil CR1 is de-energized
OFF  contacts CR1-1 are open
R  light R is off
 contacts CR1-2 are closed
 light G is on
G

CR1-2 ON

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Relay Circuit Operation

L1 L2
S
CR1

CR1-1 With switch S closed:

ON
 coil CR1 is energized
R
 contacts CR1-1 are closed
 light R is on
 contacts CR1-2 are open
G  light G is off

CR1-2 OFF

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Magnetic Contactor

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

PLC Used In Conjunction With A Contactor

Contactor Pump
power contacts

L2
High-current
wiring
L1

Coil
terminals

Low-current
wiring
L2 L1
Ir. Tugino, ST., MT., IPM., ASEAN Eng.
PLC output module

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 Magnetic Motor Starter

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Across-The-Line AC Starter Operation

Low-current
control circuit

High-current
power circuit
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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PLC Control Of A Large Motor Load

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Manually Operated Switches

Pushbutton switches are

Normally Open (NO) pushbutton

Normally Closed (NC) pushbutton

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Manually Operated Switches

PRESSED
ON
NOT PRESSED
OFF
R
R
L1 L2
L1 L2
G
G
OFF
Ir. Tugino, ST., MT., IPM., ASEAN Eng.
ON

Selector Switch

Contacts
Off Position A B
Hand Auto
Hand X

A Off

B Auto X
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Selector Switch Motor Reversing

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Dual In-Line Package (DIP) Switches

ON

OFF

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Mechanically Operated Switches

limit switch

Symbols
NO Contact

NC Contact

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Typical Limit Switch Circuit

L1 Stop Forward L2
FWD Limit
F
F R
OLs
Limit switches
Reverse
R
F REV Limit

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Temperature Switch

Symbols

NO Contact NC Contact

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Temperature Switch Control of a Motor

Closing ON

Rising
temperature

Motor

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Pressure Switch

Bellows
Switch

Symbols

NO Contact NC Contact
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Starter Operated By A Pressure Switch

Closing ON
Rising
pressure

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Level Switch

Switch

Symbols

Float

NO Contact NC Contact

Two-wire level switch

control of starter.

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Sensors
Sensors are input transducers used for detecting and
often measuring the magnitude of something. They
convert mechanical, magnetic, thermal, optical, and
chemical variations into electric voltages and currents.

Photoelectric
sensor

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Proximity Sensor

Proximity sensors or switches detect the presence of

an object without making physical contact with it.

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Output Control Devices

A variety of output control devices can be operated by the
controller output module to control traditional processes.
These include:

Solenoid Solenoid
Control Alarm
Pilot light relay valve

Heater Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Motor starter Small motor

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 Seal-In Circuits
A seal-in circuit is a method of maintaining
current flow after a momentary switch has
been pressed and released.
Hardwired Seal-In Circuit
Motor
Start Stop starter coil

M
M
The seal-in auxiliary contact of the
starter is connected in parallel with
Seal-in contact the Start button to keep the starter
coil energized when the Start button is
Ir. Tugino, ST., MT., IPM., ASEAN Eng.
released.

Programmed Seal-In Circuit

Ladder logic program

Inputs Output
Motor L2
L1
Stop starter
Start PB Stop PB coil (M)
M
Start
Motor
starter
M
coil (M)

Both the Start and Stop buttons are examined

for a closed condition because both buttons must
be closed to cause the motor starter to operate.
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

15
 Latching Relay
Latching relays are used where it is
necessary for contacts to stay open
and/or closed, even though the coil
is energized momentarily.
L1 L2 Electromagnetic latching
ON
relay circuit
L
When the ON button is
OFF
momentarily actuated, the
latch coil is energized to set
U
the relay to its latched
position. The relay does not
have to be continuously
PL energized to hold the
Contact shown with relay contact closed.
Ir. Tugino, ST., MT., IPM., ASEAN Eng.
in the unlatched position

Programmed Latching Relay Instruction

Command Name Symbol Description

OTL sets the bit to
“1” when the rung
becomes true, and
Output Latch retains its state when
OTL the rung loses
continuity or a power
cycle occurs

OUT resets the bit to

“0” when the rung
OTU Output becomes true and
Unlatch retains it

XXX Latch and unlatch

coils have the same
XXX address
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Latching Relay Program
ON ON
Latch rung

OFF OFF
Unlatch rung

Output rung

0
1
When the ON button is momentarily actuated, the latch rung
becomes true and the latch status bit (10) is set to 1, and so the
output is switched on. This status bit will remain on (1) when
logic continuity of Ir.
the Tugino, ST., MT., IPM., ASEAN Eng.
latch rung is lost.

PLC Water Level Program

The program for this process

Pump Low High
is designed to control the level of
running level level
water in a storage tank by turning a
discharge pump on and off.
Modes of Operation

High sensor Off Position: the pump

switch will stop if it is running
and will not start if it is
stopped.

Low sensor
switch

Pump motor
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 PLC Water Level Program

OFF /Man
Positions ( water
at a low level)

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Sequential Control Process

Sequential controls are required for processes that
demand certain operations to be performed in
specific order.
Filling operation Capping operation

Bottle movement

In this filling and capping operation, the tasks are:

(1) fill bottle
(2) press on cap
These tasks Ir.
must beST.,
Tugino, performed in theEng.
MT., IPM., ASEAN proper order.

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 Combination Control Process
Combination control processes require that
operations be performed without regard to the
order in which they are performed.
Labeling process
Label solenoid 1

Label
solenoid 2

In this labeling operation, the tasks are:

(1) place label 1 on bottle
(2) place label 2 on bottle
The order in which the tasks are preformed does not really matter.
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Automatic Control
Automatic control involves maintaining a desired
set-point.
Automatic furnace temperature
control

In this operation the set-point is selected by

Furnace
means of the touch screen interface. If there
is a deviation from that set point, an error is
determined by comparing the output against
PLC
the set point and using this error to make a
correction. This requires some form of
feedback from the output back to the control
for the input.
Touch screen
interface
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Hardwired Sequential Process
The sequential task is as follows: Auxiliary Features:
1. Start button is pressed.  An emergency stop button
2. Table motor is started. that will stop the table, for any
3. Package moves to the limit switch reason, before the package
and stops. reaches the limit switch
position
 A red pilot light to indicate
the table has stopped
STOP  A green pilot light to indicate
the table is running
Package
RUN Motor

Limit switch
(LS1) START

Emergency
Ir. Tugino, ST., MT., IPM., ASEAN Eng.
STOP

Summary of the control task:

Hardwired Sequential Process • Start button is actuated.
• CR1-1 closes to seal in CR1
• CR1-2 opens, switching the
Emergency red stop pilot light off
Start Stop • CR1-3 closes, switching the
PB1 PB2 CR1 green run pilot light on
1 • CR1-4 closes to energize the
motor starter and motor
LS1 • The package moves to the
CR1-1 limit switch to actuate it and
STOP de-energize coil CR1
2 R • CR1-1 opens to open the
CR1-2 seal-in contact
RUN
• CR1-2 closes, switching the
3 G
red pilot light on
CR1-3 • CR1-3 opens, switching the
4 M green pilot light off
• CR1-4 opens to de-energize
CR1-4 OL the starter coil, stop the
motor, and end the sequence
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Programmed Sequential Process

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Writing a Program from a Narrative Description

Description :
A simple drilling operation requires the drill press to turn on only if there is a
part present and the operator has one hand on each of the start switches. This
precaution will ensure that the operator's hands are not in the way of the drill.

PB1 PB2
Drill
motor
Switches

Part sensor
Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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Writing a Program from a Narrative Description
Description :
A simple drilling operation requires the drill press to turn on only if there is a
part present and the operator has one hand on each of the start switches. This
precaution will ensure that the operator's hands are not in the way of the drill.

PB1 and PB2 and the part

sensor must be activated to
make the drill motor operate.

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Motorized Door Program

Description :
A motorized overhead garage door is to be operated automatically to preset
open and closed positions.

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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 Motorized Door Program

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Continuous Filling Operation Program

Description :
A continuous filling operation requires boxes moving on a conveyor to be
automatically positioned and filled.
Hooper
PL Run

PL Standby
Solenoid
Level PL Full
switch

Photo
Motor
switch

START
Ir. Tugino, ST., MT.,
STOPIPM., ASEAN Eng.

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 Continuous Filling Operation Program

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

Terimakasih

Ir. Tugino, ST., MT., IPM., ASEAN Eng.

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