Combined Na

Information Sheet 1.1.
2
Specifications and capabilities of programmable control
Learning Objectives : After reading this INFORMATION SHEET, YOU

MUST be able to:
1.) Explain the capabilities of programmable logic controller

2.) Discuss the different considerations in choosing the
appropriate programmable control
3.) Identify the different technical specifications of your controller
4.) Identify programmable controller components and modules
Introduction to PLC and its technical capabilities will be tackled in this

section. We will be using the SIEMENS S7-300 CPU controller in
explaining and discussing the abilities of this type of computer.
PLC
―PLC‖ stands for Programmable Logic Controller A computer used
commonly in the industry to control different electro-mechanical devices and
components by programmed instructions.
The abbreviation "PLC" and the term "Programmable Logic Controller"
are registered trademarks of the Allen Bradley Company(Rockwell
Automation). The company built the first PLC under the leadership of Odo
Struger in 1968.
Also known as ―programmable controller‖ or ―simply controller‖
Code No. Develop Mechatronics Control Circuits Date Developed: Date: Revised Page #
ELC724310 and Software Programs July 22, 2013 25
The demand for fast production of cars in the late 60’s lead to a
search for a sophisticated system that would allow fast switching of signal
and easy to modify system, lead to the development of controllers.
It is the automotive industry that fully utilizes the usage of PLC in the
production line. Controller played an important role in automation. It
replaced many physical electrical components and devices like relays,
timers and counters in the field.
The evolution of PLC from a single digit input and output (I/O’s) to
hundreds of inputs capabilities expand its application different field
Advantages of PLC
1.) Less wiring

2.) Cost Effective
3.) Easy to change configuration
using supported software
4.) Easy fault detection
Relay Connection
Application of PLC
1.) SEQUENTIAL CONTROL

a.) Relay Logic Control
b.) Timer and Counter Functions
2. COMPLEX CONTROL
a.) Arithmetic Operation
b.) Analog Process Control PLC Connection
c.) Servo/Stepper Motor Control
d.) Supervisory Control and Data
Acquisition (SCADA)
Today’s demand for high quality and productivity can hardly be
fulfilled economically without electronic control equipment. With rapid
technology developments and increasing competition, the cost of
programmable controls has been driven down to the point where a PLC-
versus-relay cost study is no longer necessary or valid. Programmable
controller applications can now be evaluated on their own merits.
INDSUTRIAL APPLICATIONS OF PLC

Since its inception, the PLC has been successfully applied in virtually
every segment of industry, including steel mills, paper plants, food-processing
plants, chemical plants, and power plants.
PLCs perform a great variety of control tasks, from repetitive ON/OFF
control of simple machines to sophisticated manufacturing and process
control. A few of the major industries that use programmable controllers, as
well as some of their typical applications are shown below.
CHEMICAL/PETROCHEMICAL MANUFACTURING/MACHINING
Batch process Assembly machines
Finished product handling Boring
Materials handling Cranes
Mixing Energy demand
Off-shore drilling Grinding
Pipeline control Injection/blow molding
Water/waste treatment Material conveyors
Metal casting
GLASS/FILM Milling
Cullet weighing Painting
Finishing Plating
Forming Test stands
Lehr control Tracer lathe
Packaging Welding
Processing
FOOD/BEVERAGE Blast furnace control

Accumulating conveyors Continuous casting
Blending Rolling mills
Brewing Soaking pit
Container handling
Distilling
Filling Bulk material conveyors
Load forming Loading/unloading
Metal forming loading/unloading Ore processing
Palletizing Water/waste management
Product handling
Sorting conveyors P
Warehouse storage/retrieval Burner control
Weighing Coal handling
Cut-to-length processing
LUMBER/PULP/PAPER Flue control
Batch digesters Load shedding
Chip handling Sorting
Coating Winding/processing
Wrapping/stamping Woodworking
Because the applications of programmable controllers are
extensive, it is impossible to list them all so, we provide a small sample of
how PLCs are being used in industry.
AUTOMOTIVE
Internal Combustion Engine Monitoring. A PLC acquires data recorded
sensors located at the internal combustion engine. taken
water temperature, oil temperature, RPMs, torque, exhaust temperature,
pressure, manifold pressure, and
Carburetor Production Testing. PLCs provide on-line analysis of

carburetors in a production assembly line. The systems significantly reduce the
time, while providing greater yield and better quality carburetors. Pressure,
and fuel and air flow are some of the variables
Monitoring Automotive Production Machines. The system monitors total

rejected parts, parts produced, machine cycle time, and machine
Statistical data is available to the operator anytime or after each
Power Steering Valve Assembly and Testing. The PLC system controls
machine to ensure proper balance of the valves and to maximize left and right
CHEMICAL AND
Ammonia and Ethylene Processing. controllers monitor

control large compressors used during ammonia and ethylene
PLC monitors bearing temperatures, operation of clearance pockets,
speed, power consumption, vibration, discharge temperatures, pressure,
suction
Dyes. PLCs monitor and control the dye processing used in the textile industry.
match and blend colors to predetermined
Chemical Batching. The PLC controls the batching ratio of two or more
in a continuous process. The system determines the rate of discharge of
material and keeps inventory records. Several batch recipes can be logged
retreived automatically or on command from the
Fan Control. PLCs control fans based on levels of toxic gases in a

production environment. This system effectively removes gases when a preset
of contamination is reached. The PLC controls the fan start/stop, cycling,
speeds, so that safety levels are maintained while energy consumption is
Gas and Distribution. controllers monitor

regulate pressures and flows of gas transmission and distribution systems. Data
gathered and measured in the field and transmitted to the PLC
Pipeline Pump Station Control. PLCs control mainline and booster pumps
crude oil distribution. They measure flow, suction, discharge, and tank
limits. Possible with SCADA (Supervisory Control and
Acquistion) systems can provide total supervision of the
Oil Fields. PLCs provide on-site gathering and processing of data pertinent
characteristics such as depth and density of drilling rigs. The PLC controls
monitors the total rig operation and alerts the operator of any possible
GLASS PROCESSING
Annealing Lehr Control. PLCs control the lehr used to remove the internal stress
from glass products. The system controls the operation by following the annealing
temperature curve during the reheating, annealing, straining, and rapid cooling
processes through different heating and cooling zones. Improvements are made in
the ratio of good glass to scrap, reduction in labor cost, and energy utilization.
Glass Batching. PLCs control the batch weighing system according to stored glass
formulas. The system also controls the electromagnetic feeders for infeed to and
outfeed from the weigh hoppers, manual shut-off gates, and other equipment.
Cullet Weighing. PLCs direct the cullet system by controlling the vibratory cullet
feeder, weight-belt scale, and shuttle conveyor. All sequences of operation and
inventory of quantities weighed are kept by the PLC for future use.
Batch Transport. PLCs control the batch transport system, including reversible belt
conveyors, transfer conveyors to the cullet house, holding hoppers, shuttle
conveyors, and magnetic separators. The controller takes action after the discharge
from the mixer and transfers the mixed batch to the furnace shuttle, where it is
discharged to the full length of the furnace feed hopper.
MANUFACTURING/MACHINING
Production Machines. The PLC controls and monitors automatic production
machines at high efficiency rates. It also monitors piece-count production and
machine status. Corrective action can be taken immediately if the PLC detects a
failure.
Transfer Line Machines. PLCs monitor and control all transfer line machining
station operations and the interlocking between each station. The system receives
inputs from the operator to check the operating conditions on the line-mounted
controls and reports any malfunctions. This arrangement provides greater machine
efficiency, higher quality products, and lower scrap levels.
Wire Machine. The controller monitors the time and ON/OFF cycles of a wire-
drawing machine. The system provides ramping control and synchronization of
electric motor drives. All cycles are recorded and reported on demand to obtain the
machine's efficiency as calculated by the PLC.
Tool Changing. The PLC controls a sychronous metal cutting machine with several
tool groups. The system keeps track of when each tool should be replaced, based
on the number of parts it manufactures. It also displays the count and replacements
of all the tool groups.
Paint Spraying. PLCs control the painting sequences in auto manufacturing. The
operator or a host computer enters style and color information and tracks the part
through the conveyor until it reaches the spray booth. The controller decodes the
part information and then controls the spray guns to paint the part. The spray gun
movement is optimized to conserve paint and increase part throughput.
MATERIALS HANDLING
Automatic Plating Line. The PLC controls a set pattern for the automated hoist,
which can traverse left, right, up, and down through the various plating solutions.
The system knows where the hoist is at all times.
Storage and Retrieval Systems. A PLC is used to load parts and carry them in
totes in the storage and retrieval system. The controller tracks information like lane
numbers, the parts assigned to specific lanes, and the quantity of parts in a particular
lane. This PLC arrangement allows rapid changes in the status of parts loaded or
unloaded from the system. The controller also provides inventory printouts and
informs the operator of any malfunctions.
Conveyor Systems. The system controls all of the sequential operations, alarms,
and safety logic necessary to load and circulate parts on a main line conveyor. It
also sorts products to their correct lanes and can schedule lane sorting to optimize
palletizer duty. Records detailing the ratio of good parts to rejects can be obtained
at the end of each shift.
Automated Warehousing. The PLC controls and optimizes the movement of

stacking cranes and provides high turnaround of materials requests in an automated,
high-cube, vertical warehouse. The PLC also controls aisle conveyors and case
palletizers to significantly reduce manpower requirements. Inventory control figures
are maintained and can be provided on request.
METALS
Steel Making. The PLC controls and operates furnaces to produce metal in
accordance with preset specifications. The controller also calculates oxygen
requirements, alloy additions, and power requirements.
Loading and Unloading of Alloys. Through accurate weighing and loading

sequences, the system controls and monitors the quantity of coal, iron ore, and
limestone to be melted. It can also control the unloading sequence of the steel to a
torpedo car.
Continuous Casting. PLCs direct the molten steel transport ladle to the continuous-
casting machine, where the steel is poured into a water-cooled mold for solidification.
Cold Rolling. PLCs control the conversion of semifinished products into finished
goods through cold-rolling mills. The system controls motor speed to obtain correct
tension and provide adequate gauging of the rolled material.
Aluminum Making. Controllers monitor the refining process, in which impurities are
removed from bauxite by heat and chemicals. The system grinds and mixes the ore
with chemicals and then pumps them into pressure containers, where they are
heated, filtered, and combined with more chemicals.
POWER
Plant Power System. The programmable controller regulates the proper distribution
of available electricity, gas, or steam. In addition, the PLC monitors powerhouse
facilities, schedules distribution of energy, and generates distribution reports. The
PLC controls the loads during operation of the plant, as well as the automatic load
shedding or restoring during power outages.
Energy Management. Through the reading of inside and outside temperatures, the
PLC controls heating and cooling units in a manufacturing plant. The PLC system
controls the loads, cycling them during predetermined cycles and keeping track of
how long each should be on or off during the cycle time. The system provides
scheduled reports on the amount of energy used by the heating and cooling units.
Coal Fluidization Processing. The controller monitors how much energy is
generated from a given amount of coal and regulates the coal crushing and mixing
with crushed limestone. The PLC monitors and controls burning rates, temperatures
generated, sequencing of valves, and analog control of jet valves.
Compressor Efficiency Control. PLCs control several compressors at a typical

compressor station. The system handles safety interlocks, startup/shutdown
sequences, and compressor cycling. The PLCs keep compressors running at
maximum efficiency using the nonlinear curves of the compressors.
PULP AND PAPER

Pulp Batch Blending. The PLC co nt r ols sequ en ce op er a ti on, i ngr e di ent
measurement, and recipe storage for the blending process. The system allows
operators to modify batch entries of each quantity, if necessary, and provides
hardcopy printouts for inventory control and for accounting of ingredients used.
Batch Preparation for Paper-Making Processing. Applications include control of

the complete stock preparation system for paper manufacturing. Recipes for each
batch tank are selected and adjusted via operator entries. PLCs can control feedback
logic for chemical addition based on tank level measurement signals. At the
completion of each shift, the PLC system provides management reports on materials
use.
Paper Mill Digester. PLCs control the process of making paper pulp from wood
chips. The system calculates and controls the amount of chips based on density and
digester volume. Then, the percent of required cooking liquors is calculated and
these amounts are added to the sequence. The PLC ramps and holds the cooking
temperature until the cooking is completed.
Paper Mill Production. The controller regulates the average basis weight and
moisture variable for paper grade. The system manipulates the steam flow valves,
adjusts the stock valves to regulate weight, and monitors and controls total flow.
RUBBER AND PLASTIC

Tire-Curing Press Monitoring. The PLC performs individual press monitoring for
time, pressure, and temperature during each press cycle. The system alerts the
operator of any press malfunctions. Information concerning machine status is stored
in tables for later use. Report generation printouts for each shift include a summary
of good cures and press downtime due to malfunctions.
Tire Manufacturing. Programmable controllers are used for tire press/cure systems
to control the sequencing of events that transforms a raw tire into a tire fit for the
road. This control includes molding the tread pattern and curing the rubber to obtain
road-resistant characteristics. This PLC application substantially reduces the space
required and increases reliability of the system and the quality of the product.
Rubber Production. PLCs provide accurate scale control, mixer logic functions, and
multiple formula operation of carbon black, oil, and pigment used in the production
of rubber. The system maximizes utilization of machine tools during production
schedules, tracks in-process inventories, and reduces time and personnel required
to supervise the production activity and the shift-end reports.
Plastic Injection Molding. A PLC system controls variables, such as temperature

and pressure, which are used to optimize the injection molding process. The system
provides closed-loop injection, where several velocity levels can be programmed to
maintain consistent filling, reduce surface defects, and shorten cycle time.
SELECTING PLC SYSTEM
Deciding on the right controller for a given application has become

increasingly more difficult. With the explosion of new products, including
general- and special-purpose programmable controllers, system selection now
places an even greater demand on the designer to take a system approach to
selecting the best product for each task.
Programmable controller selection affects many factors, so the
designer must determine which characteristics are desirable in the control
system and which controller best fits the present and future needs of the
application.
The designer should understand the different ranges of
programmable controller products and the typical features found within each
range. This understanding will enable the designer to quickly identify the type
of product that comes closest to matching the application’s requirements.
TYPES OF PLC
1.) Compact type (also known as Shoebox and Brick type)

It is a type of PLC where input and output ports are
connected in one package together with the CPU and power supply. This
type is small and with fix number of Inputs and Outputs (I/O’s). They are
designed for simple applications and suitable for standalone systems
Today, compact type is also known as Mini PLC because their
capabilities is limited and half compared to a regular PLC.
Compact Type Omron CPM1A

Photo Courtesy of OMRON
2.) Modular Type
This is a type of PLC where power supply, CPU, input and output unit
are distinct and detached physically from each other. Connection ports
connect each unit to build a powerful controller. In this type, expansion to a
much higher I/O’s and other modules is possible. Though in some compact
type PLC, it is possible to expand using additional connector but its still
depends on CPU’s capability, the same goes to modular type.
Power CPU
Supply
Input and Output Modules
SIEMENS Modular type PLC
PLC can be categorized based on their I/O capabilities. It is the

number of inputs and outputs signal they can process. They can be
categorized to micro, small, medium and large PLC.
MICRO PLC – less than 100 I/Os

SMALL PLC – less than 526 I/Os
MEDIUM PLC – less than 1028 I/Os
LARGE PLC – less than 5120 I/Os
Selecting the right programmable controller for a machine or
process involves evaluating not only current needs, but future
requirements as well. If present and future goals are not properly
evaluated, the control system may quickly become inadequate and
obsolete.
Keeping the future in mind when choosing a programmable

controller will minimize the costs of changes and additions to the system.
For example, with proper planning, future memory expansion may only
require the installation of a memory module; furthermore, the addition of a
peripheral may be as easy as connecting the device to the communication
port. A local area network can also ease the future integration of
programmable controllers into a plant wide communication scheme.
Once the basic control application has been defined, the user should
begin evaluating the controller requirements, including:
• input/output
• type of control
• memory
• software
• peripherals
• physical and environmental
INPUT/ OUTPUT CONSIDERATIONS

Determining the amount of I/O required is typically the first step
in selecting a controller. Once the decision has been made to automate
a machine or process, determining the amount of I/O is simply a
matter of counting the discrete and/or analog devices that will be
monitored or controlled.
This count will help to identify the minimum size constraints for
the controller. Remember that the controller should allow for future
expansion and spares (typically10% to 20% spares), although spares
do not affect the choice of PLC size.
Discrete Inputs/Outputs. Input/output interfaces with

standard ratings are available for accepting signals from sensors and
switches (e.g., push buttons, limit switches, etc.), as well as ON/OFF
control devices (e.g., pilot lights, alarms, motor starters, etc.). If these
input/output devices receive power from separate sources, then the
discrete interface circuits must have isolated commons (return lines).
Typical discrete AC inputs/outputs range from 24 to 240 V, and typical
DC inputs/outputs range from 5 to 240 V.
Input circuits vary from one manufacturer to another.
Nevertheless, characteristics like debouncing circuitry, which protects
against false signals, and surge protection, which guards against large
transients, are desirable in any input circuit. Another good input
circuit quality is optical or transformer isolation between the high-
power input and the interface’s control logic circuitry.
Siemens Digital Input

Module 16xDC24V
(321-1BH02-0AA0)
Properties of SM 321; DI 16 x DC 24 V:
● 16 inputs, electrically isolated in groups of 16

● Rated input voltage 24 VDC
● suitable for switches and 2- /3-/4-wire proximity switches
(BEROs)
*BERO - is the trade name used by Siemens to identify its line of

―no-touch‖ sensors.
When evaluating discrete outputs, the following are key

characteristics: fuses, transient surge protection, and isolation
between the power and logic circuits. Fused circuits cost more initially,
but they usually cost less than having a fuse installed externally.
These circuits should also have easily accessible fuses, so that
replacing fuses does not require shutting down several other devices
for a long period of time. Moreover, fused output circuits should have
blown fuse indicators, as well as an output current rating and a
specified operating temperature (typically 60 F) that fits the
application’s requirements.
Siemens Digital
Output Module 16x
REL. AC120/230V
(322-1HH01-0AA0)
Properties of SM 322; DO 16 x Rel. AC 120/230 V:
● 16 outputs, electrically isolated in groups of 8
● Load voltage 24 VDC to 120 VDC; 24 VAC to 230 VAC
● Suitable for AC/DC solenoid valves, contactors, motor starters,
FHP motors and signal lamps.
Analog Inputs/Outputs. Analog input/output interfaces sense

signals generated by transducers. These interfaces measure quantity
values, such as flow, temperature, and pressure, and are used to
control voltage or current output devices. Typical interface ratings
include –10 to +10 V, 0 to +10 V, 4 to 20 mA, and 10 to 50 mA.
Some manufacturers provide special analog interfaces that accept

low-level signals (e.g., RTD, thermocouple). Typically, these interface
modules accept a mix of thermocouple or RTD signals on a single
module. Users should consult the vendor concerning specific
requirements.
Analog input module

SM 331; AI 2 x 12 Bit;
(6ES7331-7KB02-0AB0)
Properties of SM 331; AI 2 x 12 Bit:
(Analog Input)
● Two inputs in one channel group
● Programmable measurement type for each channel group
– Voltage
– Current
– Resistance
– Temperature
● Programmable resolution at each channel group
(9/12/14 bits + sign)
● Any measuring range selection per channel group
● Programmable diagnostics and diagnostic interrupt
● Programmable limit value monitoring for one channel
● Programmable hardware interrupt when limit is exceeded
● Electrically isolated from the CPU and load voltage
(not for 2DMU)
Analog output module

SM 332; AO 2 x 12 Bit;
(6ES7332-5HB01-0AB0)
Properties of SM 332; AO 2 x 12 Bit:

(Analog Output)
● 2 outputs in one group

● The outputs can be set separately as
– voltage output
– current output
● Resolution 12 bits
● Programmable diagnostics and diagnostic interrupt
● Electrically isolated to backplane bus interface and load voltage
● Supports parameter reassignment in RUN
Special Function Inputs/Outputs. Sometimes an application
requires a special type of I/O conditioning (e.g., positioning, fast
input, frequency, etc.) that may be impossible to implement using
standard I/O modules. Special function I/O modules and smart
modules, a type of special interface, can perform this task. Typically,
these interfaces process all of the field data within the module itself,
thus relieving the CPU from performing this time- consuming duty. For
example, PID, three-axis positioning, and stepper motor modules are
special function I/O modules that make control implementation much
easier. These modules reduce programming and implementation time.
Remote Inputs/Outputs. Remote I/O modules are convenient,

cost-effective processing devices, especially when used in large
systems. Remote I/O subsystems, which are located away from the
CPU and connected to it by twisted-pair cables, can dramatically
reduce wiring costs, both from a labor and a material standpoint.
Another advantage of remote I/O subsystems is that inputs and outputs
can be strategically grouped to control separate machines or sections of
a machine or process. This grouping provides easy maintenance and
allows start-up without involving the entire system.
Most controllers that have remote I/O have remote digital I/O.
However, users who require remote analog I/O should check to see if
this feature is available in the products being considered.
I/O Bus Networks. I/O bus networks, which include device bus
and process bus networks, should be considered in applications
requiring decentralized control within the PLC system. I/O bus
networks provide a topology that allows the direct connection of field
devices to a bus network, thereby simplifying wiring. At the same
time, these networks let the PLC directly receive I/O field device
information about the status of the device. However, the system’s I/O
field devices must be compatible with the I/O bus network to take
advantage of these enhanced communications features
CATEGORY OF CONTROL
With the advent of new, smarter programmable controllers, the

decision about the type of control has become a very important
consideration. Questions such as, What type of control should I use?
are now asked more often when automating a process.
Knowing process application and future automation
requirements will help the user to decide what type of control, and
thus PLC, is required. Possible control configurations include
individual control, centralized control, and distributed control.
Individual Control
or segregated control, is used when a PLC controls a single

machine with only local I/O or with local and a few remote I/O.
This type of control does not normally require communication with
any other controllers or computers. Individual control is primarily
applied to OEM and end-user equipment, such as injection-
moulding machines, small machine tools, and small, dedicated
batching processes. When deciding on this approach, the user
should consider whether future inter-controller communication
will be desired. If so, the user can choose the appropriate
controller for the initial installation to avoid extra design expenses
at a later date.
PLC
Machine
Individual Control
Centralized control
is used when a central PLC controls several machines or
processes. This type of control can have many subsystems spread
throughout the factory. Each of these subsystems may interface
with specific I/O devices that may or may not be related to the
same control. A centralized programmable controller
communicates only with its subsystems and/or peripherals; it
does not exchange data with other PLCs.
PLC
Machine Machine Machine
Centralized Control
The flexibility and potential advantages of a centralized

application depend on the PLC used and the system designer’s
design philosophy. For example, centralized control can be
implemented as the large, individual control of a large process or
the centralized control of a number of highly complex, small
processes.
One distinct disadvantage of centralized control is that, if the

main PLC fails, the whole process stops. Redundant systems can
be used to overcome this problem in large, critical, central
controls that require a backup. Several manufacturers offer this
redundancy option.
Distributed Control
The need to have several main PLCs communicating with each

other has brought about distributed control. This type of control
employs local area networks (LANs), which allow several PLCs to
control different stages or processes locally while constantly
interchanging information about the process. Communication
among PLCs occurs at very high speeds (up to 1 megabaud)
through single coaxial or fiber-optic cables. Despite this powerful
configuration, communication between two different
manufacturers’ LAN systems can be difficult. Therefore, the user
should properly define the process application’s functional
requirements from the beginning.
PLC PLC PLC PLC
Machine Machine Machine Machine
Distributed Control
MEMORY CONSIDERATION
The two main factors to consider when choosing memory are

the type and the amount. An application may require two types of
memory: non-volatile memory and volatile memory with a battery
backup. A non-volatile memory, such as EPROM, can provide a
reliable, permanent storage medium once the program has been
created and debugged. If the application will require on-line
changes, then it should probably be stored in read/write memory
supported by a battery. Some controllers offer both of these
options, which can be used individually or in conjunction with
each other.
Small PLCs normally have a fixed (non-expandable) memory
capacity of 1/2K to 2K words. Therefore, the amount of memory is
not a major concern when selecting a small controller. In medium
and large controllers, however,
The amount of memory required for a given application is a

function of the total number of inputs and outputs to be
controlled and the complexity of the control program. The
complexity refers to the amount and type of arithmetic and data
manipulation functions that the PLC will perform. For each of
their products, manufacturers have a rule-of-thumb formula that
helps to approximate the memory requirement. This formula
involves multiplying the total number of I/O by a constant
(usually a number between 3 and 8). If the program involves
arithmetic or data manipulation, this memory approximation
should be increased by 25 to 50%.
Although memory requirement formulas do a good job of

estimating memory needs, the best way to obtain memory
requirement data is to create the program and count the number
of words used. Knowledge of the number of words required to
store each instruction will allow the user to determine exact
memory requirements.
SOFTWARE CONSIDERATION
During system implementation, the user must program the

PLC. Because the programming is so important, the user should
be aware of the software capabilities of the product they choose.
Generally, the software capability of a system is tailored to handle
the control hardware that is available with the controller.
However, some applications require special software

functions that are beyond the control of the hardware
components. For instance, an application may involve special
control or data acquisition functions that require complex
numerical calculations and data-handling manipulations. The
instruction set selected will determine the ease with which these
software tasks can be implemented. It will also directly affect the
time required to implement and execute the control program.
Siemens Step 7 Siemens TIA Portal
PERIPHERALS CONSIDERATION
The programming device is the key peripheral in a PLC

system. It is of primary importance because it must provide all of
the capabilities necessary to accurately and easily enter the
control program into the system. The two most common types of
programming devices are handheld units and personal computers.
Handheld units, which are small and low cost, are typically used
to program relatively small control programs in small PLCs. The
amount of information that can be displayed on a handheld unit is
normally a single program element or, in some cases, a single
program rung.
Programming Handheld
device
Personal
computers provide a better way to
program a system if the control program is large. Many PLC
manufacturers provide software that allows their PLCs to be
programmed using a standard PC. Laptop PCs equipped with
programming and documentation software provide even more
programming flexibility by joining the ease of PC programming
with the transportability of handheld programming devices.
Laptop as programming device
In addition to the programming device, a system may

require other types of peripherals at certain control stations to
provide an interface between the controller and the operator. The
most common peripheral is the line printer, used for obtaining a
hardcopy printout of the program and for sending report
information about the process. If a PC is used as a graphic
interface to a PLC system, both systems must have compatible
DDE (dynamic data exchange) drivers to properly interface with
peripherals.
Peripheral requirements should be evaluated along with the

CPU, since the CPU will determine the type and number of
peripherals that can be interfaced to the system. The CPU also
influences the method of interfacing, as well as the distance that
peripherals can be placed from the PLC.
PHYSICAL AND ENVIRONMENTAL CONSIDERATIONS
The physical and environmental characteristics of the

various controller components will significantly impact total
system reliability and maintenance. Ambient conditions, such as
temperature, humidity, dust level, and corrosion, can affect the
controller’s ability to operate properly. The user should determine
operating conditions (i.e., temperature, vibration, EMI/ RFI, etc.),
and packaging requirements (i.e., dustproof, drip proof, rugged-
ness, type of connections, etc.) before selecting the controller and
its I/O system. Most programmable controller manufacturers
provide products that have undergone certain environmental and
physical tests (e.g., temperature, EMI/RFI, shock, etc.). Users
should be aware of the tests performed and whether or not the
results meet the demands of the operating environment.
PLC REQUIREMENT CHECKLIST
Here are the checklists of the features a user should look for
when evaluating PLC requirements. The data also provides typical
specifications for these features. Note that the list covers all
product ranges, from small to very large; therefore, some PLCs
may not have all of these features due to their range
characteristics.
(See next page for the complete list)
PLC Requirement Checklist
PLC Requirement Checklist
I/O System Checklist Typical Specifications
I/O Count
Digital count Maximum of 128 I/O (mixable)
Analog count Maximum of 16 I/O (mixable)
Digital I/O
Inputs
Points/module 4 points/module
Input type AC, DC, nonvoltage, etc.
Input ratings 110 VAC, 220 VAC, 5–24 VDC, etc.
Maximum inputs/channel 64 points/channel
Input status indicators Power, logic
Isolation 1500 volts optical
Outputs
Points/module 16 points/module
Output type AC, DC, contact, etc.
Output ratings 110 VAC, 220 VAC, contact
Output current (amps/point) 1 amp/point with all outputs ON at 115 VAC
Maximum outputs/channel 64 points channel
Output status indicators Power, individual blown fuse, logic
Output protection Fuses, suppression on contact output
Analog I/O
Inputs
Points/module 4 analog inputs/module
Resolution 11 bits
Input type Current, voltage
Input ratings 4–20 mA, 0–5 volts, 0–10 volts
Built-in transducer Thermocoupler input
Maximum inputs/channel 32 points/channel
Power supply Internal to PLC
Outputs
Points/module 2 analog outputs/module
Output type Current, voltage
Output ratings 4–20 mA, 10–50 mA, 0–10 volts
Maximum outputs/channel 16 points/channel
Power supply
+15 VDC and –15 VDC
Remote I/O
Digital
Distance 1500 ft
I/O per remote 32 I/O per remote
Communication link Twisted-pair, 100 ohms impedance
Analog
Distance 5000 ft with receiver/transmitter
I/O per remote 16 I/O per remote
Communication link Coaxial
I/O System Checklist Typical Specifications
Special I/O
High-speed pulse counter Local and remote, 50 kHz
Fast electronic input 5 microsecond pulse width minimum
Interrupt module Yes
Absolute encoder Direct connection to encoder
Incremental encoder Not available
BCD I/O module Remote, 4 and 8 BCD digits
Stepper motor Yes
ASCII communications module Full ASCII 300–4800 baud
Host computer Yes, protocol decode on module
LAN I/O module Extra board in CPU
PID module Local and remote, 2 loops per module
Language module Basic interpreter module
I/O Bus Network
Device bus
Networks supported DeviceNet, InterBus-S, and SDS
Number of nodes 64 nodes, 2048 devices
Structure Trunkline
Process bus
Networks supported Profibus and Fieldbus foundation
Media Coaxial
Speed 2 Mbaud
Physical
Wire size to I/O 20 AWG with 2 wires per I/O
Separate commons Yes for 4 pts/module, no for 16 pts/module
Removable under power Yes
Disturb wiring to remove I/O No, disconnect screw from I/O module
CPU Checklist Typical Specifications
Processor
Microprocessor 16-bit microprocessor and multiprocessor
board
Scan time 10 msec/K of memory
Communication ports Two RS-232C ports
Memory
Memory type RAM, EEPROM
Total system memory 64K
Application memory size 8K for user
Word size 8 bits
Memory utilization 1 word per element (coil or contact)
Memory protection Yes, key switch
Power Supply
Incoming power 120/240 VAC, 24 VDC
Frequency 50/60 Hz
CPU Checklist Typical Specifications
Power Supply
Voltage variation +15%, –10%
Overvoltage protection Yes
Current limiting Yes
Maximum current supply 100 mA at 14 VDC, 2.5 amps at 5 VDC
Isolation 1500 volts
Location Built-in CPU
Environmental
Operating temperature 0–60 C
Humidity 5–90% relative humidity, noncondensing
EMI/RFI Satisfies NEMA and IEEE tests
Noise 1000 volts peak-peak, 1 microsecond
Vibration Withstands 16.7 Hz, double amplitude
Shock 10g each direction
Software Checklist Typical Specifications
Language
Ladder or Boolean Ladder language
High-level Functional blocks
IEC 1131-3 Conforms to IEC 1131-3 with SFCs
Software Coils
Number of internals 128
Number of timers 32 with maximum count of 9999 sec BCD
Number of counters 166
Number of shift registers 32, 16 bits each
Number of drum timers 16
Timer’s time base 0.1, 1.0 seconds
Timer type ON delay and OFF delay
Counter type Up/down counter
Latch coil 32
Transitional coil 16, OFF/ON and ON/OFF
Master control relays 8
Global coil 256 in LAN
Global register 128 in LAN
Fault coil Yes, detection of CPU failure
Interrupt coil Yes
Math
Addition Yes, double precision
Subtraction Yes, double precision
Multiplication Yes
Division Yes
Square root Yes
Floating point Yes, 1E + 38, 1E – 38
Trigonometric functions Yes, sine and cosine in IEC 1131-3 ST
language
Software Checklist Typical Specifications
Data Handling
Number of registers 128, 16 bits each
Data size in registers +32767, –32767, and 9999 BCD
Compare Yes, <, >, and =
Conversions Binary-BCD, BCD-binary
Move Registers and single files
Matrix AND, OR, XOR, NAND
Tables Move to ASCII or binary tables
PID Software functional block, 20 loops
LIFO Yes
FIFO Yes
Jump Conditional and direct
Subroutines Yes
ASCII instructions Yes, print and read
Sort No
Machine diagnostics Yes
Programming and Storage
Typical Specifications
Device Checklist
Personal Computer
Physical
Computer type Desktop and laptop
Display size 14 to 21" screen
Graphics Yes
DDE driver Yes
Ladder matrix size 10 7 elements, scrolling for IEC 1131-3
Built-in storage Yes
Local area network Yes
Communication RS-232C and 20 mA current loop
Incoming power 115/230 VAC
Keyboard type Mylar or standard keys
Functional
Intelligent Yes
Single scan No
Power flow Yes, element intensified on screen
Off-line programming Yes
Monitor function Yes
Modify function Yes
Force I/O Yes, indicates forcing on mainframe
Search No
Mnemonics Yes
Documentation Built-in software module
Manual Programmer
Physical
Display type LCD or LED
Ladder matrix size 7 4 elements
Programming and Storage
Device Checklist
Manual Programmer
Physical
Communication RS-232C
Incoming power From unit
Keyboard type Mylar
Functional
Intelligent No
Single scan No
Power flow Yes
Monitor function Yes
Modify function Yes
Force I/O Yes
Search No
Mnemonics Yes, also messages
Storage Devices
Floppy disk In personal computer
Computer Yes, through computer module
Electronic memory module Yes, for a small PLC
System Diagnostics
Checklist
Power Supply
Power loss detection Yes, after 3 cycles
Voltage level detection Yes, DC levels for CPU
Diagnostic monitoring Continuously
Memory
Memory OK Yes, checksum and LED indicator
Battery OK Yes, LED indicator
Diagnostic monitoring At power-up only
Processor
Local Yes, watchdog timer and LED indicator
Remote Yes, indicator in CPU
Diagnostic monitoring Continuously
Communication
Local I/O Yes
Remote I/O Yes, checksum
Programming device CRT port OK and RS-232C OK
Diagnostic monitoring During transmission
Fault Indications
CPU Yes, external relay contacts
Remote Yes, external contacts at remote driver
LAN Yes, internal coil
I/O Yes, detects presence of I/O module
OTHER CONSIDERATIONS
An evaluation of the previously discussed hardware and software

requirements will narrow the selection of the PLC down to one of a few
possible candidates. More than likely, two or more products will meet all of
the requirements of the preliminary system design, meaning that a final
decision must still be made. At this point, the user should evaluate a few
more factors, which can lead to the selection of the product that best fits
the system specifications and the application requirements. The user
should discuss these factors with the potential vendors.
PROVEN PRODUCT RELIABILITY
The reliability of the controller plays an important role in overall

system performance. Lack of reliability usually translates into downtime,
poor quality products, and higher scrap levels.
The user can investigate several factors to determine the proven

reliability of a particular product. Mean-time-between-failures (MTBF)
studies can be helpful if the user knows how to evaluate the data. These
studies provide information about the average time between equipment
malfunctions and how long the equipment will operate without a failure.
Knowledge of a similar application in which the product has been
successfully applied is also useful.
A sales representative can provide this information and even, on

occasion, arrange a site visit. Moreover, the user should ensure that the
vendor can truly satisfy any unique or peculiar specifications (e.g., EMI and
vibration requirements). Finally, the user should research the burn-in
procedures for the product (e.g., the total system burn-in process or the
parts burn-in process).The burn-in process involves operating the product
at an elevated temperature to simulate extended operation in order to force
an electronic board or part to fail. If a part passes the burn-in procedure, it
will have an extremely high probability for proper operation. Usually, the
vendor can provide MTBF and burn-in information upon request.
STANDARDIZATION OF PLC EQUIPMENT
A last consideration when making the final decision on a PLC is the

possibility of future plans to standardize machinery—that is, to use only
products from a given manufacturer and product line. Many companies are
adopting this practice for good reasons. Several vendors are creating
complete product families of PLCs that cover the entire range of capabilities,
thus making standardization more feasible. Another current trend by
manufacturers is to build completely inter-compatible product families,
with products ranging from very small to very large PLCs. These families
share the same I/O
SIEMENS S7- 300 CPU
We will be using Siemens S7-300 CPU, the CPU with medium to large
program memory and quantity framework. Specifically we will S7-300
CPU315-2PN/DP which works on -25 to +70 degrees Celsius of working
environment.
It has a CPU with 384 Kbyte working memory capabilities. A 0.05

micro seconds (μs) processing time for bit operations and 0.09 μs for word
operations. It’s a fast processing PLC CPU
Number Description
① Status and error indicators
② Slot for the SIMATIC Micro Memory Card
incl. the ejector
③ Mode selector
④ MAC address and 2D bar code
⑤ 1. interface X1 (MPI/DP)
⑥ Power supply connection
⑦ 2. Interface X2 (PN), with dual-port
switch
⑧ PROFINET Port 2
The Port 2 status is signaled using a dual-
color LED (green/yellow):
* LED lit green: LINK to a partner is active
* LED changes to yellow: active data traffic
(RX/TX)
R: Ring port for setting up a ring topology
with media redundancy
⑨ PROFINET Port 1
The Port 1 status is signaled using a dual-
color LED (green/yellow):
* LED lit green: LINK to a partner is active
* LED changes to yellow: active data traffic
(RX/TX) CPU315- 2PN/DP
6ES7315-2EH14-0AB0
R: Ring port for setting up a ring topology
with media redundancy
PLC Components
PLC system components are the same on either type of PLC. Each part
is very important in its smooth operation. A missing single part or
components would paralyze PLC and it will be irrelevant. At this discussion
we will focus on modular type PLC components.
Here are the components:
1.) Power Supply – gives power to the CPU unit and other
modules. Its input voltage range would be
100V – 240V AC and output voltage typically
240V AC and 5 - 24Vdc. It usually found
besides the CPU unit.
Power Supply Unit Power Supply Power Supply

for AB Compact Unit for Unit for
Logix L32E OMRON NJ SIEMENS S7-
Series 300
2.) CPU (Central Processing Unit)

It is the brain of the PLC which executes different operation
required by input signals and delivers to applicable output.
Memory chips, microprocessor and logic circuits can be seen
inside the CPU module. Communication ports are also visible
within the module.
Allen Bradley Omron Siemens CPU
Compaq Logix NJ301-1100 CPU 315-2 PN/DP
L32E CPU CPU
COM Port
3.) Input and Output (I/O)

This is where external devices and components interact
with the CPU. Input devices and signals are being interfaced to input
port or modules while the results are being taken out of output port or
module.
There are two types of I/O in PLC, analog and digital.
Digital I/O devices must be only in one state.

Either 1 or 0, true or false etc.
Analog I/O or continuous devices sense
and respond to a varying value.
Of course, digital I/O process digital signal while analog I/O process
analog signal. In digital input it is important to note that there are two
types input devices connection. They are either sourcing (PNP) or sinking
(NPN).
PLC
Analog Signals Digital Signals
PLC signals
Sourcing Sinking
4.) Communication
Communication module is one of the important part of PLC. It is use to

connect and network controller to other controller and their respective
devices, mainly use for data exchange of control devices.
Allen Bradley (AB) developed and uses the deviceNet technology. AB
promotes the technology by opening the technology to different PLC vendors
for advancement and modification purposes.
DeviceNet Technology is now managed by Open DeviceNet Vendors

Association (ODVA) an independent organization not connected to
Allen Bradley located in North America. Upgrading and changes to the

technology are now handled by ODVA where Omron Company is a member.
That’s why Omron also use the technology.
Siemens use the PROFIBUS (Process Field Bus) technology specifically
PROFIBUS DP (Decentralized Peripherals), a standard in field bus
communication, mostly used by European PLC manufacturer. Use to
connect and operate system, sensors and actuator in a centralized
controller.
SIEMENS Profibus Allen Bradley’s

Omron’s
Connection DeviceNet
DeviceNet
Module
Module
SELF CHECK 1.1.2
Matching type
Direction: Match the descriptor from column I to the terminologies in
the column II. Write the letter of your choice on your answer sheet.
I II
1.) A computer used commonly in A. Sinking Type
the industry to control different
electro-mechanical devices and
components by programmed
instructions.
2.) The company that first B. Sourcing type
built a PLC in 1968
3.) Siemens created and used this C. Large PLC
type of network technology
4.) Allen Bradley and Omron use D. Triac Type
this type of networking
technology on PLC
5.) Also known as shoebox and E. Transistor Type
Brick type controller
6.) A PLC with less than 1028 F. Micro PLC
I/Os
7.) A controller where CPU, power G. Compact Type
supply and modules are not
intact in one module.
8.) A PLC with more than H. Rockwell Automation
100 I/Os
9.) An input module connected to a I. DeviceNet
PNP output type input device
to work properly.
10.) An output module which is J. Modular type
voltage dependent means they
switch AC and DC voltages.
K. Small PLC
L. ProfiBus
M. Medium PLC
N. Power Supply
O. PLC
P. Relay Type
Q. Omron
R. Siemens
ANSWER KEY 1.1.2
1.) O
2.) H
3.) L
4.) I
5.) G
6.) M
7.) J
8.) K
9.) A
10.) P
Task Sheet 1.1.2
Title: Programmable Logic Controller

identification and familiarization
Performance Objectives: Given the controller equipment present, you
should identify and familiarize the type of
controller and its module
Supplies/Materials: Pen and bond paper
Equipment: Programmable controller CPU

Controller Modules ( Input, Output and
Communication)
Controller Power Supply
Steps/ Procedure:
1.) Proceed to the working area where the PLC

is placed.
2.) In your worksheet, identify the type of PLC
present and its brand. Also, include the
model and its physical description like ―It
has consisted of Ethernet port for
communication‖. And include the specific
model and order number.
3.) Identify also the different modules available
and its type or classification. Include the
specific model and order number
4.) When you identify the input and output
modules, count the number of points or port
available.
5.) Present your data to your trainer
Assessment Method: Portfolio using the output of this activity
Performance Criteria Checklist 1.1.2
Trainees Name:__________________________________Date:_________________
CRITERIA Yes No
Are all modules of PLC system identified?
Are descriptions on controller CPU stated clearly?
Is needed power supply ratings included?
Are the model and order number presented on

each module including the CPU are correct?
Did the trainee identify the type of PLC

given to them?
Is communication module identified properly?
Information Sheet 1.1.3
Processing and communication speed of the programmable
control

MUST be able to:
1.) Discuss the interface of programmable controller and

programming device
2.) Identify the type of communication mode of PLC
3.) Analyze the processing of data signals of PLC using its
memory
4.) Configuration of actual hardware modules and programmable
control software
Selecting PLC is already discussed in the previous section. All you want
to consider in choosing the right and appropriate controller for your needs.
Though, the specification considerations on communication devices are
reviewed, in this section we will further explain how the PLC communicate or
connect to programming device, and how it process signals going in and out
the system.
PLC operation
Controller works like a normal computer. Input device like keyboard
and mouse triggers the action, while the CPU scans and examines the action
and output device reveal the results of CPU. The same goes to PLC, where
input devices like switch and sensor generates signal going to controller. The
signal will know be process and sent to memory.
Controller will start to scan all inputs and process instructions and
operations in the memory. After that, necessary output signals are sent to
port or module where results are exhibit and displayed on devices.
Read Execute Result
Operation Sequence
EXECUTE RESULT
READ
PLC
MEMORY
INPUTS OUTPUTS
PLC Scan
PLC Program
For the PLC to be useful, it must first have a Program or Logic for the
CPU to execute. A system engineer or PLC programmer will first create the
program logic in a programming device (these days it is usually software
running on a personal computer). This logic can be written in Ladder Logic,
Instruction List, Sequential Function Charts, or any of the IEC languages.
The programmer will then download the program to the PLC. This is
usually done by temporarily connecting the programmer to the PLC. Once the
program is installed or downloaded to the CPU – it is usually not necessary
for the PC to remain connected.
Basic Scan
Once the program is in the CPU – the PLC is then set to “run”, and the
PLC executes the application program repeatedly. In addition to executing
the program, the CPU regularly reads the status of the input devices, and
sends data to the output devices. The Input system senses the status of the
real world inputs (a switch, a level, etc.), translates them to values that can
be used by the CPU, and writes those values to the Input table. The
application program is executed, and writes values to the Output table. The
Output system then converts the output value to a real world change (motor
turns on, valve opens, etc.)
This process of reading inputs, executing logic, and writing outputs is
called the PLC Scan or Sweep.
The CPU continuously Reads Inputs, Solves Logic, and Writes to the
outputs (there are other tasks the CPU does – which will be discussed later).
It is important to understand the scan because it may dictate how a
programmer structures logic.
Memory
The control program or application program is stored in memory. As
the PLC executes logic, it may also read and store values to memory. The
values may also be used and referenced by the application program.
PLC SYSTEM CONFIGURATION
Controller alone cannot achieve the desired and required output.

Additional peripherals and elements are take into account to accomplish
the task and job of a good and useful system.
Programming device
This are elements that are interfaced to the controller (PLC) to give
instructions and operations by using a programming language software,
usually a personal computer (PC), laptop or any handheld device with
display/keypad capable and compatible to controller.
Portable Laptop
Programming software
It is use to create, test , and debug programs applications that are
understandable by PLC. Also, different programming language are
integrated in a single software in accordance to international standards of
such software. Each manufacturer of controller developed their
programming software like Step 7 and Totally Integrated Automation (TIA)
by Siemens, RS Logix by Allen Bradley and SysMac Studio by Omron
ALLEN BRADLEY
SIEMENS
(AB)
RS Logix
Step 7 TIA
5000
OMRON
Sysmac
Studio
Programming or communication device medium
Devices used to communicate controller to programming device and

automated systems properly.
Serial port connection allows connecting the programming device to a

controller. Uploading and downloading of programs is possible. Usually it is
not a separate module; it is packaged within the controller. Allen Bradley
Compact Logix L32E controller is capable of this type of connection.
RS-232 cable RS-232 to USB adapter

from Allen Bradley ( for PC connection)
You can create your own cable, just follow the wiring
connections below for your do it yourself (DIY) cable.
PC Controller
Multi Point Interface (MPI) adapter
It connects SIEMENS PLC port (like a serial interface port) to
serial interface (USB) of Personal Computer (PC). MPI adapter is not
just an ordinary device; it is composed of circuitry inside for fast
communication speed.
SIEMENS MPI adapter with

LED Indicator
Ethernet connection
is the most common standard interface for most, if not all,
controller built by majority of PLC manufacturer. And some of the
reasons are due to its flexibility and technology, which is also present
to all commercially available computer.
Ethernet cable
(RJ 45)
CONTROLLER SET UP
We will connect our controller to programming device(which is our PC

or laptop) through Ethernet, a much easier way to set up our PLC. And we
will have to configure our IP settings on programming device in accordance
to a connected controller or interface device like HMI.
A sample communication configuration is given below with respective
IP address for each device and equipment.
PLC
Human Machine
Interface (HMI)
IP Address : 192.168.0.2
Subnet Mask :
255.255.255.0
IP Address : 192.168.0.1
Subnet Mask :
255.255.255.0
Switch
Laptop
IP Address : 192.168.0.10
Subnet Mask :
255.255.255.0
iDG Siemens PLC Trainer
Educational trainer kit in either field would be a great help in learning

the knowledge and skills the industry needs. Though trainers are
specializes type, they offer comprehension and familiarity in what to expect
at the actual set up.
The trainer’s input and output module port are well protected with
circuit that would safeguard the actual unit or module from improper and
inappropriate connections.
In Siemens trainer, it is composed of the usual PLC set up, Power
supply, Central Processing Unit (CPU), Digital Input and Output Module,
and Analog Input and Output Module.
Trainer’s Input port

The trainers input are composed one position push button and selector
switch. The first eight bits of first module is connected to eight pushbutton
of the trainer. The address range is from 0.0 to 0.7.
The selector switch is designated for the first 8 bits of the second input
module, as shown in the photo. The selector switch address range is from
2.0 to 2.7
Trainer’s Output port
The trainers output are all equipped with LED indicator display. Just
make sure to configure your module accordingly. The printed address in the
trainer are 4.0 - 4.7, 5.0 – 5.7, 6.0 – 6.7 and 7.0 – 7.7 accordingly.
The following are some information and specifications to know about
Siemens PLC trainer.
Input Voltage : 220 Vac

Output Voltage: 24 Vdc and 10 Vdc
Input connection common : -24 Vdc, internally input
COM is connected, no need to connect on output port or wire

connection at terminal block. And Siemens PLC trainer input type is same
with the actual configuration of the input module which is a Sinking (NPN)
type module. Output port is a relay type of output module. It is not polarity
sensitive and can accommodate AC and DC signal voltages so don’t worry!
Trainer’s modular 16
Trainer’s modular input Trainer’s modular
bits data input and
and output unit potentiometer and
output unit
meter unit
CONTROLLER START UP AND CHECKING
Prior to applying power to the system, the user should make several
final inspections of the hardware components and interconnections. These
inspections will undoubtedly require extra time. However, this invested time
will almost always reduce total start-up time, especially for large systems
with many input/output devices. The following checklist pertains to
prestart-up procedures:
1. Visually inspect the system to ensure that all PLC hardware

components are present. Verify correct model numbers for each
component.
2. Inspect all CPU components and I/O modules to ensure that they
are installed in the correct slot locations and placed securely in
position.
3. Check that the incoming power is correctly wired to the power

supply(and transformer) and that the system power is properly
routed and connected to each I/O rack
4. Verify that the I/O communication cables linking the processor to

the individual I/O racks correspond to the I/O rack address
assignment.
5. Verify that all I/O wiring connections at the controller end are in
place and securely terminated. Use the I/O address assignment
document to verify that each wire is terminated at the correct point.
6. Check that the output wiring connections are in place and properly
terminated at the field device end.
7. Ensure that the system memory has been cleared of previously

stored control programs. If the control program is stored in EPROM,
remove the chips temporarily.
MECH072213 and Software Programs July 22, 2013 69
STEP 7 software
Step 7 software is a SIEMENS programming software use to connect S7

CPU family to a programming device or workstation.
There are different types of PLC and a bunch of manufacturer. Each
company develops their own software for their controller. And sometimes,
some company tend change their software as they upgrade their controller.
STEP 7 start up
1.) Click the Step 7 SIMATIC Manager icon

on the desktop
Or
Go to Start - All Programs - Siemens

Automation
folder – SIMATIC folder – click SIMATIC
Manager icon
2.) A “ New Project” wizard will appear and

choose the appropriate CPU type and Order
no. information. Then click Next.
3.) Select or check OB1
“Cycle Execution” .
Select the programming language (it will
be discuss further on next chapter), for
now, select LAD (ladder).
Then click Next.
4.) Enter a name for the project like

SAMPLE_Project. Then click Finish to
create the project with configuration set.
5.) After a project is created.

The same window in the right
would appear with project name
and CPU type.
SIMATIC Manager
Simatic Manager is part of Step 7 software where configuration of

hardware and blocks are accomplished. It is the basic application for
configuring and programming.
You can perform the following functions in the SIMATIC Manager: Set
up projects, configure and assign parameters to hardware, configure
hardware networks, program blocks, debug and commission your programs
and access to the various functions is designed to be object oriented, and
intuitive and easy to learn.
You can work with the SIMATIC Manager in one of two ways:
a.) Offline, without a programmable controller connected
b.) Online, with a programmable controller connected
Title bar contains the title of the window and icons for controlling the window.
The title bar and menu bar are always found at the top of a window
Menu bar contains all menus available in the window like File, Edit, Insert,
PLC, View, Options, Window and Help.
Toolbar contains icons (or tool buttons) which provide shortcuts to
frequently used and currently available menu bar commands available with a
single mouse click
If access to a button is not possible in the

current configuration, the button is grayed out.
System Menu contains the move, size , minimize, maximize and close
applications when logo is clicked in the title bar .
Title of the active window indicate the title of the window, name of the
project and the location of active project
Active buttons for minimize, maximize and close actions at

SIMATIC Manager window is available
SET UP COMMUNICATION
Communication medium is used when interfacing controller with the

programming device. When your physical hardware are connected, let’s now
connect them in line with the programming software used. Also kindly
check “Controller Set up” in previous pages for additional information for
your reference of IP addresses.
Depends on the availability of each communication medium, you
can choose either. But of course, they offer different characteristics and
specifications. Like MPI adapter, it uses MPI technology which offers high
speed transmission than Ethernet but MPI adapter is quite expensive
compared to RJ 45 cable. Choose the right interface in accordance to your
needs and intended application.
Communication via PROFINET/ Communication via

Ethernet Multi-Point Interface/ Decentralize
Peripherals (MPI/DP)
STEP 7 communication set up
1.) In the SIMATIC Manager

window, go to options then
scroll down. You will see “Set
PG/PC Interface”, click it.
2.) A window would appear for the selection of PG/PC interface medium. Select
the applicable medium that you have or going to use. You can add and remove
interface medium installed in your system.
3.) After a selection of medium or interface is made. You can configure your
hardware controller components.
Interfacing is a means of communicating your controller to the

workstation. It’s always been said that it really depends on application of the
controller in choosing a right and applicable interface.
MPI is one of the oldest technique to do the parameterization which is still
used primarily by engineers who does the commissioning. Though, it has some
limitations like baud rate.
Ethernet is universally accepted way for the communication of PLC with
PC and then helps in further server-client arrangement.
Configuring PLC modules
In SIMATIC Manager, it has a hierarchy of objects in the right pane of
window. First is the name of the project, then the CPU type under SIMATIC
station and S7 Program blocks where you can create and test a program.
We already created a sample project using a wizard. Now, we need to
configure our hardware and communicate our hardware to our Step 7
software.
1.) After creating a project, go to SIMATIC 300 Station for S7-300, just a
single left click of mouse. A hardware icon and the CPU type you choose
during project wizard will appear.
2.) Double click on Hardware icon
3.) A catalogue of PSU, CPU,

Rack, Signal Modules,
Profibus, ProfiNet will
appear.
4.) Within the catalogue, choose the appropriate modules with the same
model and order information to your actual module configuration. Then drag
the item to the left window pane and automatically it will be register. Start
with your PSU up to the last module within the rack.
5.) Make sure that order number in your HW configuration is same with the
actual unit. In Siemens, it is printed in front of the actual module, so don’t
forget to check each digital input and output module. Also, check your
analog input and output module.
Specific data and information is located just below the catalogue for
further checking and verification.
Additional information given on the lower pane like firmware version,

MPI address, input and output address for each module, is available.
6.) If all modules were already uploaded and updated, it should look the same
with the photo below. And then, kindly click “download to module” icon to save
the configuration to the controller.
6.) Then just follow the sequence from selecting the CPU type up to starting the
controller from STOP to RUN mode. Save and compile if all is done.
Any changes made to your Hardware Configuration, you must always

download that configuration to your controller. Because not doing so, would retain
your old settings before the changes was made.
After compiling, saving and downloading your configuration to the controller, you
can check you final data in the HW config window of SIMATIC Manager. Each module
must be properly represented in the final information shown, from the Power Supply
to the last module which is analog output.
Download and Upload
These two terms are common on PLC configuration and programming.

Some people tend to compare these terms to normal computing (PC) or usage
of internet where download and upload are common activities. And due to
that comparison, some become confused to whether what is what, between
the two on PLC. In reality PC and PLC, download and upload, are the same.
It is only on distinguishing what type of computer receives and accepts the
data.
A good definition is given by Institute of Electrical and Electronics
Engineers (IEEE) defined the two ( IEEE Std 610.5-1990. IEEE Standard Glossary of
Data Management Terminology) as:
Download
To transfer some collection of data from a computer memory to
another storage location. To transfer some collection of data from the
memory of one computer to the memory of a second computer that is
relatively smaller than the first; for example, to transfer data from a
mainframe computer to a microcomputer.
Upload
To transfer some collection of data from some storage location to a
computer memory. To transfer some collection of data from the memory of a
small computer to the memory of a relatively larger computer; for example, to
transfer data from a microcomputer to a mainframe computer.
Download
Upload
SELF CHECK 1.1.3
Identification
Direction: Identify the correct and appropriate answer on each
number within the group of words below. Then write the correct
answer on your answer sheet
1.) The process of reading inputs, executing logic, and writing

outputs
2.) It is where the control program or application is stored
3.) This are elements that are interfaced to the controller (PLC)
to give instructions and operations
4.) It is use to create, test , and debug programs applications
that are understandable by PLC
5.) Controller software used by Siemens
6.) The most common standard interface in PLC manufacturer
7.) It connects SIEMENS PLC port (like a serial interface port)

to serial interface (USB) of Personal Computer (PC)
8.) Controller software used by Allen Bradley
9.) To transfer data from a mainframe computer to a

microcomputer.
10.) To transfer data from a microcomputer to a mainframe

computer
Upload Download Siemens PLC

MPI Ethernet Serial Port
Programming Programming Programming
device software PLC
Step 7 TIA Portal RS Logix 5000
Sysmac Studio Memory PLC Scan/ Scan
Read Execute USB cable
ANSWER KEY 1.1.3
1.) PLC Scan/ Scan
2.) Memory
3.) Programming Device
4.) Programming software
5.) Step 7 / TIA Portal
6.) Ethernet
7.) MPI
8.) RS Logix 5000
9.) Download
10.) Upload
Task Sheet 1.1.3
Title: Set-up programmable logic controller and

programming device
Performance Objectives: Given the CPU controller and modules you’ve
identified in previous task, you can set up the
programmable logic control and programming
device using communication device
Equipment: Programmable controller CPU

Controller Modules ( Input, Output and
Communication)
Controller Power Supply
Laptop
MPI adapter
Ethernet cable
Steps/ Procedure:
1.) Prepare the controller’s power supply, CPU

and I/O modules.
2.) Make sure that the controller’s power supply
is turned off.
3.) Prepare the programming device and put it
near the programmable controller.
4.) Prepare a communication device like
Ethernet cable or MPI adapter.
5.) Using the Ethernet cable, connect the one
end to Ethernet port of your controller and
the other end to Ethernet port of your
programming device like laptop. As shown
below.
6.) Using MPI, connect one end to MPI port of
your controller and the other end to USB
port of your programming device like laptop.
As shown below
6. Call your trainer to check the setup
Assessment Method: Portfolio using performance criteria checklist

and questioning
CRITERIA Yes No
Is the controller’s power supply turned off?
Is Ethernet cable connected properly to the

controller?
Is the MPI adapter connected properly to the
controller?
Is the Ethernet cable connected properly to
the programming device?
Is the MPI adapter interface connected properly to
the USB port of your programming device?
Is Siemens PLC trainer main switch OFF before
plugging to AC outlet?
Is Siemens CPU in STOP mode before plugging to
AC outlet?
Is controllers power supply switch OFF before
plugging to AC outlet?
Is PLC trainer’s cable plug organized according to
OH and S standards?
Is laptop adapter cable organized according to
OH and S standards?
Is created project has a name?
Is PLC CPU interface to programming device
and programming software?
Are all controller modules configured in
programming software?
Are the configured modules in programming software
saved or downloaded to PLC CPU?
Comments/Suggestions:
Trainer:__________________________________________Date:______________
Operation Sheet 1.1.3
Title: Start up operation of SIEMENS iDG PLC

Trainer and programming
device
Performance Objectives: To explain the start-up operation of PLC and
programming device specifically the SIEMENS
iDG PLC trainer.
Equipment: SIEMENS iDG PLC trainer

Laptop
MPI adapter
Ethernet cable
Steps/ Procedure:
1.) Check the main ON/OFF switch of the

trainer, make sure it is OFF.
2.) Check SIEMENS PLC power supply switch,
make sure it is OFF.
3.) Make sure your PLCs CPU is in STOP mode
or the switch pointer is on STOP.
4.) Connect the plug of PLC trainer to 220V AC

outlet. Make sure that the cable plug is in a
covered area.
5.) Turn ON first the PLC trainer’s switch. A red

indicator light on the switch will turn on.
6.) Turn ON the PLC power supply as seen
above.
7.) Then, switch the PLCs CPU to RUN mode or

turn the switch to RUN. In the previous
section, SIEMENS CPU LED indicator is
discussed for different LED indication.
8.) Now, turn on your programming device or
laptop.
9.) Make sure that laptop adapter and PLC
trainer’s cable are properly positioned to
avoid accident.
10.) Call your trainer to check the setup

and questioning
Job Sheet 1.1.3
Title: Configure SIEMENS iDG PLC

trainer and programming
device
Performance Objectives: To configure PLC specifically the SIEMENS
iDG PLC trainer and programming software
Equipment: SIEMENS iDG PLC trainer

Laptop
MPI adapter
Ethernet cable
Programming software
Steps/ Procedure:
1.) In your laptop, click the icon.
2.) A “New Project” wizard will appear and

choose the appropriate CPU type and Order
no. information. Then click Next.
3.) Select or check OB1 “Cycle Execution” .

Select the programming language (it will be
discuss further on next chapter), for now,
select LAD (ladder). Then click Next
4.) Enter a name for the project like

SAMPLE_Project. Then click Finish to create
the project with configuration set.
5.) In the SIMATIC Manager window, go to
options then scroll down. You will see “Set
PG/PC Interface”, click it.
6.) Select the applicable medium that you have

or going to use.
7.) After creating a project, go to SIMATIC 300

Station for S7-300, just a single left click of
mouse. A hardware icon and the CPU type
you choose during project wizard will
appear.
8.) Double click on Hardware icon
9.) A catalogue of PSU, CPU, Rack, Signal
Modules, Profibus, ProfiNet will appear.
10.) Drag the item to the left window pane and

automatically it will be register. Start with
your PSU up to the last module within the
rack.
11.) If all modules were already uploaded and

updated, it should look the same with the
photo below. And then, kindly click
“download to module” icon to save the
configuration to the controller.
12.) Call your trainer to check the configuration

and questioning
Types of unit input and output devices

MUST be able to:
1.) Enumerate different kinds of input and output devices

2.) Analyze how to connect properly input devices especially sensor
according to its output type
3.) Differentiate the type of sensors
Controller modules and its configuration are discussed in the previous

section to give you an overview of the capabilities and applications of
controller. In this section, we will begin to undertake different kinds input
and output devices which can be attached to a PLC to perform to an
intended function.
INPUT AND OUTPUT DEVICES
Utilizing the power of PLC, it is connected or interfaced to differen

external devices and component. Input devices like switch, push button
proximity sensor and optical sensor are common. While solenoid valve, light o
lamp, motor (through contactor) are common output devices in the industry.
In choosing proper devices for your controller, keep in mind to check th
following:
a.) Voltage rating either AC or DC
b.) Current rating
c.) Device configuration either PNP or NPN
d.) Operating temperature
INPUT
are devices that indicates and provides control signal to the system.
Toggle Switch
a switch is an electrical component that can break an electrical circuit,
interrupting the current or diverting it from one conductor to another
Limit Switch
a limit switch is a switch operated by the motion of a machine part o
presence of an object
Push-Button Switch
A push-button (also spelled pushbutton) or simply button is a simpl
switch mechanism for controlling some aspect of a machine or a process
Selector/selective switch
A type of switch that can be turned to different positions to make
connection with the contacts in that particular position
SENSOR
As majority of manufacturing industry are totally engaging or gearing up
on automating most of their processes, sensor devices played a big role in thi
big changes. Majority of input elements, if not all, in production line or lin
relies on sensor technology, a technology that continues to evolve and
innovate.
A wide variety of sensors are now available in the market that suits you
needs. But of course, each manufacturer offers additional and new features t
the device compared to others.
Sensor also called detector, an input device that measures a physica
quantity and converts it into a signal (mostly electrical and electronic
acknowledged by human or by an instrument.
Humans also have set of sensors embedded within our body. It is an input
to our every action. I am talking about our five senses; sight, hearing, taste,
touch and smell. Using these senses we can control our every actions
depends on the level or range of tolerance set by our mind.
Sensor wiring configurations
Most sensors use solid state circuits to perform switching action. Sensors
usually use two, three or four wires from making connections to the load.
These load, as discussed, would be lamp, bulb and PLC. The colour coded
wirings are based on European standards.
Two wire Sensors
This configuration is connected in series to the load, the same
way a normal switch is connected in a normal circuit.
The brown wire is always connected to the positive of power supply.

The blue wire is always connected to the negative of power supply
The connections of the sensor wires to the power supply are made eithe
directly or through the load. The way that they are connected is based on th
type of sensor used.
The two types of two wire sensors are sourcing type and sinking type
The principles of sourcing and sinking type are discussed thoroughly in th
previous chapter.
The term sourcing and sinking refers to the conventional flow of current
which from the positive potential (supply) to the negative potential (common)
Three wire Sensors
As the name implies, it is composed of three wires. The wires are used t
connect the sensor to the power supply and load. Each of the wires are colou
coded based on European standards.

The black wire is the output of the sensor
The two types of three wire sensors are sourcing type and sinking type.
The principles of sourcing and sinking type are discussed thoroughly in the
previous chapter.
When a conventional current flows out of the sensor to the load it i

referred to as sourcing type. The current flows, only when a target or object i
detected.
Since the conventional current flow from + to -, the sourcing’s senso
output must switch to a positive potential when the target is connected.
To enable the current from the sensor’s output to flow, the other lead o
the load must be connected to the more negative (common) potential of th
power supply.
When a conventional current flows out of the load to the sensor, it is

referred to as sinking type. The current flows, only when a target or object is
detected. Since the conventional current flow from + to -, the sinking’s sensor
output must switch to a more negative potential when the target is connected.
To enable the current from the sensor’s output to flow, the other lead of
the load must be connected to the positive potential of the power supply.
Four wire Sensors

As the name implies, it is composed of three wires. Two wires are used to
connect the sensor to the power supply and the other two wires are connected
to two different loads. Each of the wires are colour coded based on European
standards.

The black wire is connected directly to the other load
The white wire is connected directly to the other load
When a conventional current flows out of the sensor to the load it

is referred to as sourcing type. The current flows, only when a target or
object is detected. To source current, the white and black wires send current
to the negative of the power source through the load.
The white output wire (Out 1) is labelled N.O., the abbreviation fo
normally open. This designation means that when a target is not detected
current will not flow from the sensor, through the white wire to the load.
The black output wire (Out 2) is labelled N.C., the abbreviation fo
normally close. This designation means that when a target is not detected
current will flow from the positive of the supply, through the sensor and load
to the negative of the power supply.
When a target is detected, the white wire will source current to its load
and the black wire will stop conducting current.
The white output wire (Out 1) is labelled N.O., the abbreviation fo

normally open. This designation means that when a target is not detected
current will not flow from the positive of the power supply, and through th
load, the white wire, the sensor and the blue wire to the negative of the powe
supply.
The black output wire (Out 2) is labelled N.C., the abbreviation fo
normally close. This designation means that when a target is not detected
current will flow from the positive of the supply, through the load and sensor
to the negative of the power supply.
Proximity Sensors
A type of input devices which detects the presence or absence of an objec
without physical contact. These types of sensors only have two states detect o
no detect same as 1 or 0, true or false that’s why it is also known as Binar
sensor.
Compared to mechanical contact limit switches, which are usually bein
used to set a perimeter to allowable range, it is obvious, proximity sensor offer
a number of advantages like fast switching, contactless, long life of unit an
many others.
Basically, different type of proximity sensors offers different level o
physical detection. It is either detects only metal components, magneti
materials or any type of materials.
Common types are inductive sensors, capacitive sensors,

magnetic sensors and photoelectric sensors
Inductive Proximity Sensor
An electronic proximity sensor, which detects metallic objects without
touching them.
Autonics Inductive Proximity Sensor (PSN117-5DN)
Wire Connection:
Brown – Positive supply

Blue – Negative supply
Black – Signal
This type of inductive proximity sensor is a normally open NPN outpu

type device, which means, you can only connect this sensor to a PNP type o
PLC input. Always be careful in wiring this type of devices because sensors ar
sensitive devices a wrong supply to a different pin would destroy it.
FESTO Inductive Proximity Sensor (SIEN-M12NB-PS-K-L)

This type of inductive proximity sensor is a normally open PNP outpu
type Device, which means, you can only connect this sensor to a NPN type o
PLC input. Sensors output type are either sinking or sourcing. It is your job t
make sure that the sensor you’re buying is compatible to your controller. Ever
legitimate manufacturer provides detailed specifications for your reference and
documentation.
The same with first type of FESTO inductive sensor discussed, it is also
PNP output type sensor. Most of Europe uses this type of sensor output. Whil
most of Asia use NPN type of sensor output. The difference between the two i
the positioning of the load to the circuit. Load is equivalent to our PLC inpu
module.
With NPN type of PLC input, the load or PLC common is connected to th
negative supply or ground. While with PNP type, the load is connected to th
positive supply whether it is 12Vdc or 24Vdc
Capacitive proximity sensors

Sense the position of metallic and non-metallic targets such as glass
plastic, paper and wood or any conductive target.
Magnetic proximity sensor

are non-contact proximity devices that are used to detect magnetic
objects (e.g. permanent magnets). When the sensor detects a magnetic material
or object, the sensor is activated . There are two different types of magnetic
sensor we had, as shown in the photo below
Photoelectric sensor or photo eye
is a device used to detect the distance, absence, or presence of an
object by using a light transmitter, often infrared, and a photoelectric receiver
There are different methods in which an optical sensor operates or how

the sensing takes place especially in range of application. It is also called
the optical sensor’s modes of operation
Three common sensing mode operations:
1.) Diffused
2.) Retro-reflective (Reflex)
3.) Opposed Mode (Through Beam)
a.) Diffused Mode

A signal coming from the device directly beamed to an aimed object will
diffuse and scatter but not all will be wasted, some will be reflected back to
the device that would eventually activate it.
As shown in the figure above, the transmitter and receiver unit ar

packaged in a single unit. As the signal is sent to a material, the same uni
receives that signal and then activate the sensor unit. This set-up would b
cost effective because you will not need to buy an additional unit just t
receive the signal compared to other modes.
Two example of diffused sensor are shown below. The first one made b
Korean sensor manufacturer Autonics, is an NPN output type, three wired
sensor and red light indicator.
Second, is FESTO’s version of optical diffuse sensor with two LED
indicator for distance ranges. Two LED (green and yellow) would light fo
shorter distance detection and single yellow LED for farther distance.
Diffuse sensor with Background Suppression
In diffused mode sensing, the sensor uses the target to reflect light bac
to it, eliminating the need for a secondary device such as a reflector. In
applications, targets can vary greatly in color, which will directly affect th
range of the sensor. This varying sensing distance is known as black-whit
differential. The black-white differential is simply the difference in distanc
between where a diffused sensor detects a 90% reflective white card vs. a 6%
reflective black test card under the same conditions. Sensor manufacturer
normally provide black-white differential data in the form of a graph so tha
customers have a guideline when applying them to the application.
Background suppression sensors are specifically designed to
ignore the background behind an object regardless if the background is lighter,
darker or the same color of the object. In addition, these sensors can also
detect targets regardless of color, texture, surface, or finish. Background
suppression sensors can often solve applications that cause standard diffuse
sensors to false trip or not trip at all.
These types of sensors are applicable on the following applications:
Conveyors, Material Planning, Error proofing, and Packaging Assembly
The basic principal behind background suppression is triangulation.

An LED transmits light through a lens in a straight line toward the target. The
target reflects light back to the receiver lens and elements (R1 and R2 in the
figure) at some angle. The distance between the sensor and the target
determines the angle in which light is reflected back to the receiver. The closer
the target is to the sensor, the greater the angle of reflection.
As can be seen in Figure, θ > θ1 and causes the light to be directed to

receiver element R1. As the target moves away and the angle decreases, the
light will be directed to receiver element R2. Which element is receiving light
enables the sensor to differentiate between a target and the background. This
is purely based on the distance from the sensor, not on the amount of received
light.
Principle of diffuse sensor with background suppression

FESTO’s Diffuse sensor with background suppression
(SOEG-RTH)
b.) Retro-reflective (reflex) sensor

is a commonly used sensor in manufacturing sector. It contains emitte
and receiver in one packaging.
Normal operation, it emits light beam to the reflector or any special

reflectorized material and deflects back to the sensor.
Object detected, light beam would be interrupted and sensor’s outpu

would change state, from 1 to 0 or from true to false. An LED indicato
would tell the change of status.
c.) Opposed mode or through beam sensor
One of the most commonly used photo sensor in manufacturing and
automation. Same principle with reflective sensor, but one of the differences i
that transmitter and receiver or deflector is on separate unit.
The distance of detection is much higher than the normal reflectiv

sensor that’s why it is used for long range and precise position sensing.
Transmitter and receiver unit is placed opposite to each other for th
proper displacement of beam.
LED indicator is only available at the receiver side of the sensor set
up.
Fibre - optic unit Sensor
Today, as more manufacturing companies engaged majority of thei

process in automation, the need of more precise and sophisticated inpu
devices like sensor is very much needed.
Sensor is the eye and ear of the automation process in the production
line and other manufacturing stages. That’s why long range of advantages o
fibre optic is introduced to sensor technology.
Fibre optic unit sensor provides long distance coverage compared t
regular proximity sensors.
Reed switch / sensor
An electrical switch operated by an applied magnetic field. It was invented

at Bell Telephone Laboratories in 1936 by W. B. Elwood. It consists of a pair o
contacts on ferrous metal reeds in a hermetically sealed glass envelope. Th
contacts may be normally open, closing when a magnetic field is present, o
normally closed and opening when a magnetic field is applied.
A magnetic field (such as from an energized coil around the glass tube
or a permanent magnet moved towards it) will cause the contacts to pull
together, thus completing an electrical circuit.
OUTPUT
are devices that activates and modify the process and sequence. It als
serves as an indicator that a process or sequence has been accomplished, b
responding to the output signal received.
Lamps
have a thin wire filament which becomes very hot and glows brightl
when a current passes through it. Today, they a using semiconductor LED’s t
lamps and lights for lower power consumptions.
Buzzer
is an electronic signalling device commonly used to produce soun
which works from oscillator, the electromagnetic coil and magnet.
Motors
are machine that produces mechanical movement (rotation) when
supplied by electricity. Controlling the motor by PLC, we should connect it t
magnetic contactor and relay.
Relay
A type of switch operated by an electrical signal, most relays use an

electromagnetic coil to drive the mechanical parts or switch on different
position or mode. Relays can switch small to large voltage either AC or DC
using only small amount of DC voltage to activate the coil inside. Usual coil
voltage is 24 Vdc which can switch up to 30 Vdc and up to 250 Vac.
Single Coil, Two Connections Four Coil, Four Connections

Relay Relay
Solenoid valve
is electromechanical valve that controls the flow of liquid or gas b
running or stopping an electric current through a solenoid, which is a coil o
wire, thus changing the state of the valve.
JIC and IEC standard symbols
SELF CHECK 1.1.4
Multiple Choice:
Choose the best answer. Write the letter of your choice on your
answer sheet.
1.) An electrical component that can break an electrical circuit
interrupting the current or diverting it from one conductor to another
a.) Switch
b.) Sensor
c.) Buzzer
d.) Push Button
2.) It is also called detector
a.) Lamp
b.) Sensor
c.) Buzzer
d.) Switch
3.) In sensor technology, the standard wire color for supply voltage is?
a.) Blue
b.) Red
c.) Black
d.) Brown
4.) A type of sensor which detects the presence or absence of an objec
without physical contact.
a.) Reflective (Reflex)
b.) Inductive
c.) Proximity
d.) Through Beam
5.) A type of sensor in which the transmitter and receiver is on separat

unit.
a.) Opposed Mode
b.) Diffused Mode
c.) Background suppression
d.) Reflective Mode
Enumeration:
ANSWER KEY 1.1.4
Multiple Choice:
1.) A
2.) B
3.) D
4.) C
5.) A
Enumeration:
1.) Diffused Mode

2.) Retro-reflective (reflex)
3.) Opposed Mode (Through Beam)
Task Sheet 1.1.4
Title: Familiarization on different input and

output devices
Performance Objectives: Given the lessons about input and output
devices explained to you, you can identify
different type of input and output devices.
Equipment: Laptop
Input devices( Sensor, Switch, Push Button)
Output devices ( Buzzer, Lamp,
Solenoid Valve)
Steps/ Procedure:
1.) Go to laboratory area.

2.) Prepare your paper and pen. Different input
and output devices can be seen
in the room.
3.) Identify at least five input and output devices
that you can see in the laboratory area.
4.) Give complete details to each device like name,
type, model number (if available) and voltage
rating ( if indicated)
5.) Create a simple table incorporating all the
criteria indicated in number 4.
6.) Present your work to the trainer

CRITERIA Yes No
Are the identified devices present in working area?
Are the identified inputs and output devices correct?
Are details given on each device like name, type,

model number and voltage rating (in available)?
Are the sensors prepared correct?
Is 24 VDC power supply rating checked befor

e being used?
Is vernier caliper set to zero before being used?
Is unit of measurement in mm?
Are all materials presented on the table used?
Trainer:__________________________________________Date:______________
Job Sheet 1.1.4
Title: Different kinds of sensor for different

application and function
Performance Objectives: Given the lessons about input and output
devices explained to you, you can differentiate and
assess the functions of different sensor.
Equipment: Laptop
Input devices( Sensor, Switch, Push Button)
Output devices ( Buzzer, Lamp,
Solenoid Valve)
24VdcPower supply
Banana plugs/Connecting wires
Vernier Caliper
Multester
Steps/ Procedure:
1.) Get the following type of sensor;

a) Inductive Proximity Sensor
b) Capacitive Proximity Sensor
c) Diffused type sensor
d) Retro-reflective Sensor
e) Opposed Mode Sensor
2.) Prepare the 24 Vdc power supply.
3.) Get a multi-tester and test the voltage of the
power supply.
4.) Using the standard color code for sensor (unless
indicated), connect the positive and negative
supply to sensor wirings.
5.) An LED indicator is present on each sensor, if
detection is done.
6.) Use the digital vernier caliper to measure the
distance of detection from the object. Set first to
zero.
7.) Using the same table format below, tabulate your

measurement in mm to different materials
indicated and sensors.
Sensor Materials
Metal Copper Plastic Wood Paper Black White
Inductive
Capacitive
Diffused
Reflex
Opposed
mode
8.) Present your result to your trainer
Assessment Method: Portfolio assessment

Safety precautions of programmable control

MUST be able to:
1.) Discuss the safety precautions needed on handling

programmable control
2.) Explain the importance of knowing safety procedures on
handling programmable control
3.) List different recommendations on programmable control and
components placement
Every PLC maker has their own safety procedures and precautions in
handling the controller. These include wiring and maintenance cautions of
the controller. We will tackle these safety precautions in this section.
Although programmable controllers are tough machines, a little
foresight during their installation will ensure proper system operation.
General cautions for PLC enclosures

The following recommendations address preliminary considerations
for the location and physical aspects of a PLC enclosure:
1.) The enclosure should be located so that the doors can fully open for
easy access when testing or troubleshooting wiring and components.
2.) The enclosure depth should provide adequate clearance between the
closed enclosure door (including any print pockets mounted on the
door) and the enclosed components and related cables.
3.) The enclosure’s back panel should be removable to facilitate
mounting of the components and other assemblies.
4.) The cabinet should contain an emergency disconnect device installed
in an easily accessible location.
5.) The enclosure should include accessories, such as AC power outlets,
interior lighting, and a gasketed, clear acrylic viewing window, for
installation and maintenance convenience.
Environmental cautions
The effects of temperature, humidity, electrical noise, and

vibration are important when designing the system layout. These factors
influence the actual placement of the controller, the inside layout of the
enclosure, and the need for other special equipment.
The following considerations help to ensure favourable environmental

conditions for the controller:
1.) The temperature inside the enclosure must not exceed the maximum
operating temperature of the controller (typically 60°C).
2.) If the environment contains “hot spots,” such as those generated by
power supplies or other electrical equipment, a fan or blower should
be installed to help dissipate the heat.
3.) If condensation is likely, the enclosure should contain a thermostat
controlled heater.
4.) The enclosure should be placed well away from equipment that
generates excessive electromagnetic interference (EMI) or radio
frequency interference (RFI). Examples of such equipment include
welding machines, induction heating equipment, and large motor
starters.
5.) In cases where the PLC enclosure must be mounted on the controlled
equipment, the vibrations caused by that equipment should not exceed
the PLC’s vibration specifications.
Courtesy of http://www.emon.com
Grounding
Proper grounding is an important safety measure in all electrical

installations. When installing electrical equipment, users should refer to
Philippine Electric Code (NEC), which provides data about the size and types of
conductors, color codes, and connections necessary for safe grounding of
electrical components.
The following grounding practices have significant impacts on the

reduction of noise caused by electromagnetic induction:
1.) Ground wires should be separated from the power wiring at the point
of entry to the enclosure. To minimize the ground wire length within
the enclosure, the ground reference point should be located as close
as possible to the point of entry of the plant power supply.
2.) All electrical racks/chassis and machine elements should be

grounded to a central ground bus, normally located in the magnetic
area of the enclosure.
3.) The enclosure should be properly grounded to the ground bus, which
should have a good electrical connection at the point of contact with
the enclosure.
4.) The machine ground should be connected to the enclosure and to the
earth ground
POWER REQUIREMENTS
The source for a PLC power supply is generally single-phase and 120 or
240VAC. If the controller is installed in an enclosure, the two power leads
(L1hot and L2 common) normally enter the enclosure through the top part of
the cabinet to minimize interference with other control lines.
POWER REQUIREMENTS
The system power supply and I/O devices should have a common AC
source. This minimizes line interference and prevents faulty input signals
stemming from a stable AC source to the power supply and CPU, but an
unstable AC source to the I/O devices.
Common AC source
Isolation Transformers
Another good practice is to use an isolation transformer on the AC power
line going to the controller. An isolation transformer is especially desirable
when heavy equipment is likely to introduce noise into the AC line.
NOISE, HEAT, AND VOLTAGE REQUIREMENTS
Implementation of the previously outlined recommendations should

provide favorable operating conditions for most programmable controller
applications. These adverse conditions include excessive noise and heat and
nuisance line fluctuations.
Excessive Noise.
Electrical noise seldom damages PLC components, unless extremely high

energy or high voltage levels are present. However, temporary malfunctions due
to noise can result in hazardous machine operation in certain applications.
Noise usually enters a system through input, output, and power supply
lines. Noise may also be coupled into these lines electrostatically through the
capacitance between them and the noise signal carrier lines. The presence of
high-voltage or long, closely spaced conductors generally produces this
effect.
Excessive Heat.
Programmable controllers can withstand temperatures

ranging from 0 to 60°C. They are normally cooled by convection, meaning
that a vertical column of air, drawn in an upward direction over the surface of
the components, cools the PLC. To keep the temperature within limits, the
cooling air at the base of the system must not exceed 60°C.
The PLC components must be properly spaced when they are installed to
avoid excess heat. The manufacturer can provide spacing recommendations,
which are based on typical conditions for most PLC applications.
Typical conditions are as follows:
• 60% of the inputs are ON at any one time

• 30% of the outputs are ON at any one time
• the current supplied by all of the modules combined meets
manufacturer-provided specifications
• the air temperature is around 40°C
Situations in which most of I/O’s are ON at the same time and the air
temperature is higher than 40°C are not typical. In these situations, spacing
between components must be larger to provide better convection cooling.
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I/O INSTALLATION, WIRING, AND PRECAUTIONS
Input/output installation is perhaps the biggest and most critical job
when installing a programmable controller system. To minimize errors and
simplify installation, the user should follow predefined guidelines.
All of the people involved in installing the controller should receive these
I/O system installation guidelines, which should have been prepared during the
design phase. A complete set of documents with precise information regarding
I/O placement and connections will ensure that the system is organized
properly. Furthermore, these documents should be constantly updated during
every stage of the installation
I/O MODULE INSTALLATION
Placement and installation of the I/O modules is simply a matter of

inserting the correct modules in their proper locations. This procedure involves
verifying the type of module (115 VAC output, 115 VDC input, etc.) and the slot
address as defined by the I/O address assignment document.
Each terminal in the module is then wired to the field devices that have
been assigned to that termination address. The user should remove power to
the modules (or rack) before installing and wiring any module.
WIRING CONSIDERATIONS
Wire Size
Each I/O terminal can accept one or more conductors of a
particular wire size. The user should check that the wire is the correct gauge
and that it is the proper size to handle the maximum possible current.
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Wire and Terminal Labeling
Each field wire and its termination point should be labeled using a
reliable labeling method. Wires should be labelled with shrink-tubing or tape,
while tape or stick-on labels should identify each terminal block. Color coding
of similar signal characteristics (e.g., AC: red,DC: blue, common: white, etc.)
can be used in addition to wire labeling.
Typical labeling nomenclature includes wire numbers, device names or
numbers, and the input or output address assignment. Good wire and terminal
identification simplifies maintenance and troubleshooting.
Wire Bundling
Wire bundling is a technique commonly used to simplify
the connections to each I/O module. In this method, the wires that will be
connected to a single module are bundled, generally using a tie wrap, and then
routed through the duct with other bundles of wire with the same signal
characteristics. Input, power, and output bundles carrying the same type of
signals should be kept in separate ducts, when possible, to avoid interference.
WIRING PROCEDURES
Once the I/O modules are in place and their wires have been bundled, th
wiring to the modules can begin. The following are recommended procedures fo
I/O wiring:
1.) Remove and lock out input power from the controller and I/O before
any installation and wiring begins.
2.) Verify that all modules are in the correct slots. Check module type
and model number by inspection and on the I/O wiring diagram.
3.) Check the slot location according to the I/O address assignment
document.
4.) Loosen all terminal screws on each I/O module.
5.) Locate the wire bundle corresponding to each module and route it
through the duct to the module location. Identify each of the wires in
the bundle and check that they correspond to that particular module.
6.) Starting with the first module, locate the wire in the bundle that
connects to the lowest terminal. At the point where the wire is at a
vertical height equal to the termination point, bend the wire at a right
angle towards the terminal.
7.) Cut the wire to a length that extends 1/4 inch past the edge of the
terminal screw. Strip approximately 3/8 inch of insulation from the
end of the wire. Insert the insulated end of the wire under the
pressure plate of the terminal and tighten the screw.
8.) If two or more modules share the same power source, jumper the
power wiring from one module to the next.
9.) If shielded cable is being used, connect only one end to ground,
preferably at the rack chassis. This connection will avoid possible
ground loops. A ground loop condition exists when two or more
electrical paths are created in a ground line or when one or more paths
are created in a shield). Leave the other end cut back and unconnected,
unless otherwise specified.
10.) Repeat the wiring procedure for each wire in the bundle until the
module wiring is complete.
11.) After all of the wires are terminated, check for good terminations by
gently pulling on each wire.
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SELF CHECK 1.1.5
Enumeration:
1.) Give at least three general recommendations for PLC enclosures
2.) Give at least five wiring recommended procedures
3.) Give the three wiring considerations
ANSWER KEY 1.1.5
Enumeration:
1.) a. The enclosure should be located so that the doors can fully
open for easy access when testing or troubleshooting wiring
and components.
b. The enclosure’s back panel should be removable to facilitate
mounting of the components and other assemblies.
c. The cabinet should contain an emergency disconnect device
installed in an easily accessible location
2.) a. Remove and lock out input power from the controller and I/O
before any installation and wiring begins.
b. Verify that all modules are in the correct slots. Check module
type and model number by inspection and on the I/O wiring
diagram.
c. Check the slot location according to the I/O address assignment
document.
d. Loosen all terminal screws on each I/O module.
e. Locate the wire bundle corresponding to each module and route
it through the duct to the module location.
3.) a. Wire size

b. Wire and Terminal Labelling
c. Wire Bundling
LEARNING OUTCOME # 2: DEVELOP SOFTWARE PROGRAMS
FOR MECHATRONICS CONTROL AND
SYSTEMS
CONTENTS:
1. Controller and electrical standards

2. Techniques and procedures in wiring programmable controls
3. I/O addressing and tagging techniques
4. Shop and system layout
5. Procedures and techniques in programming the programmable control
.
ASSESSMENT CRITERIA:
1. Input and output addresses are correctly assigned.

2. Assigned addresses are properly tagged
3. Software program is developed and compiled using appropriate
code
4. Appropriate ergonomic standards are observed to reduce fatigue
while working on the computer
5. Safety practices are applied in checking the wiring of programmable
controls.
6. Industry company policies on appearance standards and
cleanliness are strictly followed
CONDITIONS:
Trainees must be provided with the following:
1. EQUIPMENT
a. Set of programmable control with the following hardware
components
b. CPU
c. Power supply
d. Input and output
e. Handheld programmer
2. INSTRUMENT:
Multi-tester
3. TOOLS/ACCESSORIES
Input devices such as; pushbutton, selector and limit
switches; photoelectric sensors and proximity sensor
Output devices such as; lamps, magnetic contactor, solenoid

valves with pneumatic cylinders and other pneumatic
12 VDC power supply
Long nose pliers
Diagonal pliers
Set of screw driver
Allen wrenches
Soldering iron
Engineering drawings and working plans
Hardware component manual
Personal protective equipment
4. SUPPLIES AND MATERIALS

a. Wires
b. Terminal blocks
c .Office supply
d .Alligator clips
METHODOLOGIES:
1. Lecture/discussion
2. Demonstration
3. Self-paced Instructions
4. Multimedia
ASSESSMENT METHODS:
1. Written test
2. Practical test
3. Direct observation
4. Interview (oral)
Learning Experiences
Learning Outcome 2
DEVELOP SOFTWARE PROGRAMS FOR MECHATRONICS CONTROL

AND SYSTEMS
Learning Activities Special Instructions

1. Read Information Sheet 1.2.1 on Read and understand the
Control and Electrical Standards Information sheet and check
2. Answer Self check 1.2.1 yourself by answering the Self
Check.
Compare your answers with You must answer the questions
Answer Key 1.2.1 correctly before proceeding to
3. Perform Task Sheet 1.2.1 on the next activity.
familiarization of Philippine
Electrical Code 2009 In this Learning Outcome, you
will describe the techniques,
Evaluate your output using the precautions and procedures in
Performance Criteria Checklist wiring a PLC and external
1.2.1 before showing it to your devices.
trainer
4. Read Information Sheet 1.2.2 on Understanding the content of
Techniques and procedures in each information presented
wiring programmable controls would be your foundation on
5. Answer Self check 1.2.2 steeping the next learning
outcome.
Compare your answers with
Answer Key 1.2.2 Task Sheet, Operation Sheet
and Job Sheet will help you to
6. Perform Task Sheet 1.2.2 on
practice to skills
how to create a PLC module
wiring connection
The performance Criteria
checklist will guide and help
Evaluate your output using the
you evaluate your work as you
Performance Criteria Checklist
are practicing your skill.
1.2.2 before showing it to your
trainer
Evaluate your own work using
7. Perform Job Sheet 1.2.2 on how
the Performance Criteria. When
to connect through wirings a
you are ready, present your
PLC module and external devices
work to your trainer for final
evaluation and recording.
If you have any questions or
inquiries don’t hesitate to ask
I/O addressing and tagging
techniques
9. Answer Self check 1.2.3
After doing all activities of this
Compare your answers with LO, you are ready to proceed to
Answer Key 1.2.3 the next LO on Test and Debug
10. Perform Task Sheet 1.2.3 on Developed Software Program
how to tag name at PLC input
and output addresses

trainer
11. Read Information Sheet 1.2.4
on Shop and system layout

Answer Key 1.2.4
how to create a PLC system
layout

trainer
14. Read Information Sheet 1.2.5
on Procedure and techniques in
programming the programmable
control

Answer Key 1.2.5
how to design a ladder logic
program

trainer
17. Perform Job Sheet 1.2.5 on
how to create a ladder logic
trainer
Controller and Electrical Standards
Learning Objectives: After reading this INFORMATION SHEET, YOU

MUST be able to:
1.) List applicable programmable control international standards

2.) Describe appropriate Philippine Electrical standards for
3.) Differentiate standards related to programmable control
In this section, we will discuss international and domestic standards

applicable on hardware and software proficiency of a programmable controller.
Though in the previous section we detailed some recommendations from
choosing your controller up to installation and start-up operation, we will
identify in this section applicable standards, codes and laws covering the
programmable controllers as a whole.
INTERNATIONAL STANDARDS
Today, there are many manufacturers of PLC in the world tha

want to take some share in the growing industry of automation and PLC
application.
Same to other computers, programmable controller
manufacturing is also covered by an international standard. The standard wa
under IEC (International Electro technical Commission) were Philippines is a fu
member.
International Electrotechnical Commission (IEC); Commissio
électrotechnique internationale (CEI), in French) is a non-profit, non
governmental international standards organization that prepares an
publishes International Standards for all electrical, electronic and relate
technologies – collectively known as "electrotechnology".
IEC standards cover a vast range of technologies from powe

generation, transmission and distribution to home appliances and offic
equipment, semiconductors, fibre optics, batteries, solar energy
nanotechnology and marine energy as well as many others.
IEC 61508 (Functional safety of electrical/electronic/programmable
electronic safety-related systems)
Functional safety is part of the overall safety that depends on a system o

equipment operating correctly in response to its inputs.
Electrical, electronic or programmable electronic systems increasingl
carry out safety functions. These systems are usually complex, making i
impossible in practice to fully determine every failure mode or to test al
possible behaviour.
It is difficult to predict the safety performance, although testing is stil
essential. The challenge is to design the system in such a way as to preven
dangerous failures or to control them when they arise covers the design o
safety system
Dangerous failures may arise from:

a. incorrect specifications of the system, hardware or soft-ware;
b. omissions in the safety requirements specification (e.g. fail-
ure to develop all relevant safety functions during different
modes of operation);
c. random failures of hardware;
d. systematic failures of hardware and software;
e. common cause failures;
f. human error;
g. environmental influences (e.g. electromagnetic,
temperature, mechanical phenomena);
h. supply system voltage disturbances (e.g. loss of supply, reduced
voltages, re-connection of supply
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IEC 61508 contains requirements failures in E/E/PE( electrical/electronic/

programmable electronic) safety-related systems
necessary to carry out the safety function (i.e. from sensor, through contro
logic and communication systems, to final actuator, including any critica
actions of a human operator).
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An E/E/PE system may be safety-related even if it does not have an

direct control over potentially hazardous equipment. For example a
information-based decision support tool might be safety-related if erroneou
results affect safety.
Objectives
The standard aims to:
1. release the potential of E/E/PE technology to improve
both safety and economic performance;
2. enable technological developments to take place within an
overall safety framework;
3. provide a technically sound, system-based approach, with
sufficient flexibility for the future;
4. provide a risk-based process for determining the required performanc
of safety-related systems;
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by industry but can also help with developing sector standards
(e.g. machinery, process chemical plants, medical or rail) or produc
standards (e.g. power drive systems); provide a means for users and
regulators to gain confidence when using computer-based technology;
6. provide requirements based on common underlying principles
to facilitate:
 improved efficiencies in the supply chain for suppliers of
subsystems and components to various sectors,
 improvements in communication and requirements (i.e.
to increase clarity of what needs to be specified),
 the development of techniques and measures that could
be used across all sectors, increasing available resources,
 the development of conformity assessment services if
required.
Parts framework of IEC 61508
The standard consists of 7 parts:
1. IEC 61508-1, General requirements;

2. IEC 61508-2, Requirements for electrical/electronic/
programmable electronic safety-related systems;
3. IEC 61508-3, Software requirements;
4. IEC 61508-4, Definitions and abbreviations;
5. IEC 61508-5, Examples of methods for the determination
of safety integrity levels;
6. IEC 61508-6, Guidelines on the application of
IEC 61508- 2 and IEC 61508-3;
7. IEC 61508-7, Overview of measures and techniques.
We will further elaborate each part but you can go to IEC websit
www.iec.ch for additional information.
IEC 61508 is the basis for a published nuclear sector standard. It is als
currently being used as a basis for developing other sector standards (e.g
machinery, process) and product standards (e.g. power drive systems). It i
therefore influencing the development of E/E/PE safety-related systems an
products across all sectors.
Many requirements of IEC 61508, particularly in parts 2 and 3, are no
repeated in the application sector or product standards but are referenced
instead. The result is that most users will need IEC 61508 also.
The market for any product, component or subsystem that complies with
IEC 61508 is potentially very large since in principle they are capable o
meeting the requirements of any sector standard based on IEC 61508.
IEC 61131
is an IEC standard for programmable controllers. It was known as IEC
1131 before the change in numbering system by IEC.
Standard IEC 61131 is divided into several parts:

1. Part 1: General information
2. Part 2: Equipment requirements and tests
3. Part 3: Programming languages
4. Part 4: User guidelines
5. Part 5: Communications
6. Part 6: Functional safety
7. Part 7: Fuzzy control programming
8. Part 8: Guidelines for the application and
implementation of programming languages
Industrial automation systems have been based for many years on the IEC
61131 standard, which was first published in 1992. The standard, which i
considered as one of the most important ones in industrial automation, defines
model and a set of programming languages (part 3) for the development o
industrial automation software.
Courtesy of http://www.automation.siemens.com
SIEMENS TIA Portal
Control engineers predominantly use it to specify the software part of thei

systems, mainly when programmable logic controllers (PLCs) are used. However
the standard has been criticized the past few years for not addressing any mor
the requirements of today’s complex industrial automation systems and not bein
compliant with state of the art software engineering practiced.
For example, it is claimed in that current software architectures o
industrial process measurement and control systems (IPMCS), such as IEC
61131-3, do not conceptually support reconfiguration and distribution. I
addition, as claimed, the concepts of 61131 “are not the state of the art in
software engineering anymore”, even though not explicitly stating which concept
the standard does not support and which of the supported ones are not any mor
state of the art.
IEC 61131-3
IEC 61131-3 is the third part (of 8) of the open international standard IEC
61131 for programmable logic controllers, and was first published in
December 1993 by the IEC. The current (third) edition was published in
February 2013. It is the only standard valid worldwide for the programmin
languages of programmable logic controllers
Part 3 of IEC 61131 deals with programming languages an
defines two graphical and two textual PLC programming language standards:
a. Ladder diagram (LD), graphical
b. Function block diagram (FBD), graphical
c. Structured text (ST), textual
d. Instruction list (IL), textual
e. Sequential function chart (SFC), has elements to organiz
programs for sequential and parallel control processing.
IEC 61131-3 is the first real endeavour to standardize programming

languages for industrial automation. With its worldwide support, it i
independent of any single company.
IEC 61131-3 standard is the result of a task force(IEC TC65 SC655B
comprised of seven or more international companies, representing severa
decades of experience in the field of industrial automation.
Within the standard four programming languages are defined

This means that their syntax and semantics have been defined, leaving n
room for dialects. Once you have learned them, you can use a wide variety o
systems based on this standard.
The choice of programming language is dependent on:
• The programmers’ background

• The problem at hand
• How thoroughly the problem is specified
• The structure of the control system
• The interface to other people / departments
All four languages are interlinked: they provide a common suite, with a lin
to existing experience. In this way they also provide a communication tool
combining people of different backgrounds.
Ladder Diagram has its roots in the USA. It is based on the graphica
presentation of Relay Ladder Logic.
Instruction List is its European counterpart. As a textual language, i

resembles assembler.
Function Block Diagram is very common to the process industry. I

expresses the behavior of functions, function blocks and programs as a set o
interconnected graphical blocks, like in electronic circuit diagrams. It looks at
system in terms of the flow of signals between processing elements.
Structured Text is a very powerful language with its roots in Ada, Pasca
and “C”. It is well suited for, and can be used to define the nature of comple
Function Blocks, which can then be used within any of the other languages.
Top-down vs. Bottom-up

Also, the standard allows two ways of developing your program: top dow
and bottom up. Either you specify your whole application and divide it into su
parts, declare your variables, and so on or you start programming you
application at the bottom, for instance via derived functions and function blocks.
Having a standard over such a broad application area brings numerou
benefits for users and programmers:
• Reduced waste of human resources, in training,

debugging, maintenance and consultancy.
• Creating a focus to problem solving via a high

level of software reusability.
• Reduced misunderstanding and errors.
• Programming techniques usable in a broad

environment: general industrial control.
• Combining different components form different programs

projects, locations, companies and/or
countries.
PHILIPPINE ELECTRICAL CODE

Philippine Electrical Code is not a textbook. It gives no background
reasons, application or illustration of rules and regulations set down in the Code
The code is more of a catalogue of rules for an electrical installation. The Cod
definition of term is not the same as a definition for the same word in a standar
dictionary
2009
PHILIPPINE
ELECTRICAL
CODE
Historical Background
- The first documented case of a Code as a requirement of rules wa

published on 16th Nov. 1881 entitled “The Dangers of Electric Lighting”
- The first NEC was developed in 1897, eighteen after the invention o
incandescent light bulb by Thomas A. Edison.
Since 1911, the NFPA of Quincy, Massachusetts, has been responsible fo
the maintenance and publication of the NEC.
- Regularly revised (every three years) to reflect the evolution of
products, materials, and installation techniques.
- 21 Separate Committee, each consisting of 15-20 persons. Members
of each committee meet several times, discuss proposed changes
accepting some and rejecting others, and rewrite (as required) th
sections of the Code that were assigned to their committee.
The 2009 PEC used the 2005 Edition of the National Electrical Cod
as referenced Code
NFPA 70s NEC 2014 Edition
National Fire Protection Association (NFPA) of U.S. has been the develope
and publisher of the NEC since 1911. The NEC sets the standard for saf
electrical installation and inspection to protect people and property from
electrical hazards. It is one of the most widely used codes for the buil
environment in the world.
PURPOSE
The primary objective of the code is to establish basic material
quality and electrical works standards for the safe use of electricity fo
light, heat, power, communications, signalling and for other purposes. It i
also for practical safeguarding of persons and property from hazards arisin
from the use of electricity. Compliance to the PEC will ensure safety an
prevention of electrical fires.
The PEC is a safety standard not a design guide. Electrical design
must comply with the requirements of PEC to ensure safety.
It is not intended as a design specification or an instruction manua

for untrained persons. The term untrained persons can be interpreted t
mean anyone who does not have an understanding of electricity an
electrical construction. It can also mean that the Code assumes a perso
reading or studying it knows and understands basic Ohm Law, Kirchoff’
Law, the triangle of fire, etc.
SCOPE
PEC 2009 covers the installation of electrical conductors, equipment
and raceways, monitoring, signalling, and communications conductors
equipment, and raceways; and optical fibers and raceways installed within
or on, to from:
 Public and private buildings.
 Electric Gen. Plants
 Industrial plants
 Transformer stations
 Permanent & Temporary S/s
 Airfields
 Railways switchyard
 Yards, carnival, parks, parking and other lots
 Quarries and mines
 Watercraft
 Dockyards
 Trailers
 Mobile Homes and recreational vehicles
 Offshore facilities
NOT COVERED
The following are not covered by PEC 2009;
 Installations in railway rolling stock, aircraft, or automotiv

vehicles
 Installations of railways for generation, transformation
transmission, or distribution of power used exclusively for operation o
transmission stock
BOARD OF ELECTRICAL ENGINEERING

A Philippine Regulations Commission’s body who render the
final decision in the interpretation of any portion of the PEC, in case of
controversy.
CLASSIFICATION OF CODE RULES
Wiring Install
Design ation
Rules Rules
Manuf
acturi
ng
Wiring Design Rules
It is to determine sizes and rating of circuit conductors and devices.
Example:
1. Branch circuit conductors supplying a single motor shall have an
ampacitynot less than 125% of the full-load current. Section 4.30.2.22.
2. The disconnecting means for motor circuits shall have an amper
rating of at least 115% of the full-load current rating of the motor. Section
4.30.10.10(a)
Installation Rules
It deals with installation rules and safety
Example:
1. Adisconnectingmeansshallbelocatedwithinsightfromthemotorcontrolle
.Section4.30.1022.
2. In class II Division I Locations, motors, generators, and other rotatin
electric machinery shall be dust ignition proof or totally enclosed pipe ventilated
and shall be approved for class II locations.Sections5.02.8
Manufacturing Rules
It deals with different manufacturing rules
Example:
1. A motor shall be marked with the following information:
a. Manufacturer’s Name
b. Rated Volts and Full-load Amperes
c. Rated Frequency and Number of Phases, if an alternating curren
motor, etc.
d. Rated full-load speed
SELF CHECK 1.2.1
Matching type
Direction: Match the descriptor from column I to the terminologies in th
column II. Write the letter of your choice on your answer sheet.
I II
1.) A non-profit, non-governmental A. National
international standards Electrical Code
organization that prepares and
publishes International Standards
for all electrical, electronic and
related technologies – collectively
known as "electrotechnology”
2.) The Functional safety of B. Philippine
electrical/electronic/programmable Electrical Code
electronic safety-related systems
3.) It was known as IEC 1131 before C. IEC 61131
the change in numbering system by
IEC
4.) IEC 61131 standard was D. IEC 61131-3
first published
5.) It is the only standard valid E. Ladder Diagram
worldwide for the programming
languages of programmable logic
controllers
6.) A PLC programming language which F. Instruction List
has its roots in the USA
7.) A PLC programming language which G. 1992
has its roots in the Europe
8.) A very powerful language with its H. 1994
roots in Ada, Pascal and “C”
9.) The code is more of a catalogue of I. Structured Text
rules for an electrical installation in
the Philippines
10.) A Philippine Regulations J. IEC
Commission’s body who render the
final decision in the interpretation
of any portion of the PEC, in case
of controversy.
K. JIC
L. Board of
Electrical Engineering
M. Board of
Electronics Engineerin
N. IEC 61511
ANSWER KEY 1.2.1
1.) J
2.) O
3.) C
4.) G
5.) D
6.) E
7.) F
8.) I
9.) B
10.) L
Task Sheet 1.2.1
Title: Philippine Electrical Code 2009

familiarization
Performance Objectives: Given the Philippine Electrical Code of 2009
background, you should identify and
familiarize the specific article appropriate to
be used.

Philippine Electrical Code 2009
(Hard copy or Soft Copy)
Equipment: Laptop
Steps/ Procedure:
1.) Get your hard copy of Philippine Electrical

Code 2009, if not available, ask the trainer
for the softcopy.
2.) Identify the specific articles in PEC which
discuss the mounting and cooling of
equipment.
3.) Identify the PEC article which discusses the
grounding of equipment and devices
4.) Identify the PEC article which covers wiring
methods for all wiring installations
5.) Discuss in your own words the content of
Article 4.0 of PEC 2009.

CRITERIA Yes No
Are the identified articles for mounting and cooling of

equipment at PEC 2009 correct?
Are the identified articles for grounding of equipment

and devices at PEC 2009 correct?
Are the identified articles for wiring methods for all

wiring installations correct?
Did the discussed Article 4.0 of PEC 2009 correct?
Trainer:__________________________________________Date:______________
Techniques and procedures in wiring programmable controls

MUST be able to:
1.) Identify different type of diagram

2.) Discuss various type of PLC input configurations
3.) Discuss various type of PLC output configurations
4.) Analyze how to connect external components to PLC input
5.) Analyze how to connect PLC output to external components
In this section, techniques and procedures in wiring programmable

logic controllers (PLC). On either type of PLC, the same configuration applies to
external devices connected. Proper wirings and connection of PLC I/O are very
important, to avoid accident and risk at your workplace.
INTRODUCTION
A very important subject often overlooked in the study of programmable
controllers how to connect the PLC to the system being controlled. This
involves connections of such devices as limit switches, proximity detectors,
photoelectric detectors, external high current contactors and motor starters,
lights and a vast array of other devices which can be utilized with the PLC to
control or monitor systems.
Wiring a device to the PLC involves the provision of proper power to the
devices, sizing of wiring to insure current carrying capacity, routing of wiring
for safety and to minimize interference, insuring that all connections are made
properly and to the correct terminals, and providing adequate fusing
to protect the system.
PLC
INPUTS OUTPUTS
Electrical Circuit Diagram and Ladder diagram
Electrical circuit and ladder diagram are just the same thing. Both
represents the flow of current and use schematic symbols. Electrical circui
diagram is mostly common in showing electrical parts which makes up th
circuit in top to bottom manner or horizontally oriented. Ladder diagram has
same function as the electrical circuit diagram but as the name implies, i
resembles a ladder. And it is vertically oriented, using vertical rails .The “hot
conductor or positive supply is on the left rail while the common/neutral o
negative supply is on the right rail. It is consist commonly of “rails” and
“rungs”.
S1 K1
K1 1Y1
Electrical Diagram with IEC symbol
Push Button Coil
NO contact Solenoid
Ladder Diagram with JIC symbol

Also, a notable presentation difference between the two is the use o
international standard symbols like Joint International Council (JIC) an
International Electro-technical Commission (IEC) standards.
Electrical circuit diagram usually use the IEC standard symbol whil
ladder diagram use JIC standard symbol.
Ladder diagram is also known as Ladder Logic Diagram. PLCs are usuall
programmed in ladder logic. This is because PLCs originally replaced rela
control systems, and forty years later, we still haven't quite let go.
The two diagrams are used to develop the initial design of the electrica
system/equipment. It shows the logical flow of electrical current, through
switches to loads. But it is not a “physical” representation of a wired system. I
is also used to conceptualize an electrical control system and for servicing and
troubleshooting
Point to Point (PTP) Diagram or Wiring Diagram
A wiring diagram is a simplified conventional pictorial representation of

an electrical circuit. A wiring diagram usually gives more information about
the relative position and arrangement of devices and terminals on the devices,
to help in building the device. This is unlike an electrical or ladder
diagram, where the arrangement of the components interconnections on the
diagram usually does not correspond to the components' physical locations in
the finished device
A wiring diagram is used to troubleshoot problems and to make sure tha
all the connections have been made and that everything is present. It shows th
components of the circuit as simplified shapes, and the power and signa
connections between the devices. It may go so far as to show wire colors an
numbers, and may even depict the wires in true color. Of course that doesn’t d
you any good unless you’re printing to a color printer or viewing the file from
laptop.
It is considered to be the actual “wiring diagram” for th
system/equipment. The PTP is an extension of the ladder diagram, meanin
that typically the design process starts with generating the logic and thus th
ladder diagram, from which the designer creates the wiring diagram.
Kawasaki Motorcycle wiring diagram

The simplest of all diagrams is the pictorial diagram. A pictorial diagram
is a diagram that shows a picture or sketch of the various components of
specific system and the wiring between these components . It shows a pictur
or sketch of the various components of a specific system and the wirin
between these components. This simplified diagram provides the means t
readily identify the components of a system, even if you are not familiar wit
their physical appearance.
This type of diagram shows the various components without regard t
their physical location, how the wiring is marked, or how the wiring is routed
It does, however, show you the sequence in which the components ar
connected
Pictorial diagram of automotive starter and ignition systems

PLC systems typically involve the handling of circuitry operating at
several different voltage and current levels. Power to the PLC and other devices
may require the connection of 120 VAC while photoelectric and proximity
devices may require 24 VD Motors being controlled by the PLC may operate at
photoelectric and proximity devices are in the range of milliamps while motor
currents run much higher depending upon the size of the motor – 30 amps or
more.
Power Supply: Connection to single PLC: Supply voltage 24 V DC PLC Digital I/O: Supply
phase AC mains (rated input voltage 20.4 V(DC) - 28.8 V(DC) voltage 24 V DC
120/230 VAC, 50/60 Hz) 2 A min. 8 A max.
The power requirement for the PLC being used will vary depending upon
the model selected. PLC's are available that operate on a wide range of powe
typically 24 VDC, 120 VAC and 240 VAC. Some manufacturers produce unit
that will operate on any voltage from 120 VAC to 240 VAC without an
modifications to the unit
DISCONNECT
120 - 240 VAC POWE
Fuse HOT
Fuse NEUTRAL
GND
R
Hot Neut GND

120 - 240 VAC PLC
Typical AC Wiring
This wiring also includes fusing and disconnecting for both powe
conductors. If the (-)power line is grounded at the source, the (-) disconnec
and fuse would not be required. However, as with the AC power wiring, it i
always safer to provide for fusing and disconnection of both power conductors
Care must be taken to insure that the wiring is properly connected to avoi
damage to the equipment and to the personnel coming into contact with it.
DISCONNECT
24 VDC POWER
Fuse +
Fuse _
GND
+ _ GND
24 VDC PLC
Typical DC wiring
To connect power to the PLC, the PLC may be thought of as a light bulb
that needs to be lit; the two power wires are connected to the two wires of th
light bulb and must be insulated from each other. In the case of a PLC
operating on DC power, it may be thought of as an LED. For a light bulb, i
doesn't matter which power wire connects to which light bulb wire; the ligh
will still light up. This is also true for an AC powered PLC. It generally doesn'
matter which power wire is connected to the power terminals as long as both
are connected and insulated from each other.
Courtesy of http://www.switched-on-electrical.com
In the case of the LED, though, the (+) and (-) connections must be mad
to the proper LED wires and insulated from each other if the LED is to light
The same is true for the DC powered PLC. The difference with the PLC is tha
if it is connected wrong, the damage can be very expensive.
Some might have encountered the term NPN and PNP, it just the same, a
NPN is sinking and PNP is sourcing. We will tackle and discuss more about th
two types.
Sourcing
means that the unit or module is a current source or giving current t
the load. In external devices, it is sometimes called PNP type because of th
output of the devices, especially sensors, are switched by a PNP typ
transistor.
Load can be another device or your PLC. This type of output is th
commonly used for sensor applications especially in Europe and North
America.
In sourcing configuration shown above, sensor device

(it can be proximity or optical sensor) with three wire is the standard wir
colour designation. Brown for positive supply, Blue for negative Supply an
Black for output signal.
The transistor symbol shown inside the three wire sensor indicate
the switching output of the device using PNP type transistor. So, it is a PNP
type sensor, the most common type being used in the industry. The broken
line within the transistor shows that, it is connected to other component
inside the sensor like resistor, LED’s etc.
Sinking
In sinking, input devices receive or accept current from the load. You can
compare the operation of this type to a normal “heat sink”, where it absorb
heat from a load.
The transistor symbol shown inside the three wire sensor indicates th
switching output of the device using NPN type transistor. So, it is a NPN typ
sensor, the most common type being used in the East Asia like Japan and
Korea. The broken line within the transistor shows that it is connected t
other components inside the sensor like resistor, LED’s etc.
In two wire sensor, the device serves as a current acceptor from the load
same with the three wire sensor and directly connected to the ground o
negative supply.
The connection sequence for sinking input device would be positive

supply connected to load or PLC then connected to a sinking (NPN) type
device and lastly, connected to negative supply or ground, as illustrated
above.
Just follow the input device sequence in either type or you will hav
smooth job, otherwise prepare for the worse. Because your input devices migh
not work accordingly if not properly connected especially sensor devices and
much worse you have to replace it with new one which is not cheap.
ANALOGY
In a simple analogy, it is just like a gasoline hose or nozzle connected t

the tank of your car for refuelling. The hose is the source of gasoline and you
car’s tank is the receiver. So, the hose is sourcing and tank is sinking
In another analogy, we have a simple ladder diagram with switch and

relay coil. The line voltage is 24Vdc. When switch is closed, current will flow
to the coil, which makes the switch as a source of current ideally and the rela
coil as the receiver of current. So, the switch is sourcing and coil is sinking.
Input /Output Module
PLC input and output module connects the controller to the “real world
by interfacing the external devices to the input and output module. We wi
focus on digital modules in our discussion.
In brick type PLC, input and output port are pack in single containe
together with the CPU. Modular type PLC, use modules and connect them
behind the rack to the CPU and power supply of the controller.
PLC I/O modules especially input modules are also classified to eithe
sourcing (PNP) or sinking (NPN) type. But more manufacturers today, offer
both type in a single module. Meaning the module can be interfaced o
connected to a sourcing and sinking type of input devices
TYPES OF PLC MODULES
PLC Input Module
Digital Analog
AC DC
(discrete)
Sourcin
Sourcing Sinking g and
Sinking
PLC Output Module
Digital Analog
Triac Transistor Relay
Sourcing Sinking
AC INPUT MODULE
AC input modules detect the presence or absence of AC voltage, and
convert that voltage to a low level for input to the CPU. The AC voltag
indicates the field device status. The voltage level is commonly 24, 115 or 220
VAC. Modules are available for up to 1,000 VAC. When the field devic
completes the input circuit, a path for AC exists. An LED on the front of th
module, indicates the input is present.
HOT NEUTRAL
AC INPUT MODULE
1-1IC1
SW1
IN0
PB 1
IN1
IN2
IN3
PROX 1
IN4
IN5
IN6
IN7
COM
AC INPUT MODULE CONFIGURATION
Most AC input modules use an external AC power supply fo

"interrogation" of the field devices. On-board AC power supplies increase th
size of the module and require additional heat dissipation considerations.
AC inputs may use a common neutral connection for several points o
there may be an "isolated" neutral for each point for additional faul
protection.
Analog AC input modules are not commonly used because there are n
standardized analog AC voltages or current signals.
DC (DISCRETE) INPUT MODULE
PLC input module configuration must be known first before getting th
needed input device especially proximity and optical sensors.
24 Vdc
Switch
Sensor 1
Sensor 2
Push Button
COM
Sourcing (PNP) type of PLC input module
Sensor 1 = NPN Inductive Proximity Sensor
Sensor 2 = NPN Capacitive Proximity Sensor
Remember the concept of magnet, same pole repel and opposite pol
attracts. This model or thought goes to PLC input module or port and inpu
devices as well. It simply means that, for a sourcing (PNP) type of sensor t
work, it should be connected to a sinking (NPN) type of PLC input module. And
vice versa, for a sinking (NPN) type of sensor to work, it should be connected
to a sourcing (PNP) type of PLC input module.
That’s why knowing your controller first is still the best policy. Then star
to look for appropriate inputs applicable to your needs and expectations.
So, don’t be confused to the arrangement, always remember that sam

type doesn’t work. And sensor manufacturers are giving full details and
specification to their catalogue so make sure to read all important data and
information like input voltage, output type and sensing distance. In summary
below are the configurations and results.
24 Vdc
Switch
Sensor 1
Sensor 2
Push Button
COM
Sinking (NPN) type of PLC input module
Sensor 1 = PNP Inductive Proximity Sensor
Sensor 2 = PNP Capacitive Proximity Sensor
Sourcing (PNP) device +

Sinking (NPN) PLC input module = Device working
Sourcing (PNP) device +

Sourcing (PNP) PLC input module = Not working
Sinking (NPN) device +

Sinking (NPN) PLC input module = Not working
The PLC wiring connections of PNP and NPN sensor to either type of inpu
modules are same. But as what this material keeps on saying, PLC input
module and input device must be of different type to work properly, as what,
the category above is emphasizing.
Siemens Digital Input Allen Bradley Digital Omron

Module 16xDC24V Input Module 24 Vdc Digital Input Mod
(321-1BH02-0AA0) Sink/Source 24 Vdc ID211
1769-IQ16
PLC manufacturer produce their own input and output module because o
the same reason of “compatibility” to their CPU. In the photo, we have Siemen
sinking type input module with model specification, Allen Bradley sinking and
sourcing type of input module and, Omron’s sinking and sourcing type o
input module
Allen Bradley and Omron’s input module can accept or operate both
sourcing (PNP) and sinking (NPN) type of input devices. But with Siemens, onl
PNP type device is applicable. In the sample shown above
Other way of knowing the type of module you have, is by distinguishing th
common connection of your PLC module.
OUTPUT MODULE
PLC output module configuration depends on the electrical signal
especially voltage capability of output elements you’re going to control. As
shown in the diagram for type of PLC output module, there are three types of
output module; Triac, transistor and relay type.
Triacs are solid state device good for output devices with AC
signal. Heavy inductive motor load may additional snubber circuits which ar
sold separately.Sample of Triac output is Click’s output module model CO
08TA with AC voltage capacity ranges from 17 to 240 Vac.
NEUTRAL HOT
OUTPUT MODULE
1-1OC1
COIL
OUT0
OUT1
LAMP
OUT2
OUT3
SOLENOID
OUT4
OUT5
OUT6
OUT7
TRIAC Configuration
COM
Transistors are semiconductor device use in switching large DC current with
small input current. This type of module is good for DC signal applications. I
offers higher I/O numbers compared to relay type because of transistor’s size
It also offers faster switching and long life than relay type. Sample o
transistor type is model AY81C by Mitsubishi
Transistor type
Photo courtesy of
www.saleplc.com
Transistor output type module can be sinking or sourcing, sam

understanding and concept with input configuration of sourcing and sinking.
Transistor
Sourcing Sinking
This type of output module is voltage dependent means they switch AC
and DC voltages. And they are can be interfaced easily to end user’s system
Using relays, they have a much higher rating compared to transistor. But on
of its disadvantage is it’s lifespan compared to transistor type module.
Also, output is not sensitive to polarity. Usual load voltage is 24 Vdc up t
120 Vdc and 24 Vac up to 250 Vac. Suitable for AC/DC solenoid valves
contactors, motor starters, FHP motors and signal lamps.
Omron
SIEMENS RELAY TYPE Output AB RELAY TYPE Output Digital Output Relay Mo
24 Vdc/ 250 Vac OD211
Courtesy of http://www.aboutplcs.com
RELAY OUTPUT WIRING

In either type of input and output module, just keep in mind the sayin
“what comes in, must go out”, it applies to current that flows to the devic
and module.
If you supply positive (+) voltage to your module, then your I/O devic
would be connected to the negative or neutral voltage and vice versa.
SELF CHECK 1.2.2
Identification
Direction: Identify the correct and appropriate answer on each
number within the group of words below. Then write the correct answe
on your answer sheet
1.) It means that the module is giving current to the load

2.) This type of module has two types; AC and DC (discrete).
3.) If your input device is NPN type, your input module should
be what.
4.) If your input device is PNP type, your input module should
be what.
5.) Type of PLC output module which is good for output devices
with AC signal.
6.) Type of PLC output module which use small DC input

current to switch large DC current
7.) This type of output module is voltage dependent means they

switch AC and DC voltages
8.) The usual DC supply voltage for PLC modules
9.) In sinking type input device sequence, after the load (PLC)
what is the next connection.
10.) It is also known as Sourcing type device
Sinking Triac Output Device

Sourcing Transistor Input Module
Digital Relay type Output Module
Analog 24 VDC 230 VAC
PNP 12 VDC Sourcing and
Sinking
NPN Input Device Power Supply
ANSWER KEY 1.2.2
1.) Sinking
2.) Digital
3.) PNP
4.) NPN
5.) Triac
6.) Transistor
7.) Relay
8.) 24 VDC
9.) Input device
10.) PNP
Task Sheet 1.2.2
Title: Create PLC module wiring connection

Performance Objectives: Given the discussion on PLC input and
output module, you should create a wiring
connection of external devices to the PLC
Equipment: Laptop
Steps/ Procedure:
1.) Draw a wiring diagram for PLC with eight

input and output ports. Set the figure below
as your reference.
2.) Identify the symbol of a switch and push
button then connect it to input module.
3.) Assume that the PLC input module is a PNP
Type (Sourcing).
4.) At PLC output module, connect a lamp and
buzzer. Identify first the symbol of both
devices.
5.) Assume that the PLC output module is a
relay type.
6.) Label properly each symbol and signs
7.) Use a 24 VDC as your supply voltage for
PLC and its module

CRITERIA Yes No
Is the PLC diagram has eight input and output ports?
Are switch and pushbutton symbol identified properly

and connected to PLC diagram?
Are lamp and buzzer symbol identified properly and
connected to PLC diagram?
Are input and output external devices labelled properly
with symbols and signs?
Is the supply voltage in the diagram is 24 VDC?
Is the prepared and measured power supply within

the 24VDC +/- 10% range?
Are the prepared input devices correct?
Is the supply voltage connection to PLC modules correct?
Is the connection of input devices to PLC input port

and supply voltage right?
Is the connection of output devices to PLC output port
and supply voltage right?
Trainer:__________________________________________Date:______________
Job Sheet 1.2.2
Title: PLC module wiring connections to

external devices
Performance Objectives: Given the discussion on PLC input and
output module, you should wire the
connections of external devices to the PLC
Equipment: Laptop
PLC with eight input and output port
24 VDC power supply
Multi-tester
Push button, Limit Switch or Switch
Buzzer, Lamp
Steps/ Procedure:
1.) Prepare the 24 VDC; make sure it is not

connected yet to any external devices or PLC
modules.
2.) Using multi-tester, check if the supply
voltage is energized or not.
3.) Prepare a push button and a limit switch as
your input devices.
4.) Prepare a buzzer and lamp as your output
devices
5.) Connect a DC supply to PLC modules and
take note of its polarity, “do not short the
supply”.
6.) Using the right configuration and
connection of input devices to PLC module,
connect one side of push button and switch
to the module input port. And connect the
other side to DC supply.
7.) Make sure that your PLC common or
internal common connection is different
from external devices common connection. If
you connect, + 24VDC to PLC COM port,
your external common or external devices
common should be -24VDC or 0 VDC.
8.) Using the right configuration and
connection of input devices to PLC module,
connect one side of buzzer and lamp to
module output port. And connect the other
side to DC supply. The same precautions
apply as indicated in step 7.
9.) Call your trainer for inspection

I/O addressing and tagging techniques

MUST be able to:
1.) Explain how to format I/O address at PLC software

2.) Discussed proper way of tagging I/O
3.) Describe the techniques on editing I/O symbols
We will tackle in this the addressing and tagging techniques in SIEMENS

Step 7 and TIA Portal software. The two software’s have similarity only the GUI
of TIA portal makes it more like a different one.
Addressing S7 Memory Areas

S7 controllers. like other PLCs, contain memory areas that you may
access in the user program. In the S7-300, these areas include input image (I),
output image (Q), bit memory (M), peripheral input (PI). peripheral outputs
(PQ), local (L), timer (T), and counter (C) memory areas.
Each memory area is organized in bytes, starting from byte-0. S7 memory
areas, allow access to a bit, byte (8-bits), word (l6-bits), or a double word (32-
bits).
Each absolute address, is prefixed by a unique identifier (e.g ., I, Q, M, PI,
PQ, L, T, and C) based on the area. A bit address is always referenced with the
identifier followed by the byte and bit number separated by a period (e.g., I
33.5). A memory identifier is followed by a 'B', 'W‘, or ‘D' to identify the
location as a byte, word, or double word.
Input Memory (I)

Input addresses are accessed in the program via the address area for
inputs, using the identifier letter ‘I’. An input bit is addressed I byte. bit, a
byte is addressed IB n, a word is addressed IW n, and a double word as ID n
(e.g ., I 9.7, IB 8, IW 8. or ID 8).
ID 8 Input Input Input Input

byte -0 (IB 0) byte -1 (IB 1) byte -2 (IB 2) byte -3 (IB 3)
Bit Positions 7 0 7 0 7 0 7 0
Illustration of input double word-0. Bit address I 1.7 is highlighted. On a 32-point

module, with start address of input byte-0, byte-0 is the first group of eight input circuits.
Output Memory (Q)
Output addresses are accessed in the program via the address area for
outputs, using the identifier letter ‘Q‘.
An output bit is addressed Q byte.bit, a byte is addressed QB n, a word
is addressed QW n, and a double word as QD n (e.g., Q 5.7, QB5, QW 4, or
QD 4).
QW 4 Output Byte – 4 (QB 4) Output Byte – 5 (QB 5)
Bit 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Positions
Illustration of output word word-4. Bit address Q 5. 2 is highlighted. On a 16-point

module, with start address of input byte-4, byte-4 is the second group of eight output circuits.
Bit Memory (M)

The bit memory area is the equivalent of internal storage bits in other
PLCs .Bit memory is typically used when a bit, byte, word, or double word
location is needed for on intermediate binary or digital operation.
Bit memory is typically used if the result does not need permanent
storage, but is required throughout the entire program.
Bit memory addresses are accessed in the program using the identifier
letter 'M‘. A bit location is addressed M byte.bit, a byte is addressed MB n, a
word is addressed MW n, and a double word as MD n (e.g. ., M 101.2, MB
100,MW 120 or MD 140).
Memory word – 100: A bit address is written ‘M byte.bit’

( e.g., M 101.2)
Peripheral Memory (PI/PQ)

The Identifier for accessing input modules is PI (for peripheral
input), and for output modules is PQ (for peripheral output). A byte
(PIB/PQB), word (PIW/PQW), or double word (PID/PQD) can be accessed.
The peripheral memory area not only corresponds to the addresses assigned
in the hardware configuration. for both digital modules, but also to analog
modules. Each analog I/O must be read or written on demand in your program,
via peripheral memory.
Analog input addresses are prefixed with PIW and analog outputs ore
prefixed with PQW. In LAD/FBD, the Move operation is used to read and write
analog I/O. In Statement List (STL), the load operation reads on analog input
(e.g., L PIW256) and the transfer operation writes to on analog output (e.g., T
PQW 256).
Accessing peripheral input word – 256. The next analog input channel is PIW 258
Accessing peripheral output word – 256. The next analog output channel is PQW 258.
Timer Memory (T)

The Timer Memory area of S7 memory contains the software timers of
you program. Each timer is stored in one word location, which contains both
the time preset value and the time base. Timer word locations are accessed
by preceding the location number with the
identifier 'T' to indicate timer. From the first location. timers are addressed
T0, T1,T2, and so on. The number of available timers is CPU dependent
Counter Memory (C)

The counter Memory area holds counter instructions. Like S7 timers, each
counter reserves a word location, which is addressed in the program by
preceding the location with the identifier 'C'. From the first location.
counters are addressed CO, C1, C2, and so on. The
Number of available counters is CPU dependent.
SUMMARY OF SIEMENS S7 MEMORY ADDRESSING
ABSOLUTE ADDRESS
In a STEP 7 program you work with addresses such as I/O signals, bit
memory, counters, timers, data blocks, and function blocks. You can access
these addresses in your program absolutely.
An absolute address comprises an address identifier and a memory

location (for example, Q 4.0, I 1.1, M 2.0, FB21). This type of address is
supreme; you can only address location but not the identifier and its
formation.
SAMPLE
Input= I 0.4
I is specified as Input, 0 the byte address and 4 the bit address. The byte
address and bit address are always separated with a point.
Note: For the bit address here, the 4 stands for the fifth input because the
count begins at 0.
Output = Q 5.7
Q is specified as Output, 5 the byte address and 7 the bit address. The
byte address and bit address are always separated with a point.
Note: For the bit addresses here, the 7 stands for the eighth output, because the
count begins at 0.
Edit I/O addressing
Input and output addressing is one of the things that you should forget.
You Code
canNo.
use theDevelop
default address Control
Mechatronics or youCircuits
can change
Date the addressing,
Developed: Date: the way you
Revised Page #
want it to be.
Add comments and edit symbols
You can assign symbols and add comments to input/output addresses when
you configure modules. Adding symbols and comments would help the
programmer to identify easily each component representation and equivalent.
1.) In SIMATIC Manager window,

click S7 program on the left
pane. Three icon would appear in
the right pane these are sources,
blocks and symbols. Click on
symbols
2.) Add input, memory and

output addresses that you are
intended to use. Insert symbols
and comments to each address.
3.) In actual program creation, all comments and symbols you made on
symbol table are present in the network flow.
Other way of editing symbols and comments
You can edit the symbol name and comment at your main program block
using the steps and procedures below.
1.) Right on the symbol that you want to edit. Then, Click edit symbols.
2.) Edit the symbol name and comments. The symbols will be updated if you
click the OK or Apply button.
S7 Data Types and Formats
An understanding of the data types and formats used in STEP7 is
essential as you start to organize and define your data. As each variable
required in a code block or data block is declared, you will explicitly define its
data type. A variable's data type stipulate its width in bits (e.g ., l-bit, 8-bits,
16-bits, 32-bits, etc.), and how the binary data is represented and interpreted
by STEP7.
How data is represented and interpreted is referred to as the formal
(e.g., signed integer, or character string). The range of values that a variable
may use is also determined by data type. For example, data type INT, allows a
range of -32768 to + 32767.There are three kinds of data types Elementary,
Complex, and Parameter data types. We will focus our discussion on
Elementary data types.
Elementary Data Types
Elementary Data Types refer to the group of data types that represent
variables that involve single data elements, all of which are 32-bits or less.
Variables of elementary data type may be declared in all blocks, including data
blocks, organization blocks, functions, and function blocks. Elementary data
types include BOOL, BYTE, WORD, DWORD, INT, DINT, REAL, DATE, TIME,
S5TIME,TIME-OF-DAY, and CHAR. Variables of elementary data type, may be
used as direct input or output parameters of LAD both and FBD box
instructions.
BOOL
Data type BOOL reserves a single bit for a variable that can take on the
permissible values at either TRUE or FALSE .
BYTE
A variable of data type BYTE, reserves 8-bits. These bits are not evaluated
individually, but as an 8-bit hex number. Each hex digit is represented in
four-bits, allowing a two-digit Hex value.
A constant of data type BYTE is specified using the identifier B# 16#,

where “B" is for byte, and '16' is for hex (e.g ., B# 16#0A).The permissible
range of values is from B# 16#00 to B# 16#FF
8 4 2 1 8 4 2 1 Weight
07 06 05 04 03 02 01 00 Bit No.
1 0 1 0 1 1 1 1
A F B# 16#AF
WORD
Variables of data type WORD reserve l6-bits. Data type WORD represents
a l6-bit string, where the individual bits are not evaluated as a unit, therefore a
WORD variable supports several bit-oriented uses.
A WORD variable can simply be a 16 bit binary string of 1s and 0s; a 4-
digit Hexadecimal number; a 3-digit count value in BCD; or two unsigned
decimal values, each stored in one byte (e.g., 255, 255).
Word variable interpreted as 16-bit hexadecimal
DWORD
Variables of data type DWORD reserve 32-bits. Data type DWORD

represents a 32-bit string, where the individual bits are not evaluated as a unit,
thereby allowing a DWORD variable to be used for several bit-oriented
purposes. A DWORD variable can simply be a 32-bit binary string of 1s and 0s;
an 8-digit Hexadecimal number; or four unsigned decimal values, each stored
in one byte (e.g., 255, 255, 255,1). Because the binary equivalent of Hex 0 -9 is
the same for BCD, DWORD variables may also be used in BCD operations.
INT
Variables of data type INT represent signed decimal integers in a 16-bit
word. The permissible range for data type INT variables is -32,768 to +32,767. A
constant of type INT is entered in the declaration area of a code block, data
block, or as an input value to an instruction, simply with the appropriate sign
(e.g., +2575). No identifier is required.
DINT
Variables of data type DINT represent signed decimal integers in an
S7double word (32-bits). The permissible range of DINT variables is -
2,147,483,648 to +2,147,483,647. DINT variables should be used whenever the
intended operations are expected to exceed the range of
data type INT. An initial DINT constant is entered in a code block, data
block, or as an input value to an instruction. using the long integer identifier 'L'
(e.g., L#500000).
Data type DINT variable, interpreted as signed 32-bit integer
REAL
Variables of data type REAL represent floating-point numbers (e.g.,
25.375). REAL variables are used to work with fractional numbers or to handle
calculations or measured quantities that require floating-point accuracy.
Internally, REAL variables are represented in the IEEE32- bit floating-point
format. In this format, bits 0-22 represent the mantissa, or the significant digits
of the number; and bits 23-30 represent the exponent, a signed power 10. Bit-
31 represents the sign, where 0' indicates a positive value and '1' indicates a
negative value.
(Floating-point) constant in scientific notation
DATE
A variable of data type DATE reserves on S7word, to represent a dale
value as an unsigned fixed-point number. Internally the time value is
interpreted as a fixed-point number that represents the total days since
January 01, 1990. This IEC format for specifying a date uses the identifier
'DATE#' or 'D', and the year, month and day separated by hyphens
(e.g.,DATE#2002-08-22). Data type DATE supports dates from January I. 1990
through December 2168. This range of values is expressed DATE#1990-01-01
through DATE#2168-12-31.
TIME
Variables of data type TIME reserve an s7 double word. Constants of data
type TIME are defined in units of days (D), hours (H), minutes (M), seconds
(S),and milliseconds (MS), preceded by the identifier 'TIME' or 'T'. Unit
identifiers may be entered as upper or lowercase, and unneeded units may be
omitted(e.g., TlME#I0H30M). This IEC format for specifying a time value is
intended for specifying a delay (e.g., a 'wait time' in your STL code).
Both positive and negative Time values are supported, with a range of
TIME#24d20h31m23$647ms to TIME#+24D20H31M23S647MS. The internal
representation of the time value is as a signed 32-bit fixed-point number,
interpreted by STEP7 as total milliseconds.
TIME_ OF_DA Y
A variable of data type TIME_OF_DAY reserve an S7double word. A
TIME_OF_DAY constant is specified using the identifier 'TIME_OF_DAY#' or
'TOD#' preceding the hours, minutes, and seconds which are separated by
colons (e.g., TOD#01:15:00).
Milliseconds may be added to the time using a period as the separator, or
omitting it altogether. The internal representation of the TIME_OF_DAY time
value is as a signed 32-blt fixed-point number, interpreted by STEP7 as total
milliseconds.
CHAR
A variable of data type CHAR reserves one byte (8-bits) and represents a
single ASCII character. All printable characters including upper and lower case
alphabets, numbers 0-9, and some special characters are valid.
Notation for Special CHAR Characters
S5TIME
A variable of data type S5TIME is specified to represent a preset value for
a timer. This16-bit format is the same as what was formerly used to store the
STEP5 timer preset. An initial S5TIME value is entered in units of hours (H),
minutes (M), seconds (5), and milliseconds (MS), preceded by the data type
identifier '55TIME#' or ‘S5T#‘ (e.g.,S5T#2H30M30S).The unit identifiers may be
in upper or lowercase, and unneeded units may be omitted.
Timer Word format.

The preset value of T0 = 555 x 0.1, or 55.5 sec.
Summary of S7 Elementary Data Types
SELF CHECK 1.2.3
Multiple Choice:
answer sheet.
1.) The input memory address is designated by letter
a.) O
b.) I
c.) Q
d.) M
2.) The output memory address is designated by letter
a.) O
b.) I
c.) Q
d.) M
3.) It is the equivalent of internal storage bits in other PLCs.
a.) Memory
b.) Storage
c.) Timer
d.) Counter
4.) It comprises an address identifier and a memory location
a.) Input address

b.) Output address
c.) Absolute address
d.) Real Address
5.) A data type that can take on the permissible values at either TRUE or
FALSE.
a.) BYTE
b.) BIT
c.) BOOL
d.) WORD
ANSWER KEY 1.2.3
1.) B
2.) C
3.) A
4.) C
5.) C
Task Sheet 1.2.3
Title: Tag name to PLC input and output

addresses
Performance Objectives: Given the discussion on I/O tagging, you
assign name and comments to I/O addresses
on a PLC
Equipment: Laptop
PLC software
Mouse
Steps/ Procedure:
1.) Open and turn ON your laptop

2.) Open the SIEMENS Step 7 PLC software on
the laptop
3.) Create a new project
4.) Go to S7 Programs then click on Symbols.
You will have the same windows as below
5.) Using the address I 0.0 up to I 0.7 for input,

add your choice of name and comment for
the eight inputs.
6.) Using the address Q 1.0 up to Q 1.7 for
output, add your choice of name and
comment for the eight outputs.
7.) Don’t forget to save your work.
8.) Call your trainer when you are finish.
CRITERIA Yes No
Is the software used appropriate to the actual PLC?
Is the project used was newly created?
Are the addresses used for input and output correct?
Are information’s like symbol name and comments are

filled up on all input addresses?
Are information’s like symbol name and comments are

filled up on all output addresses?
Are information’s in data addresses saved?
Trainer:__________________________________________Date:______________
Shop and system layout

MUST be able to:
1.) List applicable programmable control international standards

2.) Describe appropriate Philippine Electrical standards for
3.) Differentiate standards related to programmable control
The design of programmable controllers includes a number of rugged

features that allow PLCs to be installed in almost any industrial
environment. Although programmable controllers are tough machines, a
little foresight during their installation will ensure proper system operation.
PLC SYSTEM LAYOUT

System layout is the conscientious approach to placing and
interconnecting components not only to satisfy the application, but also to
ensure that the controller will operate trouble free in its environment.
In addition to programmable controller equipment, the system layout
also encompasses the other components that form the total system. These
components include isolation transformers, auxiliary power supplies, safety
control relays, and incoming line noise suppressors. In a carefully
constructed layout, these components are easy to access and maintain.
Courtesy of Electroblog.issm.it
PLCs are designed to work on a factory floor; thus, they can withstand
harsh environments. Nevertheless, careful installation planning can increase
system productivity and decrease maintenance problems.
The best location for a programmable controller is near the machine or
process that it will control, as long as temperature, humidity, and electrical
noise are not problems. Placing the controller near the equipment and using
remote I/O where possible will minimize wire runs and simplify start-up and
maintenance.
Courtesy of http://kr.caeonline.com
PLC inside a Tape and Reel machine
PANEL ENCLOSURES AND SYSTEM COMPONENTS
PLCs are generally placed in a NEMA-12 panel enclosure or another type

of NEMA enclosure, depending on the application. A panel enclosure holds the
PLC hardware, protecting it from environmental hazards. The enclosure size
depends on the total space required. NEMA stands for National Electrical
Manufacturers Association in America.
Mounting the controller components in an enclosure is not always
required, but it is recommended for most applications to protect the
components from atmospheric contaminants, such as conductive dust,
moisture, and other corrosive and harmful airborne substances. Metal
enclosures also help minimize the effects of electromagnetic radiation, which
may be generated by surrounding equipment.
NEMA 12 Panel
NEMA Panel Enclosures
Type 1 (Surface mount)

For indoor use to protect against contact with the enclosed equipment in
applications where unusual service conditions do not exist
Type 1 (Flush mount)

Used for the same types of applications as Type 1 surface-mounted enclosures
in situations where installation in a machine frame or plaster wall is desired
Type 3
For outdoor use to protect against windblown dust, rain, sleet, and external ice
formation
Type 3R
For outdoor use to protect against falling rain, sleet, and external ice
formation
Type 3R, 7, and 9 (Unilock enclosure for hazardous locations)

Used for the same types of applications as Type 3R, 7, and 9 enclosures but
provides a copper-free aluminum, bronze-chromated housing
Type 4
For indoor or outdoor use to protect against windblown dust and rain,
splashing water, and hose-directed water
Type 4X (Nonmetallic, corrosion-resistant, fiberglass-reinforced polyester) For

indoor and outdoor use to protect against corrosion, windblown dust and rain,
splashing water, and hose-directed water
Type 6P
For indoor and outdoor use to protect against the entry of water during
prolonged submersion at a limited depth
Type 7 (Hazardous gas locations bolted enclosure)

For indoor use in applications using hazardous gases; capable of withstanding an
internal explosion of specified gases and containing such an explosion to prevent
the ignition of the surrounding atmosphere
Type 9 (Hazardous dust locations)

For indoor use in applications where hazardous dust is present; designed to
prohibit the entry of dust as well as prevent the ignition of dust by enclosed heat-
generating devices
Type 12
For indoor use to protect against dust, falling dirt, and dripping noncorrosive
liquids
Type 13
For indoor use to protect against dust, spraying of water, oil, and
noncorrosive coolants
Different types of NEMA enclosures
The enclosure layout should conform to NEMA standards, and componen

placement and wiring should take into consideration the effects of heat,
electrical noise, vibration, maintenance, and safety.
Placement of PLC Components.
The placement of the major components of a specific controller depends

on the number of system components and the physical design or modularity of
each component.
Although different controllers have different mounting and spacing

requirements, the following considerations and precautions apply when placing
any PLC inside an enclosure:
1.) To allow maximum convection cooling, all controller components

should be mounted in a vertical (upright) position. Some manufacturers
may specify that the controller components can be mounted horizontally.
2.) The power supply (main or auxiliary) has a higher heat dissipation
than any other system component; therefore, it should not be mounted
directly underneath any other equipment
.
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Proper placement of PLC components

3.) The CPU should be located at a comfortable working level (e.g., at
sitting or standing eye level) that is either adjacent to or below the
power supply.
4.) Local I/O racks (in the same panel enclosure as the CPU) can be
arranged as desired within the distance allowed by the I/O rack
interconnection cable.
5.) Remote I/O racks and their auxiliary power supplies are generally
placed inside an enclosure at the remote location, following the same
placement practices as described for local racks.
6.) Spacing of the controller components (to allow proper heat

dissipation)should adhere to the manufacturer’s specifications for vertica
and horizontal spacing between major components.
Placement of Other Components
In general, other equipment inside the enclosure should be located away

from the controller components, to minimize the effects of noise and heat
generated by these devices.
The following list outlines some common practices for locating other
equipment inside the enclosure:
1.) Incoming line devices, such as isolation and constant voltage

transformers, local power disconnects, and surge suppressors, should
be located near the top of the enclosure and beside the power supply.
2.) Magnetic starters, contactors, relays, and other electromechanical
components should be mounted near the top of the enclosure in an
area segregated from the controller components.
3.) If fans or blowers are used to cool the components inside the
enclosure, they should be located close to the heat-generating
devices(generally power supply heat sinks).
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Proper placement of other components

The grouping of I/O modules allows signal and power lines to be routed
properly through the ducts, thus minimizing crosstalk interference.
Following are recommendations concerning the grouping of I/O modules:
1.) I/O modules should be segregated into groups, such as AC input

modules, AC output modules, DC input modules, DC output modules,
analog input modules, and analog output modules, whenever possible.
2.) If possible, a separate I/O rack should be reserved for common input
or output modules. If this is not possible, then the modules should be
separated as much as possible within the rack.
Duct and Wiring Layout
The duct and wiring layout defines the physical location of wire ways and
the routing of field I/O signals, power, and controller interconnections within
the enclosure. The enclosure’s duct and wiring layout depends on the
placement of I/O modules within each I/O rack.
The placement of these modules occurs during the design stage, when the
I/O assignment takes place.
The following guidelines should be considered to minimize electrical noise

caused by crosstalk between I/O lines:
1.) All incoming AC power lines should be kept separate from low-level
DC lines, I/O power supply cables, and I/O rack interconnection
cables.
2.) Low-level DC I/O lines, such as TTL and analog, should not be
routed in parallel with AC I/O lines in the same duct. Whenever
possible, keep AC signals separate from DC signals.
I/O wirings must cross AC line at right angle
3.) I/O rack interconnection cables and I/O power cables can be
Sometimes, this arrangement is impractical or these cables
cannot be separated from all other wiring.
4.) If I/O wiring must cross AC power lines, it should do so only at

right angles. This routing practice minimizes the possibility
of electrical noise pickup. I/O wiring coming from the conduits
should also be at right angles.
I/O wiring from a conduit

SELF CHECK 1.2.4
Enumeration:
1.) Give at least seven types of NEMA Panel enclosures
2.) Give at least three considerations when placing any PLC an
components inside an enclosure
3.) Give at least three guidelines to minimize electrical noise caused b
crosstalk between I/O lines on a duct and wiring layout.
ANSWER KEY 1.2.4
1.) A. Type 1 (Surface Mount)

B. Type 1 (Flush Mount)
C. Type 3
D. Type 3R
E. Type 4
F. Type 6P
G. Type 12
2.) A. To allow maximum convection cooling, all controller

components should be mounted in a vertical (upright) position.
B. The power supply (main or auxiliary) has a higher heat
Dissipation than any other system component; therefore, it
should not be mounted directly underneath any other
equipment.
C. The CPU should be located at a comfortable working level (e.g.,
at sitting or standing eye level) that is either adjacent to or
below the power supply.
3.) A. All incoming AC power lines should be kept separate from low -
level DC lines, I/O power supply cables, and I/O rack
interconnection cables.
B. Low-level DC I/O lines, such as TTL and analog, should not be
routed in parallel with AC I/O lines in the same duct.
C. I/O rack interconnection cables and I/O power cables can be
routed together in a common duct not shared by other wiring
Task Sheets 1.2.4
Title: PLC System Layout
Performance Objectives: Given the lessons about system layout,
recommendations and safety precautions, you
can create your own PLC system layout.
Equipment: Laptop
Siemens PLC
Steps/ Procedure:
1.) In a single bond paper, create your own PLC

system enclosure layout using the figure
below as reference
2.) Details like wire ways (conduit) and terminal
block should be included.
3.) In your layout it should contain a two digital
and analog input/output modules.
4.) Put a proper labelling and tagging on each
item.
5.) Present your work to the trainer

CRITERIA Yes No
Are the wire-ways (conduit) and terminal block included in

the PLC system enclosure layout?
Are controller, power supply and other auxiliaries

positioned correctly according to what is discussed?
Are digital and analog input/output modules

positioned accordingly?
Are labels and tags of PLC components/parts

included in the PLC system layout?
Procedures and techniques in programming the

MUST be able to:
1.) Enumerate different type of programming language available.

2.) List common parts or components of a PLC ladder logic program
3.) Identify basic logic function in ladder programming
4.) Describe how to convert electrical ladder circuit to PLC program
We will tackle in this section creating a simple program using the

basic instruction on your PLC software. We will also identify different
programming languages available but we will focus on ladder logic
programming, the most common programming language on PLC.
PROGRAMMING LANGUAGES
As PLCs have developed and expanded, programming languages

have developed with them. Programming languages allow the user to
enter a control program into a PLC using an established syntax. Today’s
advanced languages have new, more versatile instructions, which initiate
control program actions. These new instructions provide more computing
power for single operations performed by the instruction itself
The standard IEC 61131 was established to standardize the
multiple languages associated with PLC programming
Standard IEC 61131 associated with PLC programming

Ladder Diagram (LAD)
In Ladder Diagram writing the program for your control problem is like
drawing in contactor circuits. The logical connections between the binary
signals are represented by serial parallel arrangement of contacts. Each run
in the ladder ends in a coil. Complex functions are represented by boxes.
Function Block Diagram (FBD)

In Function Block Diagram writing the program for your control
problem is like drawing an electronic circuit diagram. You implement bit
logic operations by interconnecting AND and OR functions and terminate
them with simple boxes. Complex functions are also represented by boxes.
Statement List (STL) or Instruction List
In Statement List is a textual representation of the PLC
programming language, similar to machine code. Each line represents on
statement consisting of an instruction and a comment.
Structured Text
is one of the five languages supported by the IEC 61131-3 standard,
designed for programmable logic controllers (PLCs). It is a high level
language that is block structured and syntactically resembles Pascal, on
which it is based.
Sequential function chart (SFC)
is a graphical programming
language used for programmable logic
controllers (PLCs). It is one of the five
languages defined by IEC 61131-3
standard.
The SFC standard is defined in IEC
60848, Preparation of function charts for
control systems, and was based on
GRAFCET (itself based on binary petri
nets)
Program Scan
When a PLC executes a program, it must know—in real time—when external
devices controlling a process are changing. During each operating cycle, the
processor reads all the inputs, takes these values, and energizes or de-energizes
the outputs according to the user program. This process is known as a program
scan cycle. Figure below illustrates a single PLC operating cycle consisting of the
input scan, program scan, output scan, and housekeeping duties. Because the
inputs can change at any time, it constantly repeats this cycle as long as the PLC
is in the RUN mode.
PLC program scan cycle
The time it takes to complete a scan cycle is called the scan cycle time and
indicates how fast the controller can react to changes in inputs. The time required
to make a single scan can vary from about 1 millisecond to 20 milliseconds. If a
controller has to react to an input signal that changes states twice during the
scan time, it is possible that the PLC will never be able to detect this change.
The CPU will detect a change if it occurs during the update of the input
image table fi le, but the CPU will not respond to every change. The scan time is a
function of the following:
• The speed of the processor module
• The length of the ladder program
• The type of instructions executed
• The actual ladder true/false conditions
The actual scan time is calculated and stored in the PLC’s memory. The PLC
computes the scan time each time the END instruction is executed. Scan time
data can be monitored via the PLC programming. Typical scan time data include
the maximum scan time and the last scan time.
The scan is normally a continuous and sequential process of reading the
status of inputs, evaluating the control logic, and updating the outputs.
Overview of the data flow during the scan process

For single rung program each rung executed, the PLC processor will:
• Examine the status of the input image table bits.

• Solve the ladder logic in order to determine logical
continuity.
• Update the appropriate output image table bits, if
necessary.
• Copy the output image table status to all of the out-
put terminals. Power is applied to the output device
if the output image table bit has been previously set
to a 1.
• Copy the status of all of the input terminals to the
input image table. If an input is active (i.e., there is
electrical continuity), the corresponding bit in the
input image table will be set to a 1.
Scan process applied to a single rung program

For multiple rung programs each rung executed, the PLC processor will:
Step 1 Update the input image table by sensing the voltage of the input
terminals. Based on the absence or presence of a voltage, a 0 or a 1
is stored into the memory bit location designated for a particular
input terminal.
Step 2 Solve the ladder logic in order to determine logical continuity. The
processor scans the ladder program and evaluates the logical
continuity of each rung by referring to the input image table to see
if the input conditions are met. If the conditions controlling an
output are met, the processor immediately writes a 1 in its memory
location, indicating that the output will be turned ON; conversely, i
the conditions are not met a 0 indicating that the device will be
turned OFF is written into its memory location.
Step 3 The final step of the scan process is to update the actual states of
the output devices by transferring the output table results to the
output module, thereby switching the connected output devices
ON (1) or OFF (0). If the status of any input devices changes when
the processor is in step 2 or 3, the output condition will not react to
them until the next processor scan.
Scan process applied to a multiple rung program

Each instruction entered into a program requires a certain amount of time for
the instruction to be executed. The amount of time required depends on the
instruction. For example, it takes less time for a processor to read the status of an
input contact than it does to read the accumulated value of a timer or counter. The
time taken to scan the user program is also dependent on the clock frequency of the
microprocessor system. The higher the clock frequency, the faster is the scan rate.
Scanning can be horizontal or vertical
There are two basic scan patterns that different PLC manufacturers use to
accomplish the scan function. SIEMENS and Allen Bradley PLCs use the horizontal
scan by rung method. In this system, the processor examines input and output
instructions from the first command, top left in the program, horizontally, rung by
rung.
Modicon PLCs use the vertical scan by column method. In this system, the
processor examines input and output instructions from the top left command entered
in the ladder diagram, vertically, column by column and page by page. Pages are
executed in sequence. Both methods are appropriate; however, misunderstanding the
way the PLC scans a program can cause programming bugs.
NUMBER SYSTEMS
A familiarity with number systems is quite useful when working with

programmable controllers, since a basic function of these devices is to
represent, store, and operate on numbers, even when performing the
simplest of operations. In general, programmable controllers use binary
numbers in one form or another to represent various codes and quantities.
Although these number operations are transparent for the most part, there
are occasions where a knowledge of number systems is helpful.
The Basic Number System that a machine can understand is the Binary
Number System. Binary System is represented by ON and OFF or “0 and 1”.
But for the convenience of the machine users Octal and Hex Systems are
utilized.
Binary: 2 Codes; 0 and 1
Octal: 8 Codes; 0 - 7
Hex: 16 Codes; 0 - 15
PROCESS CONTROL
Most control processes require the completion of several operations t

produce the required output. Manufacturing, machining, assembling
packaging, fi nishing, or transporting of products requires the precis
coordination of tasks
Sequential Relay Logic

is a technique used to solve long and complicated sequences o
Automation Systems. The whole sequence is being divided into steps, and each
step is being represented correspondingly by a relay.
Sequential Relay Logic is commonly used in Electro-pneumatic

sequences where Valves and Cylinders are involved.
Sequential problems have long been solved using conventional logic gate
as building blocks, but using certain techniques to express and identify th
sequence logic equations that control the system outputs. Advanced PLC
instructions such as shift registers, sequencers, master control relays, drum
timers etc., are provided to simplify the design and implementation o
sequence systems.
A sequential control process is required for processes that demand tha

certain operations be performed in a specific order. Figure below illustrate
part of a bottle filling process. In the filling and capping operations, the task
are (1) fill bottle and (2) press on cap. These tasks must be performed in th
proper order. Obviously we could not fill the bottle after the cap is pressed on
This process, therefore, requires sequential control.
Sequential Control Process

Combinational Logic Control Design
Boolean algebra can be used as a tool to assist in the design of logic

networks. The original logic circuit or program is first converted into a Boolean
equation. Based on the rules governing Boolean algebra the equation is
simplified resulting in more economical or elegant, in terms of logic functions,
solution.
When dealing with fairly complex combinational logic tasks, the
requirements can also be expressed in terms of Boolean equations so that it
can be simplified before translating them into ladder logic.
As example to illustrate how a ladder diagram is translated from

Boolean equation based on the given requirement below:
To operate valve Y1 limit switches A and B and valve X are activated and
both switch C and valve Z are not activated. Valve Y1 will also operate
switch D and valve X are activated and both level switch C and valve Z are no
activated
Combination controls require that certain operations be performe

without regard to the order in which they are performed. Figure below
illustrates another part of the same bottle fi ling process.
Here, the tasks are (1) place label 1 on bottle and (2) place label 2 on
bottle. The order in which the tasks are performed does not really matter. In
fact, however, many industrial processes that are not inherently sequential i
nature are performed in a sequential manner for the most efficient order o
operations.
Combination control process

Standard logic instructions
The processing potential of binary signals can be described using th
three basic operations:
AND / OR / NOT (negation)
These basic logic operations can be used to solve combinational contro
problems.
Logic Concept
The PLC, like all digital equipment, operates on the binary
principle. The term binary principle refers to the idea that many things
can be thought of as existing in only one of two states. These states
are 1 and 0. The 1 and 0 can represent ON or OFF, open or closed,
true or false, high or low, or any other two conditions. The key to the
speed and accuracy with which binary information can be processed is
that there are only two states, each of which is distinctly different. There
is no in-between state so when information is processed the outcome is
either yes or no.
Different law of logic operation
LADDER LANGUAGE
When writing programs for PLCs, it is beneficial to have a background in

ladder diagramming for machine controls The reason for this is that at
fundamental level, ladder logic programs for PLCs are very similar to electrica
ladder diagrams. This is no coincidence. The engineers that developed the PLC
programming language were sensitive to the fact that most engineers
technicians and electricians who work with electrical machines on a day -to-da
basis will be familiar with this method of representing control logic.
This would allow someone new to PLCs, but familiar with contro
diagrams, to be able to adapt very quickly to the programming language. It i
likely that PLC programming language is one of the easiest programmin
languages to learn.
The programming method we will use would be the graphical method lik
ladder diagram, which uses schematic symbols for relay coils and contacts.
Push Button 1 Push Button 2 LAMP
Switch 1 Switch 2
Electrical Ladder
PLC program ladder

LADDER PROGRAM Elements
A LADDER program consists of separate elements that you can arrange in
series or parallel on the power rail of a network. Most program elements mus
be supplied with tags.
There is at least one rung from the power rail. Network programmin
starts at the left edge of the rung. You can expand the power rail by severa
rungs and branches.
The following figure shows elements of a LADDER network:
1) Power rail
2) Rung
3) Branch
4) Contact
5) Coil
6) Box
Power rail
Each LAD network consists of a power rail that contains at least on
rung. A network can be extended by adding additional rungs. You can us
branches to program parallel connections in the specific rungs.
Contacts
You can use contacts to create or interrupt a current-carrying connectio
between two elements. The current is relayed from left to right. You can us
contacts to query the signal state or the value of an operand and control i
depending on the result of the current flow.
The following types of contact are available to you in a LAD program:
Normally-open-contact:
Normally open contacts forward the current if the signal state of
specified binary operand is "1".
Normally-closed-contacts:
Normally open contacts forward the current if the signal state of
specified binary operand is "0".
Contact-with-additional-function:
Contacts with additional function forward the current if a specifi
condition is met. With these contacts you can also execute an additiona
function, such as an RLO edge detection and a comparison.
Coils
You can use coils to control binary operands. Coils can set or reset
binary operand depending on the signal state of the result of logic operation.
The following types of coils are available to you in a LAD program:
Standard-coils:
Standard coils set a binary operand if current flows in the coil. Th
"Assignment" instruction is an example of a standard coil.
Coils-with-additional-function:
These coils have additional functions besides the evaluation of the resul
of logic operation. Coils for RLO edge detection and program control ar
examples of coils with additional function.
Boxes
Boxes are LAD elements with complex functions. The empty box is an
exception. You can use the empty box as a placeholder in which you can selec
the required instruction.
The following types of boxes are available to you in a LAD program:
Boxes-without-EN/ENO-mechanism:
A box is executed depending on the signal state at the box inputs. Th
error status of the processing cannot be queried.
Boxes-with-EN/ENO-mechanism:
A box is only executed if the enabling input "EN" carries the signal stat
"1". If the box is processed correctly, the "ENO" enable output has signa
state "1". If an error occurs during the processing, the "ENO" output i
reset. Calls of code block are also shown in the network as boxes with
EN/ENO mechanism.
LADDER PROGRAMMING Instructions
The following discussion will introduce each of the PLC programmin
instruction categories for LAD (Ladder). The purpose of each instruction
category is briefly described, and then followed by a table that lists th
operations it includes. The operation of each instruction is explained in th
table.
BIT LOGIC Instructions

It is used in developing relay equivalent control circuits an
internal binary decision logic. With instructions that include normally-open an
normally-closed contacts, and the standard output coil. These bit logi
instructions allow development of series, parallel, and series-parallel logi
combinations. Set and Reset output instructions, also known as latch/unlatch
outputs.
BIT LOGIC Instructions Summary

TIMER Instructions
The instruction set includes five timer types, each of which i

implemented as a box function and as a simple output instruction. Separat
instructions are used to reset or monitor the timer's operation. Each timer you
specify, numbered T0,T1, T2, and so on, will reference a single word in th
timer memory area. The exact number of timers available is CPU-dependent.
TIMER Instructions Summary

COUNTER Instructions
The counter instructions include the Up counter, the Down counter, and
the Up/Down counter, which counts both up and down. The UP and Down
counters are implemented both as box functions and as output instructions
Box counter functions support the full functionality of the counter in a singl
instruction, allowing the counter to be triggered, a preset value loaded
monitored. and reset.
Each counter you specify, numbered C0, C1, C2, and so on, wi
reference a single word in the counter memory area. The exact number o
counters available is CPU-dependent.
COUNTER Instructions Summary

CONVERSION Instructions
A conversion operation changes the format or data type of a variable to

new formal or data type - generally before the data is further used. Fo
instance. a value input as BCD must be converted before use in on intege
arithmetic operation.
Conversely, If the integer result must be output to a BCD display, then
the value would need to be converted to BCD. If an arithmetic or comparison i
to be performed on the data stored in two locations, the variables must be o
the same data type or format to avoid erroneous results.
CONVERSION Instructions
INTEGER and REAL ARITHMETHIC Instructions
Arithmetic instructions support the four basic arithmetic operations o

addition, subtraction multiplication, and division on numbers of data type INT
(integer), DINT (double integer), and REAL (floating-point).
Real numbers are represented in IEEE floating- point formal-therefore
the terms REAL and Floating-Point are often used interchangeably. Thes
instructions allow the control program to perform basic production accounting
and the ability to solve simple algorithms for control, diagnostic, or othe
purposes, While the DIV_DI instruction produces the normal quotient result
the MOD_DI operation produces the remainder port of the quotient as th
result.
INTEGER AND REAL ARITHMETHIC Instructions

STANDARD MATH FUNCTIONS
In addition to the four basic arithmetic operations, the instruction set

include standard mathematical functions, as listed in the table below. Thes
operations include functions for finding angle and radian measurement
absolute value, square root, square of a number, natural log of a number. an
finally, a function to determine the exponent of a number with a radix of base e
STANDARD MATH FUNCTIONS

COMPARE Instructions
Compare instructions allow comparison of integer (INT), double-intege

(DINT), and REAL (floating-point) values. There are six compare types, each o
which may be performed using each of the three numeric data types (i.e ., INT
DINT, REAL).
The compare tests include equal, not equal, less than, greater than, les
than-or-equal, and greater-thon-or-equal. Compare operations are often use
for range checking, set paint control, or limit checks on calculations.
COMPARE Instructions
PROGRAM FLOW CONTROL Instructions
Program flow control instructions, provide one of the ways in which you
can control how your program is processed. In short, you will be able to alte
the way in which the CPU processes your program so that processing needs ar
serviced on an as-needed basis.
PROGRAM FLOW CONTROL Instructions

WORD LOGIC Instructions
Word logic operations allow you to perform standard Boolean operation

of AND, OR and Exclusive OR on two word (I6-bit) locations or two double-wor
(32-bit) locations. These instructions are quite useful in performing diagnosti
checks on machine or process states. Through the use of these instructions, th
desired states or the resulting word or double word location can be masked in
(set to '1'), using the OR operation; or masked out (set 10 '0'), using the AND
operation.
WORD LOGIC Instructions

SHIFT-ROTATE AND MOVE Instructions
Shift and rotate operations move the bit data of a specified word or doubl
word location to the left or right. These instructions are often used in material
conveying applications where information on discrete ports must be tracke d fo
some distance, while the product is in motion, and usually prior to performin
a secondary operation.
The move operation copies data from one memory location to another
leaving the source unchanged. Often, data is moved to a new location eithe
prior to performing on operation or just after on operation has been performed
in order to preserve the data. Changing a timer preset, a process set point. o
saving and stacking data for transfer to another device,all are cases where mov
operations might be used.
SHIFT Instructions
ROTATE and MOVE Instructions
Physical Components vs. Program Components
When learning PLC programming, one of the most difficult concepts t

grasp is the difference between physical components and program components
We will be connecting physical components (switches, lights, relays, etc.) to th
external terminals on a PLC. Then when we program the PLC, any physica
components connected to the PLC will be represented in the program a
program components
A programming component will not have the same reference designator a
the physical component, but can have the same name. As an example
consider a N/O pushbutton switch S1 named START. If we connect this t
input IN1 of a PLC, then when we program the PLC, the START switch will
become a N/O relay contact with reference designator I0.1 and the nam
START.
As another example, of we connect a RUN lamp L1 to output OUT3 on th
PLC, then in the program, the lamp will be represented by a relay coil wit
reference designator Q0.3 and name RUN (or, if desired, “RUN LAMP”).
PLC Input Card PLC Output Card
1-1IC1 1-1OC1
Push Button IN0 OUT0
IN1 OUT1
IN2 OUT2 LAMP
IN3 OUT3
IN4 OUT4
IN5 OUT5
IN6 OUT6
IN7 OUT7
COM COM
PLC wiring diagram
Equivalent PLC program

AND LADDER
As a programming example, consider the simple AND circuit shown below
consisting of two momentary pushbuttons in series operating a lamp
Although it would be very uneconomical to implement a circuit this simpl
using a PLC, for this example we will do so.
AND Ladder Diagram
When we convert a circuit to run on a PLC, we first remove th

components from the original circuit and wire them to the PLC as shown
below. One major difference in this circuit is that the two switches are n
longer wired in series. Instead, each one is wired to a separate input on th
PLC. As we will see later, the two switches will be connected in series in th
PLC program. By providing each switch with a separate input to the PLC, w
gain the maximum amount of flexibility. In other words, by connecting the m
to the PLC in this fashion, we can “wire” them in software any way we wish.
Push Button 1-1IC1 1-1OC1 LAMP

IN0 OUT0
IN1 OUT1
Push Button
IN2 OUT2
IN3 OUT3
IN4 OUT4
IN5 OUT5
IN6 OUT6
IN7 OUT7
COM COM
PLC Wiring Diagram

The DC supply voltage sources are actually the same source. They ar
shown separately in this figure to make it easier to see how the inputs an
output are connected to the PLC, and how each is powered.
Once we know how the external components are wired to the PLC, we can
then write our program. In this case we need to connect the two switches in
series. However, once the signals are inside the PLC, they are assigned new
reference designators which are determined by the respective terminal on th
PLC. Since Push Button 1 is connected to IN0, it will be called I0.0 “Push
Button 1” in our program. Likewise, Push Button 2 will become I0.1 “Pus
Button 2” in our program. Also, since LAMP is connected to OUT0 on the PLC
it will be called relay Q0.0 “LAMP” in our program. Our ladder program t
control LAMP is shown below
PLC Ladder AND Program
OR LADDER
The circuit for an OR ladder is shown below. Compare the difference
between the AND ladder circuit.
OR Ladder diagram
Push Button 1-1IC1 1-1OC1 LAMP

IN0 OUT0
IN1 OUT1
Push Button
IN2 OUT2
IN3 OUT3
IN4 OUT4
IN5 OUT5
IN6 OUT6
IN7 OUT7
COM COM
PLC wiring diagram
As you observed, the PLC wiring diagram for AND and OR ladder circuit is
the same. In PLC wiring, it doesn’t look to the position or location of certain
device, it’s the PLC program who executes the different devices to a desired
output.
PLC Ladder OR Program

AND and OR LADDER
The electrical and PLC wiring diagram to implement both the AND and OR
circuits is shown below. Notice here that the only change we’ve made to th
circuit is to add LAMP2 to the PLC output OUT2. Since the SWTICH1 an
SWITCH2 signals are already available inside the PLC via inputs IN1 and IN2, i
is not necessary to bring them into the PLC again. This is because of on
unique and very economical feature of PLC programming.
AND and OR Ladder Diagram
Push Button 1 1-1IC1 1-1OC1 LAMP 1

IN0 OUT0
IN1 OUT1
Push Button 2
IN2 OUT2 LAMP 2
IN3 OUT3
IN4 OUT4
IN5 OUT5
IN6 OUT6
IN7 OUT7
COM COM
AND and OR PLC wiring Diagram

Once an input signal is brought into the PLC for use by the program, you
may use as many contacts of the input as you wish, and the contacts may be o
either N/O or N/C polarity. This reduces the cost because, even though ou
program will require more than one contact of IN0 and IN1, each of the actua
switches that generate these inputs, PB1 and PB2, only need to have a singl
N/O contact.
AND and OR PLC Program
Now that we have the inputs and outputs connected, we can write th
program. We do this by simply adding to the program the additional rung tha
we need to perform the OR operation. This is shown above. Keep in mind tha
other than the additional lamp and the time it takes to add the additiona
program, this additional OR feature costs nothing.
Holding (also called Sealed, or Latched) Contacts
There are instances when a coil must remain energized after contact logi
has been found to be true even if on successive scans the logic solution
becomes false. A typical application of this would be an ON/OFF control usin
two separate switches, one to turn the equipment on and one to turn th
equipment off.
In this case, the coil being controlled by the switches must energize when
the ON switch is pressed and remain energized until the OFF switch is pressed
This function is accomplished by developing a rung which contains a holdin
contact or sealing contact that will maintain the coil in the energized state unt
released. Such a configuration is shown below.
Latched Contact
Always-ON and Always-OFF Contacts
As programs are developed, there are times when a contact is require

that is always ON. In newer PLC's there is generally a coil set aside that meet
this requirement. There are, however, some instances where the programme
will have to generate this type of contact in the ladder.
One instance where such a contact is required is for a level-triggered (no
transition-triggered) arithmetic operation that is to be performed on every scan
Most PLC's require that at least one contact be present in every rung. T
satisfy this requirement and have an always true logic, a contact must b
placed in the rung that is always true (always closed).
There are two ways to produce such a contact. One is to create a coil tha
is always de-energized and use a normally closed contact associated with th
coil. The other is to create a coil that is always energized and use a normall
open contact associated with the coil. The next figure illustrates a ladder run
that develops a coil that is always de-energized.
Always OFF/ Always De-energized
Above figure shows that output Q0.0 (LAMP) will never energized because of th
contradicting input of I0.0 (Push Button 1). Placing this rung at the top of th
program will allow the programmer to use a normally closed contact throughout th
ladder anytime a contact is required that is always on.
Figure below illustrates a rung which creates a LAMP coil (Q0.0) that is alway
energized. Notice that the logic solution for this rung is always true since eithe
normally closed Push Button 1 (I0.0) contact OR normally open Push Button 1 (I0.0
contact will always be true. This will cause coil LAMP coil to energize at th
conclusion of the solution of this rung.
This rung must be placed at the very beginning of the ladder to provide for an
energized coil on the first scan. Anytime a contact is required that is always closed,
normally open contact may be used since coil will always be energized.
Always ON/ Always Energized

SELF CHECK 1.2.5
Matching type
Direction: Match the descriptor from column I to the terminologies in th
column II. Write the letter of your choice on your answer sheet.
I II
1.) A standard that was established to A. TIMER
standardize the multiple languages associated
with PLC programming
2.) In this PLC programming language, writing B. COUNTER
the program for your control problem is like
drawing in contactor circuits
3.) A textual representation of the PLC C. LADDER
programming language, similar to machine
code
4.) It is a high level language that is block D. IEC 61131
structured and syntactically resembles
Pascal, on which it is based.
5.) During each operating cycle, the processor E. IEC 60858
reads all the inputs, takes these values,
and energizes or de-energizes the outputs
according to the user program
6.) It is required for processes that demand F. Structured text
that certain operations be performed in a
specific order
7.) It requires that certain operations be G. Statement/ o
performed without regard to the order in Instructions List
which they are performed
8.) An instructions that changes the format or H. Sequencial Control
data type of a variable to a new formal or
data type - generally before the data is
further used
9.) It activate or deactivate a device after a I. Combination
time interval has expired . Control
10.) It activate or deactivate a device after a J. Program scan
count has reached a preset value
K. Input scan
L. Conversion
M. Compare
N. IEC 61511
O. SFC
ANSWER KEY 1.2.5
1.) D
2.) C
3.) G
4.) F
5.) J
6.) H
7.) I
8.) L
9.) A
10.) B
Task Sheet 1.2.5
Title: Design a ladder logic program
Performance Objectives: Given the discussion on ladder programming

instructions and components, you should
design a ladder program for different logic
gate functions
Equipment: N/A
Steps/ Procedure:
1.) Prepare for your pen and paper

2.) Design a ladder diagram program for the
following logic functions;
 AND
 OR
 NOT
 XOR
 NAND
 NOR
 XNOR
3.) Assign an address on your input and output
components
4.) Create a PLC wiring diagram for the following
logic gate functions.
5.) Label each symbol with symbol names and
comments
6.) Put your design in a clean bond paper

Job Sheet 1.2.5
Title: Create a ladder logic program
Performance Objectives: Given the discussion on ladder programming

instructions and components, you should
create a ladder program for different logic
gate functions using PLC software
Equipment: Laptop
PLC Software
Input Devices; switch and push button
Output Devices; lamp and buzzer
Steps/ Procedure:
1.) Turn On your laptop and PLC trainer then

open the PLC application software
2.) Assign addresses for input and output
components for the following logic functions;
 AND
 OR
 NOT
 XOR
 NAND
 NOR
 XNOR
3.) Connect your input devices; switch and
pushbutton to PLC input modules, check
your wiring connections and configurations.
4.) Connect your output devices; buzzer and
lamp to PLC input modules, check your
wiring connections and configurations.
5.) Create a new project in your PLC software
application.
6.) Create a program using the assigned
addresses of the logic functions mentioned in
step 2. Use the two output devices as your
output signal.
7.) Label each symbol with symbol name and
comments and test your program using the
external devices connecter to the PLC.
8.) Call your trainer if your finish
Assessment Method: Demonstration and oral questioning
CRITERIA Yes No
Are the designed programs in accordance to what

was given to them?
Are the designed programs had an assigned addresses for

input and output components?
Are the designed programs had label with symbol names

and comments?
Did the design was put in a clean bond paper?
Are input and output components assigned

with addresses in PLC program software?
Are the input and output devices connected
properly in accordance to PLC configurations?
Is the program created a new project?
Are the program created the same with all

the logic gate functions mentioned?
Are each symbol with names and comments?
Are all programs worked when applied to the external

devices connected to PLC?
Trainer:__________________________________________Date:______________
LEARNING OUTCOME # 3: TEST AND DEBUG
DEVELOPED SOFTWARE
PROGRAM
CONTENTS:
1. Debugging programs in the programmable control

2. Safety precautions in programming and debugging the programmable
controls
1. Developed software program is run to ensure all syntax errors are

corrected
2. Function errors in the programmable control operation are properly
identified.
3. Failures/function error in the programmable control operation are
properly isolated and corrected.
4. Safety practices in programming and debugging the programmable
control are strictly observed
5. Program is downloaded using manufacturer’s procedures
CONDITIONS:
1. EQUIPMENT
components
b. CPU
c. Power supply
d. Input and output
2. INSTRUMENT:
Multi-tester

components and buzzer.
Delays, timers and counters
Diagonal pliers
Set of screw driver
Allen wrenches
Soldering iron

a. Wires
b. Terminal blocks
c .Office supply
d .Alligator clips
METHODOLOGIES:
2. Demonstration
4. Multimedia
ASSESSMENT METHODS:
1. Written test
2. Practical test
4. Interview (oral)
Learning Outcome 3
TEST AND DEBUG DEVELOPED SOFTWARE PROGRAM

Debugging programs in the Information sheet and check
programmable control yourself by answering the Self
2. Answer Self check 1.3.1 Check.
You must answer the questions
Compare your answers with correctly before proceeding to
Answer Key 1.3.1 the next activity.
3. Perform Job Sheet 1.3.1 on
Distribution system program In this Learning Outcome, you
will evaluate the requirements
Evaluate your output using the of your system before testing or
Performance Criteria Checklist debugging a software program.
trainer Understanding the content of
4. Read Information Sheet 1.3.2 on information presented would be
Safety precautions in your foundation on steeping
programming and debugging the the next learning outcome.
5. Answer Self check 1.3.2 Task Sheet, Operation Sheet
and Job Sheet will help you to
Compare your answers with practice to skills
Answer Key 1.3.2
The performance Criteria
checklist will guide and help
you evaluate your work as you
Evaluate your own work using

the Performance Criteria. When
you are ready, present your
work to your trainer for final
If you have any questions or

your trainer.
LO, you are ready to proceed to
the next LO on Maintain and
Document Developed Software
Programs
Debugging programs in the programmable control

MUST be able to:
1.) Discuss the procedures on how to run a PLC program

2.) List appropriate debugging software available for your
appropriate PLC.
3.) Explain techniques in debugging PLC program
In this section, techniques and procedures on testing and debugging

your PLC program will be tackled. Each PLC manufacturer develops its own
PLC software and debugging software or simulator. For example purposes we
will use some common PLC software’s and simulator to further discuss the
lesson.
TESTING PLC PROGRAM
Most PLCs contain some software-checking program. This checks

through the installed program for incorrect device addresses and provides a
list on a screen or as a printout of all the input/output points used, counter
and timer settings, and so on, with any errors detected
Testing the program you made can be done by following the steps and
procedures below;
1.) Configure your programming software to the actual PLC modules or
hardware. PLC configuration was discussed in the previous section
you can check the procedures on appropriate configuration.
2.) Download your program into the PLC.
Downloading of data from programming
device to PLC is tackled in the previous
section also; you can check and follow the
procedures.
3.) Set you controller hardware to RUN Mode
or START Mode
4.) Check the wiring configurations of external
devices; inputs and outputs, to PLC
modules
5.) After checking the wirings, if it’s all good,
you can use an input device like switch
and light for output device to check the
connection. PLC modules are usually attached with LED indicator.
Shown above is sample of PLC program where the power rail is already
energized, represented by a light green color, but internal I/O’s are still OFF
or de-energized, represented by a dash line. PLC software on this stage is
already ONLINE and CPU is started just waiting signals from I/O.
At this stage, a signal on input side triggers an output. It means an

input device is activated which gives an appropriate signal to LAMP.
Energized input and output is represented by a light green color telling the
programmer that a signal travels from input to output.
PLC SIMULATION
If controller is not available, some manufacturer’s offer a simulation

software on their PLC software for FREE. Though, some are offering a
simulator with additional fee. But as the technology progress, freelance
programmer and groups, offer free simulation software.
Simulation is the imitation of the operation of a real-world process or
system over time. The act of simulating something first requires that a model
be developed; this model represents the key characteristics or
behaviours/functions of the selected physical or abstract system or process.
urtesy of http://www.autoware.com
SAMPLE PLC Simulator for SIEMENS
Majority of PLC simulator not associated to the company itself offers a

simulator which is usually compatible only to a single type of PLC. Though,
some programmer says that their simulator is compatible to almost majority
of PLC but I still didn’t see or use a kind of PLC simulator, maybe in the
future, if there is really one out there.
A PLC simulator makes learning PLCs and debugging easier. PLC

software can be difficult to get the hang of, at times requiring a little practice
in order to understand the correct functions and the full scope of a
programmable logic controller. This is one reason why the use of a PLC
simulator may well be a wonderful teaching method for employees or
students.
The wide use of programmable logic controllers in business and industry
means that there are vast array of different companies who will require
training for their employees. It's simply not practical that a purchase takes
place for each employee who must use the software and study it.
PLC Simulator S7-PLC SIM compatible for Step 7

and TIA Portal Software from SIEMENS
S7-PLC SIM is separate application from SIEMENS Corporation that you

need to install to simulate the actual SIEMENS S7 controllers. It is currently
compatible with Step 7 SIMATIC Manager and TIA Portal software.
Likewise the students of collegiate programs will also be well able to use
the software in studies and for assistance in bug checking or bug tracking.
Many different kinds of businesses depend upon the Programmable logic
controller. Just a few examples of these will be theme parks and various kinds
of machine shops, including some plastic and rubber extrusion companies. In
order to know the foibles of a given software or hardware, it's imperative to
study those.
Those Programmable logic controller developers who write ladder
diagrams for PLC projects should also use a simulator and will find that it
helps them a great deal in bug tracking as well as in the entire process. Each
type of Programmable logic controller simulator software will permit you to
run those programs without having attached hardware to the PLC software.
RS Logix Emulate 5000 Chassis Monitor
RS Logix Emulate 5000 is separate application from Rockwell

Automation, makers of Allen Bradley controllers. You need to purchase this
simulator separately from the controller and programming software, which is
RS Logix 5000, to simulate the actual Allen Bradley controllers.
A separate licensing agreement is also needed if you want to have this
software from Rockwell Automation.
You may use a simulator for training in the PLC, for logic simulators, for
programming tutorials, and for those who must use the PLC. Online is a great
place to find the PLC simulator that you need. In many cases those PLC
simulators are offered free of charge and are open source software so they are
able to be improved upon and worked with so that you can build more than
you originally had from the simulator.
SYSMAC Studio Software by OMRON
SYSMAC Studio Simulation

Unlike with SIEMENS S7-PLCsim and Allen Bradley’s RS Logix Emulate
software’s, OMRON’s simulation software is integrated within its programming
software. OMRON Corporation’s previous version of PLC software does the
same thing where simulator is within the programming software to simulate
the actual controllers.
Sysmac Studio is the current and updated software that the company
promotes to be used on its NJ series of controller.
Many PLCs are fitted with a simulation unit that reads and writes
information directly into the input/output memory and so simulates the
actions of the inputs and outputs. The installed program can thus be run and
inputs and outputs simulated so that they, and all preset values, can be
checked. To carry out this type of operation, the terminal has to be placed in
the correct mode
DEBUGGING
Most engineers have taken a

programming course where they
learned to write a program and
then debug it.
Debugging involves running
the program, testing it for errors,
and then fixing them. Even for an
experienced programmer
it is common to spend more time
debugging than writing software.
Courtesy of http://www.unitytelecom.com
For PLCs this is not acceptable! If you are running the program and it is
operating irrationally it will often damage hardware. Also, if the error is not
obvious, you should go back and re-examine the program design. When a
program is debugged by trial and error, there are probably errors remaining in
the logic, and the program is very hard to trust. Remember, a bug in a PLC
program might kill somebody
Debugging is a methodical process of finding and reducing the number

of bugs, or defects, in a computer program or a piece of electronic hardware,
thus making it behave as expected. Debugging tends to be harder when
various subsystems are tightly coupled, as changes in one may cause bugs to
emerge in another.
MONITORING and FORCING
You have the option of testing the running of your user program on the
device. You can then monitor signal states and values of tags and can assign
values to tags to simulate certain situations in the running of the program.
The program status allows you to monitor the running of the program. You can
display the values of operands and the results of logic operations (RLO)
allowing you to recognize and fix logical errors in your program.
Testing with the watch table

With the watch table, you can monitor and modify the current values of
individual tags in the user program or on a CPU. You can assign values to
individual tags for testing and run the program in a variety of different
situations. You can also assign fixed values to the I/O outputs of a CPU in
STOP mode, for example to check the wiring.
WATCH TABLE
Testing with the force table

With the force table, you can monitor and force the current values of
individual tags in the user program or on a CPU. When you force, you
overwrite individual tags with specified values. This allows you to test your
user program and run through various situations. When forcing, make sure
that you keep to the necessary safety measures for forcing!
FORCE TABLE
EDITING and MODIFYING
Editing is simply the ability to make changes to an existing program

through a variety of functions. Using the editing function, instructions and
rungs can be added or deleted; addresses, data, and bits can be changed.
Again, the editing format varies with different manufacturers and PLC models.
When you program a PLC, several instruction entry modes are available,
depending on the manufacturer and the model of the unit. A personal
computer, with appropriate software, is generally used to program and
monitor the program in the PLC. Additionally, it makes possible offline
programming, which involves writing and storing the program in the personal
computer without its being connected to the PLC and later downloading it to
the PLC.
ourtesy of http://www.thelearningpit.com
With online programming the program can be modified, the modifications

can be tested, and finally they can be accepted or rejected while the PLC is
running. However, offline programming is the safest manner in which to edit a
program because additions, changes, and deletions do not affect the operation
of the system until downloaded to the PLC.
PLC
PLC Software SYSTEM
Online Programming = Editing PLC software while system is working

Offline Programming = Editing PLC software while system is OFF
An online programming mode permits the user to change the program

during machine operation. As the PLC controls its equipment or process, the
user can add, change, or delete control instructions and data values as
desired. Any modification made is executed immediately on entry of the
instruction. Therefore, the user should assess in advance all possible
sequences of machine operation that will result from the change.
Online programming should be done only by experienced personnel who

understand fully the operation of the PLC they are dealing with and the
machinery being controlled. If at all possible, changes should be made offline
to provide a safe transition from existing programming to new programming.
Program
Program
Single Scan Continuous Scan/ Test
Many manufacturers provide a continuous test mode that causes the

processor to operate from the user program without energizing any outputs.
This mode allows the control program to be executed and debugged while the
outputs are disabled. A check of each rung can be done by monitoring the
corresponding output rung on the programming device. A single-scan test
mode may also be available for debugging the control logic. This mode causes
the processor to complete a single scan of the user program each time the
single-scan key is pressed with no outputs being energized.
SELF CHECK 1.3.1
Multiple Choice:
answer sheet.
1.) It is the imitation of the operation of a real-world process or system ove
time.
A. Debugging
B. Emulation
C. Simulation
D. Testing
2.) A software from SIEMENS that used to imitate the actual function o
it’s controller
A. SIM PLC
B. PLC SIM
C. Simulator PLC
D. SIEMENS Simulator
3.) A software from Allen Bradley that used to imitate the actual
function of it’s controller
A. RS Logix Simulate 5000
B. RS Logix Emulate 5000
C. RS Logix Imitate 5000
D. None of the above
4.) A software from OMRON that used to imitate the actual function of
it’s controller especially NJ series and integrated to its software
A. OMRON SYSWAY
B. SYSWAY Studio
C. SYSMAC Studio
D. OMRON SYSMAC
5.) In this mode, the program can be modified, the modifications can b
tested, and finally they can be accepted or rejected while the PLC i
running
A. ONLINE Programming
B. OFFLINE Programming
C. STRAIGHT Programming
D. All of the above
ANSWER KEY 1.3.1
1.) C
2.) B
3.) B
4.) C
5.) A
Job Sheet 1.3.1
Title: Distribution System program
Performance Objectives: Given the discussion on test and debugging

PLC software programs, you should
Create, test and debug a ladder program for a
simple distribution system
Equipment: Laptop
PLC Software
Input Devices; push button and two sensors
Output Devices; two solenoid valve and
double acting cylinder
Steps/ Procedure:

2.) Using a simple distribution system shown at
the photo below. Follow the next instruction.
Legends:
Proximity
Sensors
3.) Assign addresses for input and output

components for input and output devices
4.) Connect your input devices; switch and
proximity sensors to PLC input modules,
check your wiring connections and
configurations.
5.) Connect your output devices; two solenoid
valves to PLC input modules, check your
initialize the process.
comments
8.) Create a new project in your PLC software
application.
9.) Create a program in ladder logic language
using the assigned addresses you made.
comments
11.) Download your program to the controller
12.) Test and debug your developed software
program using simulator, monitoring and
forcing technique.
13.) Call your trainer to check your output
before running the controller and devices.

CRITERIA Yes No
Is program created in accordance to the process

given to them?
Is program created assigned addresses

for input and output components?
Is program created with symbol names

and comments?
Are input and output devices connected

properly in accordance to PLC configurations?
Is program created was a new project?
Is ladder logic programming language used in

creating a program?
Is program downloaded to the controller or PLC?
Is program tested and debugged using

simulator, monitoring and forcing technique?
Trainer:__________________________________________Date:______________
Safety precautions in programming and debugging the

MUST be able to:
1.) Explain procedures on making a safety PLC program

2.) Discussed safety precautions in programming and debugging
3.) Analyze ergonomics hazards available in programming and
debugging PLC program
Safety procedures on making, testing and debugging your PLC program

will be discussed in this section. Ergonomics hazards applicable on making or
developing a program using a Personal Computer or Laptop, which is the most
common programmable device used, will also be considered.
SAFE PROGRAM
A careful, structured approach to designing software will cut the total
development time, and result in a more reliable system.
The fundamental rule for defining the program strategy is think first,
program later. Consider alternative approaches to solving the problem and
allow time to polish the solution algorithm before trying to program the
control function. Adopting this philosophy will shorten programming time,
reduce debugging time, accelerate start-up, and focus attention where it is
needed—on design when designing and on programming when programming.
THINK FIRST, PROGRAM LATER

Safety considerations should be developed as part of the PLC program.
A PLC program for any application will be only as safe as the time and thought
spent on both personnel and hardware considerations make it.
One such consideration involves the use of a motor starter auxiliary seal-in
contact shown below.
Motor starter programmed using the starter auxiliary seal-in contact
In place of the programmed contact referenced to the output coil

instruction. The use of the field-generated starter auxiliary contact status in
the program is more costly in terms of field wiring and hardware, but it is safer
because it provides positive feedback to the processor about the exact status of
the motor.
Assume, for example, that the OL contact of the starter opens under an
overload condition. The motor, of course, would stop operating because power
would be lost to the starter coil. If the program was written using an examine-
on contact instruction referenced to the output coil instruction as the seal-in
for the circuit, the processor would never know that power had been lost to the
motor. When the OL was reset, the motor would restart instantly, creating a
potentially unsafe operating condition.
FAIL SAFE PROGRAM

Programs should be designed so that they check for problems, and shut
down in safe ways. Most PLC’s also have imminent power failure sensors; use
these whenever danger is present to shut down the system safely.
Some design rules that will help improve the safety of a system are listed below
• Proper programming techniques and modular programming will help

detect possible problems on paper instead of in operation.
• Modular well designed programs.
• Use predictable, non-configured programs.
• Make the program inaccessible to unauthorized persons.
• Check for system OK at start-up.
• Use PLC built in functions for error and failure detection.
Since PLC ladder programming is simply an extension of hard wiring, it

is important to consider failsafe wiring when programming also. Consider the
start/stop program rung shown in the figure below. This rung will appear to
work normally; that is, when the START is momentarily pressed, relay RUN
switches on and remains on. When STOP is pressed, RUN switches off.
However, consider what happens when both START and STOP are pressed
simultaneously. For this program, START will override STOP and RUN will
switch on as long as START is pressed.
Unsafe START/STOP Program
Now consider an improved version of this program shown below. Notice

that by moving the STOP contact into the main part of the rung, the START
switch can no longer override the STOP. This program is considered safer
than the one shown above
Improved START/STOP Program with Override STOP

FORCING
The force function is essentially a manual override control function.
Forcing allows the PLC user to turn an external input or output on or off from
the keyboard of the programming device. This is accomplished regardless of
the actual state of the field device. The forcing capability allows a machine or
process to continue operation until a faulty field device can be repaired. It is
also valuable during start-up and troubleshooting of a machine or process
to simulate the action of portions of the program that have not yet been
implemented.
Forcing an Input ON
Forcing inputs manipulates the input image table file bits and thus
affects all areas of the program that use those bits. The forcing of inputs is
done just after the input scan. When we force an input address, we are forcing
the status bit of the instruction at the I/O address to an ON or OFF state.
Figure above illustrates how an input is forced ON.
Forcing outputs affects only the addressed output terminal. Therefore,
since the output image table file bits are unaffected, your program will be
unaffected. The forcing of outputs is done just before the output image table
file is updated. When we force an output address, we are forcing only the
output terminal to an on or off state. The status bit of the output instruction at
the address is usually not affected. Figure below illustrates how an output is
forced ON.
Forcing an Output ON
FORCING SAFETY MEASURES
• Before you start the "Force" function, you should ensure that no
one else is currently executing this function on the same CPU.
• Forcing can only be stopped by clicking the "Stop forcing" icon or

using the "Online > Force > Stop forcing" command. Closing the
active force table does not stop the forcing!
• Forcing cannot be undone!
• Review the differences between “modifying tags" and "forcing tags".
• If a CPU does not support the "Force" function, the relevant icons
cannot be selected.
• If the function "Enable peripheral outputs" is active on your CPU,

then forcing is not possible on this CPU. If desired, deactivate this
function in the watch table.
FORCING SAFETY
ERGONOMICS HAZARDS
Knowing the ergonomics hazards for operating your programmable

device like PC and laptop, because of long time programming, would help your
improve your health and safety.
Ergonomics is the science of fitting the job to the worker. When there is a
mismatch between the physical requirements of the job and the physical
capacity of the worker, work-related musculoskeletal disorders (MSDs) can
result. Ergonomics encompasses the practice of designing equipment and work
tasks to conform to the capability of the worker. It provides a means for
adjusting the work environment and work practices to prevent injuries before
they occur.
Courtesy of http://www.experientia.com
HAND INJURY
Musculoskeletal disorders (MSDs) affect the muscles, nerves and

tendons. Work related MSDs (including those of the neck, upper extremities
and low back) are one of the leading causes of lost workday injury and illness.
Workers in many different industries and occupations can be exposed to risk
factors at work, such as lifting heavy items, bending, reaching overhead,
pushing and pulling heavy loads, working in awkward body postures and
performing the same or similar tasks repetitively. Exposure to these known
risk factors for MSDs increases a worker's risk of injury.
Guide to Address Ergonomics-Related Hazards
with Computer Work Station
This ergonomics-related hazard identification Tool is provided to help

you identify ergonomics-related hazards that may be present for jobs/tasks
performed at an individual’s computer workstation, where a specific worker
may be at an increased risk of developing an Musculoskeletal Injury (MSI). The
tool only identifies whether hazards exist. It does not assess the level of risk,
and this tool alone should not be used to determine if ergonomics-related
hazard controls should be implemented.
CHAIR RELATED
KEYBOARD AND MOUSE OR OTHER INPUT DEVICE RELATED
MONITOR AND WORKSTATION RELATED
ENVIRONMENT RELATED
SELF CHECK 1.3.2
Multiple Choice:
answer sheet.
1.) A science of fitting the job to the worker.
A. Economics
B. Ergonomics
C. Engineering
D. Physics
2.) It only affects the addressed output terminal
A. Forcing outputs
B. Forcing inputs
C. Forcing I/O
D. Forcing device
3.) MSD means
A. Musculoskeletal dysfunction
B. Musculoskeletal disorders
C. Musculoskeletal disturbance
D. None of the above
4.) Feet cannot rest on the floor; this type of ergonomics hazards is
related to what?
A. Keyboard and mouse
B. Monitor
C. Environment
D. Chair
5.) Too mouch/ too little light; this type of ergonomics hazards is
related to what?
A. Chair
B. Keyboard and Mouse
C. Environment
D. Monitor and workstation
ANSWER KEY 1.3.2
1.) B
2.) A
3.) B
4.) D
5.) C
LEARNING OUTCOME # 4: MAINTAIN AND DOCUMENT
DEVELOPED SOFTWARE
PROGRAM
CONTENTS:
1. Procedures and techniques in maintaining programmable controls

2. Safety precautions in performing maintenance of programmable controls
3. Documentation of system and developed software program
1. Procedure and techniques in maintaining programmable controls are

correctly applied.
2. Performance of the programmable controls conformed with the
manufacturer’s specification
3. The final software program flowchart is prepared according to the set
requirement
4. Notations and descriptions are incorporated into the program for user-
friendliness
5. Copy of the software program and the external devices assignment are
prepared in softcopy and printed format for the user
CONDITIONS:
1. EQUIPMENT
components
b. CPU
c. Power supply
d. Input and output
2. INSTRUMENT:
Multi-tester

components and buzzer.
12 VDC power supply
Long nose pliers
Diagonal pliers
Set of screw driver
Allen wrenches
Soldering iron

a. Wires
b. Terminal blocks
c .Office supply
d .Alligator clips
METHODOLOGIES:
2. Demonstration
4. Multimedia
ASSESSMENT METHODS:
1. Written test
2. Practical test
4. Interview (oral)
Learning Outcome 4
MAINTAIN AND DOCUMENT DEVELOPED SOFTWARE PROGRAM

Procedures and techniques in Information sheet and check
maintaining programmable yourself by answering the Self
controls Check.
2. Answer Self check 1.4.1 You must answer the questions
correctly before proceeding to
Compare your answers with the next activity.
Answer Key 1.4.1
3. Perform Job Sheet 1.4.1 on In this Learning Outcome, you
Maintain and Troubleshoot PLC will analyze techniques and
modules procedures in maintaining and
troubleshooting programmable
Evaluate your output using the controls. And evaluate proper
Performance Criteria Checklist documentation in a
1.4.1 before showing it to your programmable control system.
trainer
4. Read Information Sheet 1.4.2 on Understanding the content of
Safety precautions in performing information presented would be
maintenance of programmable your foundation on steeping
controls the next learning outcome.
Task Sheet, Operation Sheet
Compare your answers with and Job Sheet will help you to
Answer Key 1.4.2 practice to skills
6. Read Information Sheet 1.4.3 on
Documentation of system and The performance Criteria
developed software program checklist will guide and help
7. Answer Self check 1.4.3 you evaluate your work as you
Answer Key 1.4.3 Evaluate your own work using
8. Perform Job Sheet 1.4.3 on the Performance Criteria. When
Documentation of PLC you are ready, present your
distribution system work to your trainer for final
Performance Criteria Checklist If you have any questions or
trainer

LO, you are ready to proceed to
the next module on
Maintaining and Repairing
Mechatronics Devices and
Systems
Procedures and techniques in maintaining programmable
controls

MUST be able to:
1.) Discuss the procedures and techniques on how to maintain a

programmable controller
2.) Discuss the procedures and techniques on how to troubleshoot
a programmable controller
Maintaining a programmable controller is not an easy task to do; many

considerations and preparation are need to accomplished. In this section we
will tackle procedures in maintaining and trouble shooting a Programmable
Logic Controller (PLC).
PREVENTIVE MAINTENANCE
Preventive maintenance of programmable controller systems includes only

a few basic procedures, which will greatly reduce the failure rate of system
components.
Preventive maintenance for the PLC system should be scheduled
with the regular machine or equipment maintenance, so that the equipment
and controller are down for a minimum amount of time.
However, the schedule for PLC preventive maintenance depends on the
controller’s environment—the harsher the environment, the more frequent the
maintenance. The following are guidelines for preventive measures:
 Periodically clean or replace any filters that have been installed in

enclosures at a frequency dependent on the amount of dust in the
area. Do not wait until the scheduled machine maintenance to check
the filter. This practice will ensure that clean air circulation is
present inside the enclosure.
Courtesy of http://www.wolfautomation.com
 Do not allow dirt and dust to accumulate on the PLC’s components;
the central processing unit and I/O system are not designed to be
dust proof. If dust builds up on heat sinks and electronic circuitry, it
can obstruct heat dissipation, causing circuit malfunction.
Furthermore, if conductive dust reaches the electronic boards, it can
cause a short circuit, resulting in possible permanent damage to the
circuit board.
Courtesy of http://cdn1.mos.techradar.futurecdn.net
Avoid dust and dirt in PLC
 Periodically check the connections to the I/O modules to ensure that

all plugs, sockets, terminal strips, and modules have good
connections. Also, check that the module is securely installed.
Perform this type of check more often when the PLC system is located
in an area that experiences constant vibrations, which could loosen
terminal connections.
Courtesy of mmu.ic.polyu.edu.hk
I/O checking
 Ensure that heavy, noise-generating equipment is not located too
close to the PLC.
Courtesy of http://www.scantime.co.uk
Avoid noise near PLC
 Make sure that unnecessary items are kept away from the equipment
inside the enclosure. Leaving items, such as drawings, installation
manuals, or other materials, on top of the CPU rack or other rack
enclosures can obstruct the airflow and create hot spots, which can
cause system malfunction.
Courtesy of http://wolocklott.com
Clean and Order PLC enclosure

 If the PLC system enclosure is in an environment that exhibits
vibration, install a vibration detector that can interface with the PLC
as a preventive measure. This way, the programmable controller can
monitor high levels of vibration, which can lead to the loosening of
connections.
Courtesy of http://www.ingenierosdelcobre.cl
Vibration Detector
 Keep a master copy of operating programs used.
STORAGE MEDIA
SPARE PARTS
It is a good idea to keep a stock of replacement parts on hand. This

practice will minimize downtime resulting from component failure. In a failure
situation, having the right spare in stock can mean a shutdown of only
minutes, instead of hours or days. As a rule of thumb, the amount of a spare
part stocked should be 10% of the number of that part used. If a part is used
infrequently, then less than 10% of that particular part can be stocked.
Main CPU board components should have one spare each, regardless of
how many CPUs are being used. Each power supply, whether main or auxiliary
should also have a backup. Certain applications may require a complete CPU
rack as a standby spare. This extreme case exists when a downed system must
be brought into operation immediately; leaving no time to determine which CPU
board has failed.
Courtesy of http://pwp.etb.net.co
SPARE PARTS
REPLACEMENT OF I/O MODULES

If a module must be replaced, the user should make sure that the
replacement module being installed is the correct type. Some I/O systems allow
modules to be replaced while power is still applied, but others may require that
power be removed. If replacing a module solves the problem, but the failure
reoccurs in a relatively short period, the user should check the inductive loads.
The inductive loads may be generating voltage and current spikes, in
which case, external suppression may be necessary. If the module’s fuse blows
again after it is replaced, the problem may be that the module’s output current
limit is being exceeded or that the output device is shorted.
TROUBLESHOOTING
In the event of a PLC fault, you should employ a careful and systematic
approach to troubleshoot the system to resolve the problem. PLCs are relatively
easy to troubleshoot because the control program can be displayed on a
monitor and watched in real time as it executes. If a control system has been
operating, you can be fairly confident of the accuracy of the program logic. For
a system that has never worked or is just being commissioned, programming
errors should be considered.
When a problem occurs, the first step in the troubleshooting procedure is
to identify the problem and its source. The source of a problem can generally be
narrowed down to the processor module, I/O hardware, wiring, machine inputs
or outputs, or ladder logic program. Once a problem is recognized, it is usually
quite simple to deal with. The following sections will deal with troubleshooting
these potential problem areas.
PROCESSOR Module
The processor is responsible for the self-detection of potential problems. I
performs error checks during its operation and sends status information to
indicators that are normally located on the front of the processor module. You
can diagnose processor faults or obtain more detailed information about the
processor by accessing the processor status through programming software.
Figure below shows sample diagnostics LEDs found on a processor module.
On the SIEMENS CPU controller different indicator are incorporated to its

operation. You have to know and understand each indicator and it’s
corresponding designation to avoid complications and damage to the device.
Below are LED designations and its meaning.
The processor then monitors itself continually for any problems that
might cause the controller to execute the user program improperly. Depending
on the controller, a set of fault relay contacts may be available. The fault relay
is controlled by the processor and is activated when one or more specific fault
conditions occur. The fault relay contacts are used to disable the outputs and
signal a failure .
The PLC processor hardware is not likely to fail because today’s
microprocessors and microcomputer hardware are very reliable when operated
within the stated limits of temperature, moisture, and so on. The PLC processor
chassis is typically designed to withstand harsh environments .
CPU MODE OF OPERATION
We have three modes of operation for S7-300 CPU; these are RUN, STO
and Memory Reset. Further explanations on each modes are given below.
GROUND LOOP
A ground loop condition occurs when two or more electrical paths exist in
a ground line. For example, in the figure below, the transducers and
transmitter are connected to ground at the chassis (or device enclosure) and
connected to an analog input card through a shielded cable. The shield
connects to both chassis grounds, thereby creating a path for current to flow
from one ground to another since both grounds have different potentials.
The current flowing through the shield could be as high as several
amperes, which would induce significant magnetic fields in the signal
transmission. This could create interference that would result in a possible
misreading of the analog signal. To avoid this problem, the shield should be
connected to ground on only one side of the chassis, preferably the PLC side.
In the example, the shield should only be connected to ground at the
analog input interface.
Ground loop created by shielded cable grounded at both ends
To check for a ground loop, disconnect the ground wire at the groun
termination and measure the resistance from the wire to the termination poin
where it is connected. The meter should read a large ohm value. If a low ohm
value occurs across this gap, circuit continuity exists, meaning that the system
has at least one ground loop.
Procedure for identifying ground loops
PLC INPUTS
If the controller is operating in the RUN mode but output devices do no

operate as programmed, the faults could be associated with any of th
following:
 Input and output wiring between field devices and
modules
 Field device or module power supplies
 Input sensing devices
 Output actuators
 PLC I/O modules
 PLC processor

Narrowing down the problem source can usually be accomplished b
comparing the actual status of the suspect I/O with controller statu
indicators. Usually each input or output device has at least two statu
indicators. One of these indicators is on the I/O module; the other indicator i
provided by the programming device monitor.
Checking for Input Malfunctions

Techniques on Checking Input Malfunctions
 When input hardware is suspected to be the source of a problem,

the first check is to see if the status indicator on the input modul
illuminates when it is receiving power from its corresponding inpu
device(e.g., pushbutton, limit switch).
• If the status indicator on the input module does not illuminate whe
the input device is on, take a voltage measurement across the inpu
terminal to check for the proper voltage level.
• If the voltage level is correct, then the input module should be
replaced.
• If the voltage level is not correct, power supply, wiring, or input
device may be faulty.
If the programming device monitor does not show the correct statu
indication for a condition instruction, the input module may not be convertin
the input signal properly to the logic level voltage required by the processo
module. In this case, the input module should be replaced. If a replacemen
module does not eliminate the problem and wiring is assumed to be correct
then the I/O rack, communication cable, or processor should be suspected.
PLC Input troubleshooting guide

PLC OUTPUTS
PLC output interfaces also contain status indicators that provide usefu
troubleshooting information. Like the troubleshooting of PLC inputs, the firs
step in troubleshooting outputs is to isolate the problem to either the module
the field device, or the wiring. At the output module, ensure that the sourc
power for switching the output is at the correct level. In a 120 VAC system, thi
value should be within 10% of the rated value (i.e., between 108 and 132 volt
AC).
Also, examine the output module to see if it has a blown fuse. If it doe
have a blown fuse, check the fuse’s rated value. Furthermore, check the outpu
device’s current requirements to determine if the device is pulling too much
current. If the output module receives the command to turn ON from th
processor yet the module’s output status does not turn ON accordingly, then
the output module is faulty. If the indicator turns ON but the field device doe
not energize, check for voltage at the output terminal to ensure that th
switching device is operational.
PLC Output troubleshooting guide

If no voltage is present, then the module should be replaced. If voltage i
present, then the problem lies in the wiring or the field device. At this point
make sure that the field wiring to the module’s terminal or to the terminal bloc
has a good connection and that no wires are broken. After checking the module
check that the field device is working properly. Measure the voltage coming t
the field device while the output module is ON, making sure that the return lin
is well connected to the device.
If there is power yet the device does not respond, then the field device i
faulty. Another method for checking the field device is to test it without usin
the output module. Remove the output wiring and connect the field devic
directly to the power source. If the field device does not respond, then it i
faulty. If the field device responds, then the problem lies in the wiring between
the device and the output module. Check the wiring, looking for broken wire
along the wire path.
Troubleshooting tree for a discrete output module

When a problem occurs, the best way to proceed is to try to logicall
identify the devices or connections that could be causing the problem rathe
than arbitrarily checking every connection, switch, motor, sensor, I/O module
and so on. First, observe the system in operation and try to describe th
problem. Using these observations and the description of the control system
you should identify the possible sources of trouble. Compare the logic status o
the hardwired inputs and outputs to their actual state, as illustrated below
Any disagreements indicate malfunctions as well as their approximat
location. Some of your troubleshooting can be accomplished by interpreting th
status indicators on the I/O modules. The key is to know whether the statu
indicators are telling you that there is a fault or that the system is normal.
General methods of Troubleshooting

Input troubleshooting guide
Output troubleshooting guide

TROUBLESHOOTING USING FLOWCHART ANALYSIS
As discussed in early section, flowchart is an important and easy to understand

tool in analysing certain sequence and process. Some of the common problem
encountered in troubleshooting a PLC is simplified using flowchart.
POWER LED IS TURNED OFF

RUN INDICATOR NOT LIT
PROGRAM CANNOT BE WRITTEN TO PLC
ERR/ALM INDICATOR FLASHING
SOLENOID MALFUNCTIONING Part 1
SOLENOID MALFUNCTIIONING Part 2
The best method for diagnosing input/output malfunctions is to isolate th

problem to the module, the field device, or the wiring. If both power and logi
indicators are available, then module failures become clear. The first step in solvin
the problem is to take a voltage measurement to determine if the proper voltage leve
is present at the input or output terminal. If the voltage is adequate at the termina
and the module is not responding, then the module should be replaced. If th
replacement module has no effect, then field wiring may be the problem.
A proper voltage level at the output terminal while the output device is OFF als
indicates an error in the field wiring. If an output rung is activated but the LED
indicator is OFF, then the module is faulty. If a malfunction cannot be traced to th
I/O module, then the module connectors should be inspected for poor contact o
misalignment. Finally, check for broken wires under connector terminals and cold
solder joints on module terminals.
SELF CHECK 1.4.1
TRUE or FALSE
Direction: In the problem stated below, read carefully and if the statement is
correct write TRUE as your answer otherwise FALSE.
1. Preventive maintenance will not reduce the failure rate of system

components.
2. Heavy, noise-generating equipment should be located close to the PLC
3. If the PLC system enclosure is in an environment that exhibits
vibration, install a CCTV that can interface with the PLC
as a preventive measure.
4. Leaving items, such as drawings, installation manuals, or other materials,
on top of the CPU rack or other rack enclosures can obstruct the airflow
and create hot spots, which can cause system improvement.
5. In a failure situation, having the right spare in stock can mean a shutdown
of only minutes, instead of hours or days.
6. The amount of a spare part stocked should be 20% of the number of that
part used. If a part is used infrequently, then less than 10% of that
particular part can be stocked.
7. The processor is responsible for the self-detection of potential problems.
It performs error checks during its operation and sends status
information to indicators that are normally located on the front of the
processor module.
8. The PLC processor hardware is likely to fail because today’s
microprocessors and microcomputer hardware are very reliable when
operated within the stated limits of temperature, moisture, and so on.
9. To check for a ground loop, disconnect the ground wire at the ground
termination and measure the resistance from the wire to the termination
point where it is connected. The meter should read almost zero ohm value.
10. Usually each input or output device has at least two status indicators.
ANSWER KEY 1.4.1
1. FALSE
2. FALSE
3. FALSE
4. FALSE
5. TRUE
6. FALSE
7. TRUE
8. FALSE
9. FALSE
10. TRUE
Job Sheet 1.4.1
Title: Maintain and Troubleshoot PLC modules
Performance Objectives: Given the discussion on maintaining and

troubleshooting PLC system, you should
diagnose a PLC system
Equipment: Laptop
PLC Trainer
Multi-Tester
Selector switch
Steps/ Procedure:
1.) Prepare your multi-tester

2.) Connect your input device; selector switch to
the input module of your PLC
3.) Check your configuration and wirings of
selector switch
4.) Turn ON PLC trainer and PLC power supply
5.) Set your multi-tester to DC voltage settings
6.) Turn ON your switch.
7.) Connect one pin of your tester to PLC
common and the other one to input module
port.
8.) Check the output voltage reading, it should
be within 5% tolerance of 24Vdc.
9.) Do procedures 7 and 8 to the remaining ports
of input module.
10.) Call your trainer to check your findings

CRITERIA Yes No
Is the input device connected to input module a

selector switch?
Is selector switch configuration and wirings

to PLC module correct?
Are PLC trainer and PLC power supply turned ON?
Is multi-tester’s setting correct?
Is selector switch turn ON?
Is multi-tester and PLC input module testing

connection correct?
Is the output voltage within the tolerable voltage?
Are all ports of input module checked?
Trainer:__________________________________________Date:______________
Safety precautions in performing maintenance of
programmable controls

MUST be able to:
1.) Discuss the safety precautions in performing maintenance of

2.) Identify safety methods on maintaining and troubleshooting
Safety procedures and precautions will be tackled in this section.

Making a workplace a safer place for workers, visitors and everyone within the
job site will also covered. Following safety procedures is an important aspects
if you want to have a less and almost free from accident working environment.
SAFE SYSTEMS
Modern safety legislation charges employers with duties that include
making the workplace safe and free of risks to health, ensuring that plant and
machinery are safe and that safe systems of work are established and followed.
There is thus a need to assess the risks in the workplace.
Courtesy of http://machinedesign.com
Safety Life Cycle

This means looking for hazards, that is, anything that can cause harm,
deciding who might be harmed and how, evaluating the risks that somebody
will be harmed by a hazard and whether existing precautions are adequate or
whether more needs to be done to reduce the chance of harm occurring,
recording the findings, and reviewing and revising the assessment, if
necessary.
Thus, for example, issues such as emergency stops and access doors on
equipment need to be considered, the risks assessed, and safe systems then
designed. With regard to access doors on equipment, switch contacts can be
used on such doors so that the system is stopped if the doors are not correctly
guarding equipment.
Courtesy of http://www.exida.com Courtesy of http://www.famictech.com
An important standard is IEC 61508: Functional Safety of

Electrical/Electronic/ Programmable Electronic Safety-Related Systems which is
discussed in the previous section. The standard is in seven parts, as follows:
Part 1: General requirements; Part 2: Requirements for E/E/PE safety-related
systems; Part 3: Software requirements; Part 4: Definitions and abbreviations;
Part 5: Examples of methods for the determination of safety integrity levels;
Part 6: Guidelines on the application of IEC 61508-2 and IEC 61508-3; and
Part 7: Overview of techniques and measures. To provide functional safety of a
machine or plant, the safety-related protective or control system must function
correctly, and when a failure occurs it must operate so that the plant or
machine is brought into a safe shutdown state.
SAFETY CIRCUITRY
The PLC system should contain a sufficient number of emergency circuits
to either partially or totally stop the operation of the controller or the
controlled machine or process.
These circuits should be routed outside the controller, so that the user
can manually and rapidly shut down the system in the event of total controller
failure.
Emergency circuits hardwired to the PLC
EMERGENCY STOPS
The system should have emergency stop circuits for every machine
directly controlled by the PLC. To provide maximum safety, these circuits
should not be wired to the controller, but instead should be left hardwired.
Master or Safety Control Relays
Master control relay (MCR) and safety control relay (SCR) circuits provide
an easy way to remove power from the I/O system during an emergency
situation. These control relay circuits can be de-energized by pushing any
emergency stop switch connected to the circuit.
Master start control for a PLC with MCRs enabling input and output power
Emergency Power Disconnect
The power circuit feeding the power supply should use a properly rated
emergency power disconnect, thus provides a way to remove power from the
entire programmable controller system. Sometimes, a capacitor (0.47 µF for 120
VAC,0.22 µF for 220 VAC) is placed across the disconnect to protect against an
outrush condition.
Circuit that enables/disables I/O power through MCRs and

PLC fault contact detection.
FAIL-SAFE DESIGN
All systems will fail eventually. A fail-safe design will minimize the
damage to people and equipment. Consider the selection electrical connections.
If wires are cut or connections fail, the equipment should still be safe. For
example, if a normally closed stop button is used, and the connector is broken,
it will cause the machine to stop as if the stop button has been pressed.
NO (Normally open) - When wiring switches or sensors that start actions,

use normally open switches so that if there is a
problem the process will not start.
NC (Normally Closed) - When wiring switches that stop processes use

Normally closed so that if they fail the process wil
stop. E-Stops must always be NC, and they must
cut off the master power, not just be another
input to the PLC.
Hardware
• Use redundancy in hardware.

• Directly connect emergency stops to the PLC, or the main power supply
• Use well controlled startup procedures that check for problems.
• Shutdown buttons must be easily accessible from all points
around the machine.
SAFETY RULES SUMMARY
A set of safety rules was developed by Jim Rowell (http://www.mrplc.com

"Industrial Control Safety; or How to Scare the Bejesus Out of Me").
These are summarized below.
Grounding and Fuses

• Always ground power supplies and transformers.
• Ground all metal enclosures, casings, etc.
• All ground connections should be made with dedicated wires that are
exposed so that their presence is obvious.
• Use fuses for all AC power lines, but not on the neutrals or grounds.
• If ground fault interrupts are used they should respond faster than the
control system.
Hot vs. Neutral Wiring

• Use PNP wiring schemes for systems, especially for inputs that can
Initiate actions.
• Loads should be wired so that the ground/neutral is always connected,
and the power is switched.
• Sourcing and sinking are often confused, so check the diagrams or look
for PNP/NPN markings.
AC / DC
• Use lower voltages when possible, preferably below 50V.
• For distant switches and sensors use DC.
Devices
• Use properly rated isolation transformers and power supplies for contro
systems. Beware autotransformers.
• Use Positive or Force-Guided Relays and contacts can fail safely and
prevent operation in the event of a failure.
• Some ’relay replacement’ devices do not adequately isolate the inputs
and output and should not be used in safety critical applications.
Starts
• Use NO buttons and wiring for inputs that start processes.
• Select palm-buttons, and other startup hardware carefully to ensure
That they are safety rated and will ensure that an operator is clear of
the machine.
• When two-hand start buttons are used, use both the NO and NC
outputs for each button. The ladder logic can then watch both for a
completed actuation.
Stops
• E-stop buttons should completely halt all parts of a machine that are
not needed for safety.
• E-stops should be hard-wired to kill power to electrically actuated sys-
tems.
• Use many red mushroom head E-stop buttons that are easy to reach.
• Use red non-mushroom head buttons for regular stops.
• A restart sequence should be required after a stop button is released.
• E-stop buttons should release pressure in machines to allow easy
’escape’.
• An ’extraction procedure’ should be developed so that trapped workers
can be freed.
• If there are any power storage devices (such as a capacitor bank) make
sure they are disabled by the E-stops.
• Use NC buttons and wiring for inputs that stop processes.
• Use guards that prevent operation when unsafe, such as door open
detection.
• If the failure of a stop input could cause a catastrophic failure, add a
backup.
Construction
• Wire so that the power enters at the top of a device.
• Take special care to review regulations when working with machines
that are like presses or brakes.
• Check breaker ratings for overload cases and supplemental protection.
• A power disconnect should be located on or in a control cabinet.
conduits or raceways for different voltages.
• Wire insulation should be rated for the highest voltage in the cabinet.
• Use colored lights to indicate operational states. Green indicates in
operation safely, red indicates problems.
• Construct cabinets to avoid contamination from materials such as oils.
• Conduits should be sealed with removable compounds if they lead to
spaces at different temperatures and humidity levels.
• Position terminal strips and other components above 18" for ergonomic
reasons.
• Cabinets should be protected with suitably rated fuses.
• Finger sized objects should not be able to reach any live voltages in a
finished cabinet, however DMM probes should be able to measure
voltages.
LOCKOUT-TAGOUT (LOTO) or LOCK and TAG
A safety procedure which is used in industry and research settings to

ensure that dangerous machines are properly shut off and not started up
again prior to the completion of maintenance or servicing work. It requires that
hazardous power sources be "isolated and rendered inoperative" before any
repair procedure is started.
"Lock and tag" works in conjunction with a lock usually locking the
device or the power source with the hasp, and placing it in such a position
that no hazardous power sources can be turned on. The procedure requires
that a tag be affixed to the locked device indicating that it should not be
turned on.
Courtesy of http://www.healthandsafetyontario.ca
Sequence of Lockout or Tag-out System Procedures
1. Notify all affected employees that a lockout or tag-out system is going

to be used. The authorized employee shall know the type and
magnitude of energy that the machine or equipment uses and shall
understand its hazards
2. If the machine or equipment is operating, shut it down by the normal
stopping procedure (depress stop button, open toggle switch, etc.).
3. Operate the switch, valve, or other energy isolating device(s) to isolate
the equipment from its energy source(s). Dissipate, deactivate or
restrain stored energy (such as that in springs, elevated machine
members, rotating flywheels, hydraulic systems, and air, gas, steam,
or water pressure, etc.) by methods such as repositioning, blocking,
bleeding down, etc.
4. Lockout or tagout the energy isolating devices with assigned
individual lock(s) or tag(s). Use the method(s) selected; i.e., locks, tags
and additional safety measure, etc.
5. This ensures personnel protection, and acts as a check on the
disconnection of the energy sources. Operate the push button or
other normal operating controls to make certain the equipment will
not operate.
Caution: Return operating control(s) to "neutral" or "off" position after
the test.
6. The equipment is now locked out or tagged out.
Photo courtesy of http://i611.photobucket.com

LACKOUT-TAGOUT-TRYOUT OR LACK, TAG AND TRY
(LOTOTO/LTT)
Lock, Tag, and Try (LTT) is the approved method for securing hazardous
energy sources in order to provide personal protection while performing
maintenance and service work. It is an updated and upgrade version of
Lackout-Tagout (LOTO).
Lockout: use a padlock to block the switch or valve (isolating device).

- Act of isolating an energy source and physically locking the
isolating device in the ‘off’ or ‘safe’ position.
Courtesy of https://www.acklandsgrainger.com
Courtesy of http://www.labelzone.co.uk
Tagout: place a warning tag to inform people about energy status.

- Act of isolating an energy source and/or communicating
a condition or situation.
Courtesy of http://www.geneseo.edu
Tryout: verify zero energy status
- Act of testing the energy state and administrative controls to ensure
zero energy state.
Courtesy of http://roymayall.files.wordpress.com
LockOut-TagOut-TryOut Process Steps:
1. Determine the Hazards

2. Determine the Need for a Written Work Control Document
3. Coordinate Work/Notify Others
4. Isolate Energy Sources
5. Remove and Release Potential Energy
6. Verify Lockout and Try (Attempt to Restart)
7. Perform the Work
8. Prepare to Re-Energize
9. Remove Locks and Tags
10. Energize
SELF CHECK 1.4.2
TRUE or FALSE
1. IEC 61308 standard provides functional safety of a machine or plant, the

safety-related protective or control system must function correctly, and
when a failure occurs it must operate so that the plant or machine is
brought into a safe shutdown state
2. Master control relay (MCR) and safety control relay (SCR) circuits provide
an easy way to remove power from the I/O system during an emergency
situation
3. Emergency stop provides maximum safety, these circuits should be wired to

the controller, should not be left hardwired
4. All systems especially PLC system will not fail.
5. When wiring switches or sensors that start actions, use normally open
switches so that if there is a problem the process will not start.
6. When wiring switches that stop processes use normally closed so that if
they fail the process will stop.
7. In LockOut-TagOut, operating control(s) must be returned to to "neutral" or

"off" position after the test.
8. The authorized employee shall know the type and magnitude of energy that
the machine or equipment uses and shall understand its hazards
9. Shutdown buttons must be easily accessible from all points around the
machine.
10. Some ’relay replacement’ devices do not adequately isolate the inputs
and output and should not be used in safety critical applications
ANSWER KEY 1.4.2
1. FALSE
2. TRUE
3. FALSE
4. FALSE
5. TRUE
6. TRUE
7. TRUE
8. TRUE
9. TRUE
10. TRUE
Documentation of system and developed
software program

MUST be able to:
1.) Explain system documentation procedures

2.) Discussed process considerations and materials preparation
3.) Discussed how to document all aspects of a PLC from system
configuration to register assignments
While proper PLC programming is important for a well-run application

program, all of that work is lost without adequate system documentation.
Without documentation, system activities, such as changes, installation,
and maintenance, are difficult to accomplish. In this section, we will explain
how to document all aspects of a PLC.
DOCUMENTATION
Documentation is an orderly collection of recorded information about
both the operation of a machine or process and the hardware and software
components of its control system. These records are a valuable reference
during system design, installation, start-up, debugging, and maintenance.
To the system designer, documentation should be a working tool that

is used throughout the design phase. If the various documentation
components are created and kept current during system design, they will
provide the following benefits:
 They will provide an easy way to communicate accurate information

to all those involved with the system.
 They will serve as a reference to the designer during and after the
design phase.
 They will help the designer, or someone else, answer questions,
diagnose possible problems, and modify the program if requirements
change.
 They will serve as training material both for the operators who will
interface with the system and for the maintenance personnel who will
maintain it.
 They will allow the system to be reproduced or altered to serve other
purposes.
Proper documentation comes from the compilation of hardware, as
well as software, information. The engineering or electrical group that
designs the system usually provides this information to the end user.
Although documentation is often thought of as extraneous, it is actually a
vital system component and a good engineering practice.
DOCUMENTATION COMPONENTS
System Abstract
System Configuration
I/O Wiring Connection Diagram
I/O Address assignments
Internal Storage address assignments
Storage Register Assignments
Variable Declaration
Control Program Printout
Stored Control Program
Components of a Good PLC documentation package
Courtesy of http://infosys.beckhoff.com
STEPS FOR DOCUMENTATION
SYSTEM ABSTRACT
A good system design starts with a thorough understanding of the
problem and a good description of the process to be controlled. This
assessment is followed by a systematic approach that will lead to the
implementation of the control system. Once the system is finished, the
personnel involved in the design should provide a global description, or
abstract, of the scheme and procedure used to control the process.
A system abstract should provide the following:

 a clear statement of the control problem or task
 a description of the design strategy or philosophy used to
implement the solution to the problem, which defines the
functions of the major hardware and software components of the
system, as well as why they were selected
 a statement of the objectives to be achieved
Sample of System Abstract

SYSTEM CONFIGURATION
As the name implies, the system configuration is a system
arrangement diagram. In fact, it is a pictorial drawing of the hardware
elements defined in the system abstract. It shows the location, simplified
connections, and minimum details of the system’s major hardware
components (i.e., CPU, subsystems, peripherals, GUIs, etc.).
The system configuration not only indicates the physical location of
subsystems, but also the designation of the I/O rack address assignments.
Referencing the rack address assignments allows for quick location of
specific I/O devices. For example, during start-up the user can easily
determine that I/O point 0200 (LS, PB, etc.), located in subsystem 02, is
housed in room number 24.
Sample system configuration diagram

If the programmable controller system involves a network framework
with other components, the system configuration should show a general
block diagram of the whole network (all nodes) and the major devices
connected to it.
System configuration diagram of a PLC interfacing with process bus

and device bus networks
I/O WIRING CONNECTION DIAGRAM
An I/O wiring connection diagram shows the actual connections of

field input and output devices to the PLC module. This drawing normally
includes power supplies and subsystem connections to the CPU.
Figure below illustrates an example of an I/O wiring connection
diagram. This diagram shows the rack, group, and module locations of each
field device to illustrate the termination address of each I/O point.
Input and Output wiring connection diagrams

If the field devices are not wired directly to the I/O module, then the
diagram should show terminal block numbers. This way, anyone
troubleshooting the PLC system will know which points to check in the
terminal blocks. Good I/O wiring documentation is invaluable during
installation, as well as for later reference.
Input connection wiring diagram indicating terminal block number

I/O ADDRESS ASSIGNMENTS
An I/O address assignment document identifies each field device by

address (rack, group, and terminal), the type of input or output module
(e.g.115 VAC, 24 VAC), the type of field device (e.g., limit switch, solenoid),
and the function the device performs in the field. Table below shows a
typical I/O address assignment document. This assignment document is
similar to the I/O assignment table that will be completed prior to
developing the control program.
I/O address assignment
INTERNAL STORAGE ADDRESS ASSIGNMENTS

An internal storage address assignment document is an important
part of the total documentation package. Because internals are used for
programming timers, counters, and control relay replacements and are not
associated with any field devices, programmers tend to use them freely,
without accounting for their usage. However, just as with real I/O, misuse
of internals can result in system mis-operation.
Each available system register, whether a user storage register or an
I/O register, should be properly identified. Most applications use registers
to store or hold information for timers, counters, or comparisons.
Keeping an accurate record of the use of and changes to these
registers is very critical. Just as with I/O assignment documents, the
storage register assignment table should show whether or not a register is
being used. Table below shows a typical documentation form for register
assignments.
Storage register assignment table

VARIABLE DECLARATION
In an IEC 1131-3 (IEC 61131-3 now) programming environment , the

documentation of the physical I/O addresses, internal storage addresses,
and storage address assignments requires that the devices connected to the
PLC via its I/O be declared, or defined, as variables.
Table below illustrates a typical variable declaration. A proper variable
declaration, which includes the name of the input, output, or internal,
should be included in each of the assignment documents (e.g., I/O
assignment, storage register assignment).
Variable Declaration
CONTROL PROGRAM PRINTOUT
The control program printout is a hard copy of the control logic

program stored in the controller’s memory. Whether stored in ladder form or
some other language, the hard copy should be an exact replica of the
controller’s memory. Figure below shows a typical ladder printout in its
basic format.
A basic hard copy printout shows each programmed instruction with
the associated address of each input and output. This printout, however,
does not readily provide information about each instruction’s function or
which field device is being evaluated or controlled. For this reason, the
program coding alone, without the previously mentioned documentation, is
not adequate for interpretation of the control system. Most manufacturers
provide a documentation package that allows the programming device,
generally a PC (personal computer), to enter labels or mnemonic
nomenclature for the control program elements.
The extent of the control program printout and documentation varies
from one PLC manufacturer to another. This documentation may or may not
include information pertaining to the input/output connection diagram.
Ladder Diagram Printout

CONTROL PROGRAM STORAGE
For the most part, PLC programming occurs at a location other than
where the controller will finally be installed. For this reason, the user
should save the control program on a storage medium, such as a cassette
tape, a floppy disk, or an electronic memory module. This practice allows
the user to send or carry the stored program to the installation site and
reload it into the controller’s memory quickly. This approach is usually
employed when the system uses a volatile-type memory, but it is also used
with non-volatile memory for backup purposes.
The reproducible, stored control program, like any other form of
documentation, should be kept accurate and current. A good practice is to
always have two copies, in case one is damaged or misplaced. Also, make
sure that the stored program agrees with the latest hard copy of the control
logic.
Storage Device
Documentation may seem trivial to some or too much work to others.

Whether designing their own control system or subcontracting the design,
users should ensure that a good documentation package is delivered with
the equipment.
A well-designed system is one that is not just put to work during
start-up, but can also be maintained, expanded, modified, and kept running
without difficulty. Good documentation will definitely help both the
designers and the end users in these tasks.
Remember that, regardless of the application, a design is not good
unless its documentation is also good.
SELF CHECK 1.4.3
TRUE or FALSE
1. Documentation provides an easy way to communicate accurate information

to all those involved with the system
2. Proper documentation comes from compilation only of hardware.
3. A good system design starts with a thorough understanding of the

problem and a good description of the process to be controlled
4. The system configuration only indicates the physical location of

subsystems
5. An I/O wiring connection diagram shows the actual connections of field
input and output devices to the PLC module
6. If the field devices are not wired directly to the I/O module, then the
diagram should show terminal block numbers.
7. An wiring diagram document identifies each field device by address (rack,

group, and terminal), the type of input or output module (e.g.115 VAC,
24 VAC), the type of field device (e.g., limit switch, solenoid), and the
function the device performs in the field
8. An internal storage address assignment document is an important part of

the total documentation package
9. Keeping an accurate record of the use of and changes to PLC registers is

not really critical
10. The control program printout is a hard copy of the control logic
program stored in the controller’s memory and may not be a replica of
the controller’s memory.
ANSWER KEY 1.4.3
1. TRUE
2. FALSE
3. TRUE
4. FALSE
5. TRUE
6. TRUE
7. TRUE
8. TRUE
9. FALSE
10. FALSE
Job Sheet 1.4.3
Title: Documentation of PLC distribution system
Performance Objectives: Given the discussion on documenting PLC

system and PLC software program, you
should create a documentation of a PLC
distribution system
Equipment: Laptop
PLC Trainer
PLC Software
Steps/ Procedure:

2.) Using Job Sheet 1.3.1 as your reference,
create documentation about the PLC
distribution system.
3.) Make sure that documentation components
are present in your data.
4.) Call your trainer to check your portfolio

CRITERIA Yes No
Is documentation created has system abstract?
Is documentation created has system configuration?
Is documentation created has I/O wiring

connection diagram?
Is documentation created has I/O address

assignment?
Is documentation created has internal storage

address assignments?
Is documentation created has storage

register assignments?
Is documentation created has variable declaration?
Is documentation created has control program

printout?
Is documentation created has stored control program?
Trainer:__________________________________________Date:______________

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Information Sheet 1.1.

Learning Objectives : After reading this INFORMATION SHEET, YOU

1.) Explain the capabilities of programmable logic controller

Introduction to PLC and its technical capabilities will be tackled in this

1.) Less wiring

1.) SEQUENTIAL CONTROL

INDSUTRIAL APPLICATIONS OF PLC

FOOD/BEVERAGE Blast furnace control

Carburetor Production Testing. PLCs provide on-line analysis of

Monitoring Automotive Production Machines. The system monitors total

Ammonia and Ethylene Processing. controllers monitor

Fan Control. PLCs control fans based on levels of toxic gases in a

Gas and Distribution. controllers monitor

Automated Warehousing. The PLC controls and optimizes the movement of

Loading and Unloading of Alloys. Through accurate weighing and loading

Compressor Efficiency Control. PLCs control several compressors at a typical

PULP AND PAPER

Batch Preparation for Paper-Making Processing. Applications include control of

RUBBER AND PLASTIC

Plastic Injection Molding. A PLC system controls variables, such as temperature

Deciding on the right controller for a given application has become

1.) Compact type (also known as Shoebox and Brick type)

Compact Type Omron CPM1A

SIEMENS Modular type PLC

PLC can be categorized based on their I/O capabilities. It is the

MICRO PLC – less than 100 I/Os

Keeping the future in mind when choosing a programmable

INPUT/ OUTPUT CONSIDERATIONS

Discrete Inputs/Outputs. Input/output interfaces with

Siemens Digital Input

● 16 inputs, electrically isolated in groups of 16

*BERO - is the trade name used by Siemens to identify its line of

When evaluating discrete outputs, the following are key

Analog Inputs/Outputs. Analog input/output interfaces sense

Some manufacturers provide special analog interfaces that accept

Analog input module

Analog output module

Properties of SM 332; AO 2 x 12 Bit:

● 2 outputs in one group

Remote Inputs/Outputs. Remote I/O modules are convenient,

With the advent of new, smarter programmable controllers, the

or segregated control, is used when a PLC controls a single

Machine Machine Machine

The flexibility and potential advantages of a centralized

One distinct disadvantage of centralized control is that, if the

The need to have several main PLCs communicating with each

PLC PLC PLC PLC

Machine Machine Machine Machine

The two main factors to consider when choosing memory are

The amount of memory required for a given application is a

Although memory requirement formulas do a good job of

During system implementation, the user must program the

However, some applications require special software

Siemens Step 7 Siemens TIA Portal

The programming device is the key peripheral in a PLC

Laptop as programming device

In addition to the programming device, a system may

Peripheral requirements should be evaluated along with the

The physical and environmental characteristics of the

PLC REQUIREMENT CHECKLIST

PLC Requirement Checklist

I/O System Checklist Typical Specifications

CPU Checklist Typical Specifications

Software Checklist Typical Specifications