Welcome to

Politeknik Tuanku
Sultanah Bahiyah.

For PLC And CX-Programmer

Training Course.
Duration : 2 Days course
Time : 8.30a.m - 4.30p.m
Instructor : Koh Foo Hin
En. Mohd Elias
 Development of The Course
Day 1
8.30a.m -9.00a.m : Your understanding about PLC
9.00a.m -10.00a.m : Introduction of PLC
10.00a.m -11. 00a.m : System Configuration &
Features & Function &
Unit Specification & Components
11.00p.m - 12.00p.m : Basic Command with Basic
Programming method.
2.30p.m - 4.30p.m : Exercise With Actual Application
 Development of The Course

Day 2
8.30a.m -9.00a.m : Overview of PLC
9.00a.m -12.00a.m : Continue with new Exercise
2.30p.m - 4.30p.m : Exercise With Actual Application and
briefing about the intermediate for
PLC
What kind of control system in a plant

Start & Stop

Operation
What kind of control system in a plant

Contactors, relays, timers & counters

in the control panel
 Controlling

Motor pump

Valve

Mixer
 Read & Display
Flow Rate

Float Level

Oxygen Level
Hardwire logic control circuit

Start Stop
Relay 1
Relay 1

Solenoid
Relay 1
Timer

Timer
Pump
A picture of hardwire
relay logic
 Introduction to PLC
What is PLC ?

Programmable
Logic
Controller

A solid-state device used to control

machine or process operation by means
of a stored program and feedback from
input and output devices
 Human
Sense Action
Brain
See
Hand

Listen

Leg
Taste

Touch
Mouth

Smell
You
 Power Supply
PLC
Signals
I Memory O
u Signals to
n
from t solenoids,
p
Switches, u CPU p
u motor,
Sensors, t t lamps,
etc etc.

Programming
Device
Operate by monitoring input signals and providing
output signals. When changes are detected in the input
signals, the PLC reacts, through the user-programmed
internal logic, to produce output signals
It continuously scans the program in its memory to
achieve this control
 Hardwire
PLC
Logic
 Control Device
Wired Logic PLC

General Purpose

Specific Purpose
Control sequence can be
change from time to time
Control sequence is
without need to rewire
fixed for one design
 Control Scale

Small & Medium Medium & Large

Wired Logic
PLC
 Modification
An example for hard wire logic

Start Stop Start Stop

Relay 1 Relay 1
Relay 1 Relay 1

Solenoid Solenoid
Relay 1 Relay 1
Timer
Counter
Timer Stop
#30
Pump

Counter
Pump

Hardwire logic will need to rewire everything

 Modification
The same example for PLC
Start Stop
LD START
Relay 1
OR RELAY 1
Relay 1
AND NOT STOP
OUT RELAY1 Solenoid
Relay 1
OUT SOLENOID
Timer
LD RELAY 1
TIM 000 Timer
Pump
#0020
LD TIM 000
OUT PUMP
 Modification
The same example for PLC
Start Stop
LD START
Relay 1
OR RELAY 1
Relay 1
AND NOT STOP
OUT RELAY1 Solenoid
Relay 1
OUT SOLENOID
LD RELAY 1 Stop
Counter
LD STOP #30

CNT 000
#0030 Counter
LD CNT 000 Pump

OUT PUMP

Only need to change the ladder program

 Delivery Period
Several days Almost Immediate

Wired Logic PLC

 Maintenance
Easy
Difficult

Programming
LED indicator Console

Input/output connector
can be remove easily
without using screw driver
Wired Logic
PLC
 Economic Efficiency
Advantage on Advantage on
small scale small, medium
and large

$$$
Wired Logic PLC
 Power Consumption

High Low

> 2 Amp 0.2 Amp

Wired Logic PLC

 What PLC can do
Sequence Control

Relays

Start Stop
Relay 1
Relay 1

Solenoid
Relay 1
Timer

Timer
Pump

Timers & Counters

Sophisticated Control

+
-
x
/
Arithmetic Operation

Prod Pass Reject

3 4
AA 33 4 2
5
1
BB 27 3
CC 43 8

Analog Control
Information Handling
 Supervisory Control

PLC

Computer

Printer
FA
Network

Pager

Process Monitoring
 Why & When to use PLC

Dramatically increase
in population and
housing development
Limited land for plant

A higher capacity of
plant with high
efficiency required

Upgrading of small plant to run higher capacity would

involve complicated control system, Intermittently
Decanted Extented Aeration (IDEA).

For that purpose, PLC can do the job

 Nation-wide Coverage
OMRON ELECTRONICS SDN.BHD
SALES NETWORK IN MALAYSIA

Elcomp
Trading

Ommura

Autovation
EM System

Robomatics
 Waste Water Treatment Article

Reliable Control Solution For

Waste Water Treatment
And Environmental Processes

In 1990, Omron controls were selected for a central Florida

Water treatment plant to ease capacity, productivity,efficiency
and reliability. The facility performed :

• Raw Water Pumping

• Softening
• Filtering
• Storage / Distribution
 The system included a PLC based station
at each major processing stages, tied
together with a triple-redundant network.
The PLC / Computer network improved
efficiency at the Water Treatment facility
for about one-third the cost of a distributed
control system.

One PLC control and monitors the softener

systems ; two more PLCs control the filter
systems; another PLC, located in the
control room, controls the main storage
and distribution system
Two independent host computer link networks connect the
PLCs to the Computers. A peer to peer network provides a
shared memory area to all PLCs on the network so that
critical data - valve position, tank
levels, motor status and various
plant flows are communicated
automatically. This communication
is transparent to the users

Operator interface terminals

simplify control and monitoring
of the entire operation.
Fiber optic cables were
installed for all communications
networks to protect against
lightning
Data acquisition was automated by
gathering all parameters from the
PLCs data memories and printing
daily and monthly reports.
Chemical and turbidity test results
were input into the computer by
operators for report generation
 Future Expansion & Upgrading
Maintenance
office(SCADA)
Distance : 5km ~
Modem Modem
8km

Pumps RS232C Pumps RS232 C

House: 1 House: 2
ID ID ID O O A D ID ID ID O O A D
C C D A C C D A

Pressure Inverter
Inverter Interlock,
Power
C1 C2 monitor C1 C2

Humidity
Sensors

Pump 1 Jockey Pump Pump 2 Pump 1 Jockey Pump Pump 2