Programmable Logic Controllers

Basic Level

Workbook
TP 301

With CD-ROM

Festo Didactic
093314 en
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Authorised applications and liability

The Learning System for Automation and Technology has been developed and
prepared exclusively for training in the field of automation. The training organiza-
tion and / or trainee shall ensure that the safety precautions described in the
accompanying Technical documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the training
organization and / or to third parties occurring as a result of the use or applica-
tion of the station outside of a pure training situation, unless caused by premedi-
tation or gross negligence on the part of Festo Didactic.

Order No.: 093314

Edition: 08/2002
Authors: Eckhard von Terzi, Christine Löffler, Frank Ebel
Graphics: Doris Schwarzenberger
Layout: Beatrice Huber

© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2015

All rights reserved.
+49 711 3467-0 www.festo-didactic.com
+49 711 34754-88500 [email protected]

The purchaser shall receive a single right of use which is non-exclusive, non-
time-limited and limited geographically to use at the purchaser's site/location as
follows.
 The purchaser shall be entitled to use the work to train his/her staff at the
purchaser's site/location and shall also be entitled to use parts of the copy-
right material as the basis for the production of his/her own training docu-
mentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case
of schools/technical colleges and training centres, the right of use shall also
include use by school and college students and trainees at the purchaser's
site/location for teaching purposes.
 The right of use shall in all cases exclude the right to publish the copyright
material or to make this available for use on intranet, Internet and LMS plat-
forms and databases such as Moodle, which allow access by a wide variety
of users, including those outside of the purchaser's site/location.
 Entitlement to other rights relating to reproductions, copies, adaptations,
translations, microfilming and transfer to and storage and processing in elec-
tronic systems, no matter whether in whole or in part, shall require the prior
consent of Festo Didactic.

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Preface
The Festo Didactic Learning System for Automation and Technology is
designed to meet a number of different training and vocational require-
ments, and the training packages are structured accordingly:
 Basic packages convey basic knowledge spanning a wide range of
technologies
 Technology packages deal with important areas of open and closed-
loop control technology
 Function packages explain the basic functions of automated systems
 Application packages provide basic and further training closely ori-
ented to everyday industrial practice

The technology packages encompass pneumatics, electro-pneumatics,

control pneumatics, programmable logic controllers, hydraulics, electro-
hydraulics, proportional hydraulics and control hydraulics.

Fig. 1:
Mounting Frame Pneumatics –
i.e. mobile workstation

Profile Plate

U = 230 V~

p = 6 MPa

Storage tray

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The modular design of the learning system permits applications beyond

the limits of the individual packages. PLC actuation, for example, is
therefore possible of pneumatic, hydraulic and electrical actuators.

All learning packages have an identical structure:

 Hardware
 Teachware
 Software
 Courses

The hardware consists of industrial components and installations

adapted for didactic purposes.
The courseware is matched methodologically and didactically to the
training hardware. The courseware comprises:
 Textbooks (with exercises and examples)
 Workbooks (with practical exercises, worksheets, supplementary
notes, solutions and data sheets)
 Overhead transparencies and videos (as a visual means of teaching
support)

The teaching and learning media are available in several languages.

They have been designed for use in classroom teaching, but can also
be used for self-study purposes.
In the software field, computer-based training programs, computer simu-
lating programs, CAD programs and programming software for pro-
grammable logic controllers are available.
Festo’s Didactic range of products for basic and further training is com-
pleted by a comprehensive selection of courses matched to the contents
of the technology packages.

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Table of contents
Technology package TP301 13
Layout of this workbook 14
Component/exercise table 15
Equipment set TP301 16
Notes on safety 17
Operating notes 18

Section A – Course
Components of a programmable logic controller

Exercise 1: Design and commissioning of a programmable

logic controller
Components of a PLC A-3

Programming to EN 61131 (IEC 61131)

Exercise 2: From problem to solution –

taking into consideration EN 61131 (IEC 61131)
Practical steps for PLC programming A-11

Basic logic operations

Exercise 3: Lamp circuit

The assignment function A-19
Exercise 4: Burglar alarm
The NOT function A-29
Exercise 5: Press with protective guard
The AND function A-39
Exercise 6: Bell system
The OR function A-49

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Logic control systems without latching properties

Exercise 7: Stamping device

Combination of AND/OR/NOT A-59
Exercise 8: Silo control system for two bulk materials
Combination circuit with branching A-69

Logic control systems with latching properties

Exercise 9: Fire alarm

Setting an output A-77
Exercise 10: Drill breakage monitoring
Setting and resetting an output A-85
Exercise 11: Activating a cylinder
Signal edges A-95

Logic control systems with time response

Exercise 12: Bonding of components

Pulse A-107
Exercise 13: Embossing device
Switch-on signal delay A-117
Exercise 14: Clamping device
Switch-off signal delay A-127

Sequence control systems

Exercise 15: Lifting device for packages

Linear sequence A-137
Exercise 16: Lifting and sorting device for packages
Alternative branching A-155
Exercise 17: Stamping device with counter
Counting cycles A-167

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Section B – Fundamentals

Chapter 1 Automating with a PLC B-1

1.1 Introduction B-1

1.2 Areas of application of a PLC B-2
1.3 Basic design of a PLC B-5
1.4 The new PLC standard EN 61131 (IEC 61131) B-8

Chapter 2 Fundamentals B-11

2.1 The decimal number system B-11

2.2 The binary number system B-11
2.3 The BCD code B-13
2.4 The hexadecimal number system B-13
2.5 Signed binary numbers B-14
2.6 Real numbers B-14
2.7 Generation of binary and digital signals B-15

Chapter 3 Boolean operations B-19

3.1 Basic logic functions B-19

3.2 Further logic operations B-23
3.3 Establishing switching functions B-25
3.4 Simplification of logic functions B-28
3.5 Karnaugh-Veitch diagram B-30

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Chapter 4 Design and mode of operation of a PLC B-33

4.1 Structure of a PLC B-33

4.2 Central control unit of a PLC B-35
4.3 Function mode of a PLC B-37
4.4 Application program memory B-39
4.5 Input module B-41
4.6 Output module B-43
4.7 Programming device/Personal computer B-45

Chapter 5 Programming of a PLC B-47

5.1 Systematic solution finding B-47

5.2 EN 61131-3 (IEC 61131-3) structuring resources B-50
5.3 Programming languages B-54

Chapter 6 Common elements of programming languages B-57

6.1 Resources of a PLC B-57

6.2 Variables and data types B-60
6.3 Program B-70

Chapter 7 Function block diagram B-85

7.1 Elements of function block diagram B-85

7.2 Evaluation of networks B-85
7.3 Loop structures B-87

Chapter 8 Ladder diagram B-89

8.1 Elements of ladder diagram B-89

8.2 Functions and function blocks B-92
8.3 Evaluation of current rungs B-93

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Chapter 9 Instruction list B-95

9.1 Instructions B-95

9.2 Operators B-96
9.3 Functions and function blocks B-97

Chapter 10 Structured text B-99

10.1 Expressions B-99

10.2 Statements B-101
10.3 Selection statements B-103
10.4 Iteration statements B-106

Chapter 11 Sequential function chart B-111

11.1 Introduction B-111

11.2 Elements of sequential function chart B-111
11.3 Transitions B-120
11.4 Steps B-123
11.5 Example B-135

Chapter 12 Logic control systems B-139

12.1 What is a logic control system B-139

12.2 Logic control systems without latching properties B-139
12.3 Logic control systems with memory function B-145
12.4 Edge evaluation B-148

Chapter 13 Timers B-153

13.1 Introduction B-153

13.2 Pulse timer B-154
13.3 Switch-on signal delay B-156
13.4 Switch-off signal delay B-158

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Chapter 14 Counter B-161

14.1 Counter functions B-161

14.2 Incremental counter B-161
14.3 Decremental counter B-165
14.4 Incremental/decremental counter B-167

Chapter 15 Sequence control systems B-169

15.1 What is a sequence control system B-169

15.2 Function chart to IEC 60848 B-169

Chapter 16 Commissioning and

operational safety of a PLC B-175

16.1 Commissioning B-175

16.2 Operational safety of a PLC B-177

Chapter 17 Communication B-183

17.1 The need for communication B-183

17.2 Data transmission B-183
17.3 Interfaces B-184
17.4 Communication in the field area B-185

Appendix

A Bibliography of illustrations B-187

B Bibliography of literature B-189
C Guidelines and standards B-191
D Glossary B-193
E Index B-199

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Section C – Solutions
Solution 1: Design and commissioning of a programmable
logic controller C-3
Solution 2: Practical steps for PLC programming C-5
Solution 3: Lamp circuit C-7
Solution 4: Burglar alarm C-11
Solution 5: Press with protective guard C-15
Solution 6: Bell system C-21
Solution 7: Stamping device C-25
Solution 8: Silo control system for two bulk materials C-31
Solution 9: Fire alarm C-35
Solution 10: Drill breakage monitoring C-39
Solution 11: Activating a cylinder C-43
Solution 12: Bonding of components C-47
Solution 13: Embossing device C-53
Solution 14: Clamping device C-57
Solution 15: Lifting device for packages C-63
Solution 16: Lifting and sorting device for packages C-69
Solution 17: Stamping device with counter C-75

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Technology package TP301

“ Programmable logic controllers“

The technology package TP301 "Programmable logic controllers" is a
component part of the Festo Didactic Learning System for Automation
and Technology and forms the basic level of TP300.
The training aims of TP301 are to learn how to program programmable
logic controllers and to teach the fundamentals for creating programs in
the programming languages ’ladder diagram’ (LD), ’function block dia-
gram’ (FBD), ’instruction list’ (IL), ’structured text’ (ST) and ’sequential
function chart’ (SFC). Programming is effected in accordance with EN
61131-3 (IEC 61131-3).
You have the option of using this workbook in conjunction with alterna-
tive programmable logic controllers by different manufacturers.
A basic knowledge of electro-pneumatics and sensor technology is rec-
ommended to work through technology package TP301.
The exercises in TP301 deal with the following main topics:
 Components of a programmable logic controller
 PLC programming to EN 61131 (IEC 61131)
 Basic logic operations
 Logic control systems
 Sequence control systems

The allocation of components and exercises can be seen from the com-
ponent/exercise table.

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Layout of this workbook

The workbook is structured as follows:
Section A – Course
Section B – Fundamentals
Section C – Solutions
Section D – Appendix

Section A – Course teaches the programming of programmable logic

controllers with the help of a series of progressive exercises.
Any necessary technical knowledge required for the implementation of
an exercise is provided at the beginning. Functions are limited to the
most elementary requirements. More detailed knowledge may be gained
in section B.
Section C – Solutions provides the solutions to the exercises with brief
explanations.
Section B – Fundamentals contains generally applicable technical
knowledge to supplement the training contents of the exercises in Sec-
tion A. Theoretical links are established and the necessary technical
terminology explained with the help of examples. An index provides an
easy means of locating terminology.
Section D – Appendix which contains data sheets of the used compo-
nents.

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Allocation of component and exercise

Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Signal input, electrical 1 1 1 1 1 1 1 1 1 1 1 1 1

Signalling device and distrib-
1 1 1 1 1
utor, electrical
Proximity sensor, optical 1 1 1 1 1
Proximity sensor, inductive 1 1 1 1 1
Proximity sensor, capacitive 1 1 1 1 1
Proximity sensor with cylinder
1 4 4 4 4
mounting
5/2-way single solenoid valve 1 1 2 1 1 1 1 2 2 2
5/2-way double solenoid
1 1 1
valve
Double-acting cylinder 1 1 2 1 2 2 2
Single-acting cylinder 1 1 1 1 1 1
On/off valve with filter regula-
1 1 1 1 1 1 1 1 1 1
tor valve
Manifold 1 1 1 1 1 1 1 1 1 1

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Equipment set TP301

Equipment set TP301 Description Order No. Quantity
Order No.:167101
Plastic tubing 151496
Manifold 152869 1
Single-acting cylinder 152887 1
Double-acting cylinder 152888 2
On/off valve with filter regulator valve 152894 1
Quick push-pull distributor 153128 1
Signal input, electrical 162242 1
Signalling device and distributor, electrical 162244 1
Proximity sensor with cylinder mounting 167060 4
5/2-way single solenoid valve 167074 2
5/2-way double solenoid valve 167076 1
Proximity sensor, inductive 178574 1
Proximity sensor, capacitive 178575 1
Proximity sensor, optical 178577 1

optional, not included in scope of delivery of equipment set Order No. Quantity

I/O data cable, digital 034031

Plug-in adapter 035651
Universal connection unit 162231
Power supply unit 162416
Set of cables 167091

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Notes on safety
The following notes should be followed in the interest of safety:
 Mount all components securely on the board.
 Do not switch on compressed air until all line connections have been
established and secured.
 Proceed with care when switching on the compressed air.
Cylinders may advance or retract as soon as the compressed air is
switched on.
 Switch off air supply immediately if air lines become detached. This
prevents accidents.
 Do not disconnect air lines under pressure.
 Do not exceed the permitted working pressure of 8 bar (800kPa).
 Observe general safety regulations in accordance with EN 60204-1
(IEC 60204-1).
 Use only extra-low voltages of up to 24 V DC.
 Observe the data sheets referring to the individual components, in
particular all notes regarding safety.

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Operating notes
The following rules should be observed when constructing a circuit:
 Block output 2 of the valve, if a single-acting cylinder is actuated by a
5/2-way single solenoid valve in a circuit.

Fig. 2:
Plug for output 2
of a 5/2-way valve

4 2

5 3
1

 Input signals, which would result from an actual production process

sequence, are reproduced in part by signals via push buttons or
switches.

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Section A – Course
Components of a programmable logic controller

Exercise 1: Design and commissioning of a programmable

logic controller
Components of a PLC A-3

Programming to EN 61131 (IEC 61131)

Exercise 2: From problem to solution –

taking into consideration EN 61131 (IEC 61131)
Practical steps for PLC programming A-11

Basic logic operations

Exercise 3: Lamp circuit

The assignment function A-19
Exercise 4: Burglar alarm
The NOT function A-29
Exercise 5: Press with protective guard
The AND function A-39
Exercise 6: Bell system
The OR function A-49

Logic control systems without latching properties

Exercise 7: Stamping device

Combination of AND/OR/NOT A-59
Exercise 8: Silo control system for two bulk materials
Combination circuit with branching A-69

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Logic control systems with latching properties

Exercise 9: Fire alarm

Setting an output A-77
Exercise 10: Drill breakage monitoring
Setting and resetting an output A-85
Exercise 11: Activating a cylinder
Signal edges A-95

Logic control systems with time response

Exercise 12: Bonding of components

Pulse A-107
Exercise 13: Embossing device
Switch-on signal delay A-117
Exercise 14: Clamping device
Switch-off signal delay A-127

Sequence control systems

Exercise 15: Lifting device for packages

Linear sequence A-137
Exercise 16: Lifting and sorting device for packages
Alternative branching A-155
Exercise 17: Stamping device with counter
Counting cycles A-167

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Exercise 1

Programmable logic controllers Subject

Design and commissioning of a programmable logic controller Title

Components of a PLC

 To be able to explain the basic design and mode of operation Training aim
of a PLC
 To be able to configure and commission a PLC
Nowadays, programmable logic controllers form part of any automation Technical knowledge
process. Fig. A1.1 illustrates the typical configuration of an automation
solution realised by means of a PLC. The control system shown repre-
sents the simpler, non-networked group of PLC applications.

Fig. A1.1:
PC / Automation via PLC
Programming device Display/
Control unit

PLC

Sensors

Actuators

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Exercise 1

The basic components of the control system are:

 Programmable logic controller (PLC)
By this, we understand the electronic modules through which all of
the system or machine functions to be controlled are addressed and
activated in a logic sequence.
 Sensors
These components are located directly on the system or machinery
be controlled, through to which the PLC is communicated actual sta-
tuses.
 Actuators
These components are located directly on the system or machinery
to be controlled, through which the PLC is able to change or influence
statuses and as such the technical process.
 PC or programming device
This is used to create the program containing the logic of the system
or machinery to be controlled and to transfer this to the memory of
the PLC. At the same time, these programming tools also provide
supporting functions for the testing of the PLC program and commis-
sioning of the controller.
 Display and control units
These enables you to monitor and influence the operation of the sys-
tem or machinery.

Programmable logic controller

The most important component of a control system is the PLC and its
program. Fig. A1.2 illustrates the system components of a PLC.

Fig. A1.2:
System components PLC-program
of a PLC

Input module Central control unit Output module

Sensors Actuators

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Exercise 1

A PLC is connected to the system to be controlled via input and output

modules. The system to be controlled supplies input signals (mostly
binary) via sensors to the input modules. These signals are processed
within the main processing unit, the main component of the PLC. Prior
.to formulation of IEC standards, known as "central control unit" (CCU).
The "specification" for the processing of signals is defined in the PLC
program. The result of the processing is output to the actuators of the
system to be controlled via the output module. Thus, the design of a
PLC corresponds to that of a computer.

PLC program
PLC programs consist of a logic sequence of instructions. The control
program is stored in a special, electronic readable memory, the so-
called program memory of the PLC. Special RAMs with back-up battery
are used during the program development, since its contents can always
be changed again very quickly.
After commissioning and error-free function of the controller it is a good
idea to transfer the PLC program unerasably to a read-only memory,
e.g. an EPROM. If the program is executed, it will be processed in con-
tinuous cycles.

Signals
Input signals reach the PLC via sensors. These signals contain infor-
mation about the status of the system to be controlled. It is possible to
input binary, digital and analogue signals.
A PLC can only recognise and output electrical signals. For this reason,
non-electrical signals are converted into electrical signals by the sen-
sors. Sensor examples are:
 Push buttons, switches, limit switches, proximity sensors
Output signals influence the system to be controlled. The signals can be
output in the form of binary, digital or analogue signals. Output signals
are amplified into switching signals via the actuators or converted into
signals of other energy forms. Actuators examples are:
 Lamps, buzzers, bells, contactors, cylinders with solenoid valves,
stepper motors

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Exercise 1

Problem description A control task is to be solved via a programmable logic controller (PLC).
Familiarise yourself with the basic design of a PLC.

Positional sketch

Exercise definition 1. Components of a PLC

2. Design and commissioning of the PLC you have selected

Implementation To carry out the exercise using the worksheets, refer to Section B of the
workbook and your PLC data sheet or manual.

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Exercise 1

WORKSHEET

1.1 Components of a PLC

Question 1:
What are the basic components of a programmable logic controller?

Question 2:
What are the basic modules making up the central control unit of a pro-
grammable logic controller?

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Exercise 1

Question 3:
How is electrical isolation achieved between sensor/actuator signals and
the PLC?

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Exercise 1

WORKSHEET

1.2 Design and commissioning of the PLC you have selected

Enter the technical data of the selected programmable logic controller in
the table below.

Criteria Technical data Technical data

Operating voltage
Nominal voltage
Permissible voltage range
Current consumption
Inputs
Number
Input current
Input level
Outputs
Number
Switching logic
Output voltage
Output current

Configure the PLC in accordance with the notes in the relevant data
sheet or manual.

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Exercise 1

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Solutions

Section C – Solutions
Components of a programmable logic controller

Solution 1: Design and commissioning of a

programmable logic controller
Components of a PLC C-3

Programming to EN 61131 (IEC 61131)

Solution 2: From problem to solution –

taking into consideration EN 61131 (IEC 61131)
Practical steps for PLC programming C-5

Basic logic operations

Solution 3: Lamp circuit

The assignment function C-7
Solution 4: Burglar alarm
The NOT function C-11
Solution 5: Press with protective guard
The AND function C-15
Solution 6: Bell system
The OR function C-21

Logic control systems without latching properties

Solution 7: Stamping device

Combination of AND/OR/NOT C-25
Solution 8: Silo control system for two bulk materials
Combination circuit with branching C-31

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Solutions

Logic control systems with latching properties

Solution 9: Fire alarm

Setting an output C-35
Solution 10: Drill breakage monitoring
Setting and resetting an output C-39
Solution 11: Activating a cylinder
Signal edges C-43

Logic control systems with time response

Solution 12: Bonding of components

Pulse C-47
Solution 13: Embossing device
Switch-on signal delay C-53
Solution 14: Clamping device
Switch-off signal delay C-57

Sequence control systems

Solution 15: Lifting device for packages

Linear sequence C-63
Solution 16: Lifting and sorting device for packages
Alternative branching C-69
Solution 17: Stamping device with counter
Counting cycles C-75

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Solution 1

Design and commissioning of a programmable logic controller Title

Components of a PLC

.1 1.1 Components of a PLC

What are the basic components of a programmable logic controller? Question 1

The basic components of a PLC are: Answer

 the main processing unit, formerly (central control unit)
 the input modules
 the output modules
 the program memory
 the PLC program

What are the basic modules making up the main processing unit of a Question 2
programmable logic controller?

The basic modules of an MPU are: Answer

 the control unit
 the data memory
 the arithmetic and logic unit (ALU)

How is electrical isolation achieved between sensor/actuator signals and Question 3

the PLC?

The sensor/actuator signals and the PLC are electrically isolated via an Answer
optocoupler. The main processing unit is thus separated from the exter-
nal circuit of the sensors and actuators. Interferences in these circuits
therefore cannot damage the controller.

Block diagram of an
input module
Error Optocoupler Signal to
Input- Signal
signal voltage delay the
detection control unit

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Solution 1

.2 1.2 Design and commissioning of your selected PLC

The following table lists the technical data of a Festo FPC 101B pro-
grammable logic controller as an example.

Technical data Criteria Technical data

Operating voltage
Nominal voltage 24 V DC
Permissable voltage range 16 to 30 VDC
Current consumption approx. 160 mA
Inputs
Number 21
of which 1 is a counter input

Input voltage 6 mA
Input level log. 0 = 0 to 5 V
log. 1 = 11 to 30 V
Outputs
Number 14 Transistor outputs
Type positive switching
Output voltage Operating voltage – 2 V

Output current max. 300 mA/output

Total output current max. 2.5 A

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