Universal PLC Platform

Scientech 2400GN

Product Tutorial
Ver.1.1

Designed & Manufactured by:

An ISO 9001:2008 company
Scientech Technologies Pvt. Ltd.
94, Electronic Complex, Pardesipura, Indore - 452 010 India,
+ 91-731 4211100, : info@[Link] , : [Link]
Universal PLC Platform Scientech 2400GN

Scientech 2400GN Universal PLC Platform

Table of Contents
1. Safety Instructions 5
2. Introduction 6
3. Features 7
4. Technical Specifications 8
5. Theory 10
Programmable Logic Controller (PLCs) 10
What is PLC? 11
Need for PLC 12
History of Programmable Logic Controllers (PLCS) 13
Cost Advantages over Relay 14
Functional Description 15
How does a Programmable Logic Controller Works? 20
Difference between Computer and PLC 21
General PLC Architecture 23
Advantage and disadvantage of PLC 22
Types of PLC 24
Different brands of PLC 24
Criteria of Choosing 25
Sensors & Actuators 26
Data Types and Memory Types 27
Concept of Relay Functioning 29
Sinking and Sourcing 30
Latching 36
CPU FBs-20MA Description 37
Wiring Detail of PLC 38
FBs-4A2D Hardware Description 42
Programming Languages and Techniques 41
Justification for the Use of PLCS 55
Application of PLC 57

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6. Software Installation 61
7. How to install FATEK WinProladder Software 64
8. Working Desk of the WinProladder 65
9. How to change PLC Model No. in WinProladder 66
10. Ladder Program testing 69
11. Simulation of Winproladder 71
12. Connection Detail 75
Scientech 2400 Input Output Interface PCB and 20 pin box type
connector pin detail 75
Terminal Block of Input & Output Side 76
Terminal Block Connection detail with PLC and Component 78
13. Addressing Detail 82
Input and Output Addressing Detail 82
Input and Output and component Ferrule No. Detail 83
14. Experiments
Experiment 1 84
Study and use of NO (Normally open) and NC (Normally Close) bit
Experiment 2 106
Study and use of Logic Gate (OR Gate)
Experiment 3 109
Study and use of S (Set) and R (Reset) bit
Experiment 4 113
Study and use of Memory bit
Experiment 5 116
Study and use of Timer instruction
Experiment 6 120
Study and use of Cumulative timer instruction
Experiment 7 126
Study and use of Special Memory or Pulse memory bit
Experiment 8 128
Study and use of Counter instruction
Experiment 9 133
Study and use of Compare instruction

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Experiment 10 138
Study and use of Math (Addition) instruction
Experiment 11 142
Study and use of PWM (Pulse Width Modulation) instruction
Experiment 12 146
Study and use of Move instruction
Experiment 13 150
Study and use of Jump and Label instruction
Experiment 14 156
Stud and use of Subroutine
Experiment 15 165
Stud and use of Analog Input
Experiment 16 168
Stud and use of Analog Output
15. Frequently Asked Questions 170
16. Warranty & List of Accessories 178

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Universal PLC Platform Scientech 2400GN

Safety Instructions

Read the following safety instructions carefully before operating the instrument. To
avoid any personal injury or damage to the instrument or any product connected to it.
Do not operate the instrument if you suspect any damage within.
The instrument should be serviced by qualified personnel only.

For your safety:

Use proper Mains cord : Use only the mains cord designed for this instrument.
Ensure that the mains cord is suitable for your
country.
Ground the Instrument : This instrument is grounded through the protective
earth conductor of the mains cord. To avoid electric
shock the grounding conductor must be connected to
the earth ground. Before making connections to the
input terminals, ensure that the instrument is properly
grounded.
Observe Terminal Ratings : To avoid fire or shock hazards, observe all ratings and
marks on the instrument.
Use only the proper Fuse : Use the fuse type and rating specified for this
instrument.
Use in proper Atmosphere : Please refer to operating conditions given in the
manual.
1. Do not operate in wet / damp conditions.
2. Do not operate in an explosive atmosphere.
3. Keep the product dust free, clean and dry.

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Universal PLC Platform Scientech 2400GN

Introduction
In today's environment of automation, the importance of PLC has rapidly increased.
Scientech 2400 Universal PLC Platform is an ideal setup to study the working of
PLC's used for industrial applications. Scientech 2400 has been designed to learn and
practice -
Wiring of PLC with different inputs and outputs.
Push to ON Switch, Toggle Switch, Limit switch and IR Sensor as an input to
the PLC.
Realistic Simulation that can drive visual indicators, audio indicators, and DC
motor, Pilot Lamp, Relay card

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Features
Freedom to select PLC of different makes
Open platform to explore wide PLC applications
Industrial feel & look
NO/NC Switches, Push to ON Switch, Limit Switch IR Sensor, LED's, Buzzer,
DC Motor, Relay card, Pilot Lamp
Din rail mounting for PLC
Powerful instruction sets
PC based Ladder programming
High execution speed
Extremely easy and student friendly software to develop different programs
Several sample Ladder programs
Choice of PLC and expansion modules
Easy downloading of programs
Practice Troubleshooting Skills
Compact tabletop ergonomic design
Ready Experimental details
Robust Construction

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Universal PLC Platform Scientech 2400GN

Technical Specifications

PLC CPU Type : FBs-20 MA

Digital Input : 12
Digital output : 8
Program size (Words) : 4096
Boolean Execution speed
Sec. per instruction : 0.33 µs/Sequential instruction in average
Interfacing : RS232
No. of ports : 1
Expansion Module : Expandable
Toggle Switch : 8 nos.
Push to ON Switch : 5 nos.
Limit Switch : 1 no.
IR Sensor : 1 no.
LED : 8 nos.
Buzzer : 1 no.
DC Motor : 1 no.
Pilot Lamp : 1 no.
Relay Card : 1 no.
Analog Input:
Total Channels : 4 CH
Resolution : 14 or 12 bit
Signal Resolution : 0.3mV (Voltage), 0.61uA (Current)
I/O Points Occupied : 4 RI (Input Register)
Conversion Time : Updated each scan
Accuracy : ±1 %
Max. Absolute : ±15V (Voltage), 30mA (Current)
Input Rating
Software Filter : Moving average
Average Samples : 1~16 configurable
Input Impedance : 63.2KΩ (Voltage), 250Ω (Current)
Measurement Range : Voltage: +10V, +5V, 0~10V, 0~5V,
Current: +20mA, +10mA, 0~20mA, 0~10mA

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Analog Output:
Total Channels : 2 CH
Resolution : 14 bit
Signal Resolution : 0.3mV (Voltage), 0.61uA (Current)
I/O Points Occupied : 2 RO (Output Register)
Conversion Time : Updated each scan
Accuracy : ±1 %
Max. and Min. Output : Voltage Output- 500~1MΩ
Loading Current Output- 0~500Ω
Output Range : Voltage: +10V, +5V, 0~10V, 0~5V,
Current: +20mA, +10mA, 0~20mA, 0~10mA
Operating Temperature : 0-40°C, 80 % RH
Dimension (mm) : W600 x H 390 x D 300
Weight : 8 Kg (approximately)
Product Tutorials : Online (Theory, procedure reference results etc)
Included Accessories : Interfacing cable : 1 no
Mains cord : 1 no
USB to Serial Convertor: 1 no.

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Universal PLC Platform Scientech 2400GN

Theory
Programmable Logic Controllers (PLCs):
A Programmable Logic Controller (PLC) is a specialized computer like device used to
replace banks of electromagnetic relays in industrial process control. The PLC is also
known as a programmable controller (PC). The tile "PC" for programmable controller
could be confused in common usage with "PC" used to mean personal computer. To
avoid this confusion, we shall refer to the programmable controller as a
programmable logic controller or PLC.
You can think of the programmable logic controller as a heavy-duty computer system
designed for machine control. Like a general-purpose computer, the PLC is based on
digital logic and can be field-programmed. The programming language is a bit
different because the purpose of the PLC is to control machines. The PLC is used to
time and sequence functions that might be required in assembly lines, robots, and
chemical processing. It is designed to deal with the harsh conditions of the industrial
environment. Some of the physical environment problems could include vibration and
shock, dirt and vapors, and temperature extremes. The PLC commonly has to
interface with a wide variety of both input and output devices. Some input devices
include limit and pressure switches, temperature and optical sensors, and analog- to-
digital converters (ADCs). Some output devices valves, motors and cylinders, and
Digital-to Analog converts (DAC).
Before the advent of solid-state logic circuits, logical control systems were designed
and built exclusively around electromechanical relays. Relays are far from obsolete in
modern design, but have been replaced in many of their former roles as logic-level
control devices, relegated most often to those applications demanding high current
and/or high voltage switching.
Systems and processes requiring "on/off" control abound in modern commerce and
industry, but such control systems are rarely built from either electromechanical
relays or discrete logic gates. Instead, digital computers fill the need, which may be
programmed to do a variety of logical functions.
In the late 1960's an American company named Bedford Associates released a
computing device they called the MODICON. As an acronym, it meant Modular
Digital Controller, and later became the name of a company division devoted to the
design, manufacture, and sale of these special-purpose control computers. Other
engineering firms developed their own versions of this device, and it eventually came
to be known in non-proprietary terms as a PLC, or Programmable Logic Controller.
The purpose of a PLC was to directly replace electromechanical relays as logic
elements, substituting instead a solid-state digital computer with a stored program,
able to emulate the interconnection of many relays to perform certain logical tasks.

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A PLC has many "input" terminals, through which it interprets "high" and "low"
logical states from sensors and switches. It also has many output terminals, through
which it outputs "high" and "low" signals to power lights, solenoids, contactors, small
motors, and other devices lending themselves to on/off control. In an effort to make
PLC easy to program, their programming language was designed to resemble ladder
logic diagrams. Thus, an industrial electrician or electrical engineer accustomed to
reading ladder logic schematics would feel comfortable programming a PLC to
perform the same control functions.
PLC are industrial computers, and as such their input and output signals are typically
120 volts AC, just like the electromechanical control relays they were designed to
replace. Although some PLC has the ability to input and output low-level DC voltage
signals of the magnitude used in logic gate circuits, this is the exception and not the
rule.
What is a PLC?
A Programmable Logic Controller (PLC) is an industrial computer control system
that continuously monitors the state of input devices and makes decisions based upon
a custom program to control the state of output devices.
Almost any production line, machine function, or process can be greatly enhanced
using this type of control system. However, the biggest benefit in using a PLC is the
ability to change and replicate the operation or process while collecting and
communicating vital information.

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Another advantage of a PLC system is that it is modular. That is, you can mix and
match the types of Input and Output devices to best suit your application

According to NEMA (National Electrical Manufacturer Association):

“PLC is a digitally operated electronic system, designed specially for the use in
industrial environment, which use programmable memory for internal storage of user
oriented instructions for implementing specific function such as logic, sequencing,
timing, counting & arithmetic to control, through digital & analog inputs & outputs
for various types of machines & processes.”
Both the PLC & its associated peripherals are designed so that they can be easily
integrated into an industrial control system & easily used in all intended functions.

Need for PLC

 Hardwired panel were very time consuming to time and debug and change
 The following requirement for computer controller to replace hardware panel
● Solid state not mechanical
● East to modify input and output device
● Easy programmed and maintained by plant electrician
● Be able to function in an industrial environment

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History of Programmable Logic Controllers (PLCS):

1968 : Design of PLCs developed for General Motors Corporation to eliminate
costly Scrapping or assembly line relays during model changeovers.
1969 : First PLCs manufactured for automotive industry as electronic equivalents
of relays.
1971 : First application of PLCs outside the automotive industry.
1973 : Introduction of "smart" PLCs for arithmetic operations, printer control
move, Matrix operations, CRT interface etc.
1974 : Introduction of analog PID (Proportional, integral, derivative) control,
which Made possible the accessing of thermocouples, pressure sensors etc.
1975 : First use of PLCs in hierarchical configurations as part of an integrated
Manufacturing system.
1977 : Introduction of very small PLCs based on microprocessor technology.
1978 : PLCs gain wide acceptance, sales approach $ 80 million.
1979 : Integration of plant operation through a PLC communication system.
1980 : Introduction of intelligent input and output modules to provide high speed,
accurate control in positioning applications.
1981 : Data highways enable users to interconnect many PLCs up to 15000 feet
from Each other. More 16-bit PLCs become available. Color graphic CRTs
are available from several suppliers.
1982 : Larger PLCs with up to 8192 I/O become available.
1983 : "Third party" peripherals, including graphic CRTs, operator’s interfaces,
I/O networks, panel displays, and documentation packages, become
available from many sources.

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Universal PLC Platform Scientech 2400GN

Cost Advantages over Relay

Solid State Micro Mini
Relays PLCs
Control Processor Computer

High to Low,
depending on
Hardware cost Low Equal Low High
Number of
Controls

Versatility Low Low Yes Yes Yes

Usability Yes Yes No No Yes

Maintain-Ability
Yes No No No Yes
Troubleshoot

Computer
No No Yes Yes Yes
compatible
Arithmetic
No No Yes Yes Yes
capability
Information
No No Yes Yes Yes
gathering
Industrial
Yes No No No Yes
environment
(Wiring) (Wiring)
Programming cost Very High High Low
High High
Reusable No No Yes Yes Yes

Space required Largest Large Small OK Small

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Functional Description
A programmable controller manufactured by any company has several common
functional parts. Figure illustrates a generic PLC architecture.

The diagram shows Power Supply, I/O, central processor, memory, and programming
and peripheral device subsections. Each is discussed below.
1. Input System:
Inputs are defined as real-world signals giving the controller real-time status of
process variables. These signals can be analog or digital, low or high frequency,
maintained or momentary. Typically they are presented to the programmable
controller as a varying voltage current or resistance value. Signals from
thermocouples (TCs) and resistance temperature detectors (RTDs) are common
examples of analog signals. Some flow meters and strain gauges provide
variable frequency signals, while pushbuttons, limit switches, or even
electromechanically relay contacts are familiar examples of digital, contact
closure type signals. One additional type of input signal, the register input,
reflects the computer nature of the programmable controller.

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Inputs are devices that supply a signal/data to a PLC. Typical examples of

inputs are push buttons, switches, and measurement devices. Basically, an input
device tells the PLC, "Hey, something’s happening out here…you need to check
this out to see how it affects the control program."

A discrete input, also referred to as a digital input, is an input that is either in an

ON or OFF condition. Pushbuttons, toggle switches, limit switches, proximity
switches, and contact closures are examples of discrete sensors which are
connected to the PLC discrete or digital inputs. In the ON condition a discrete
input may be referred to as logic 1 or logic high. In the OFF condition a discrete
input may be referred to as logic 0 or a logic low.

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An analog input is a continuous, variable signal. Typical analog inputs may

vary from 0 to 20 milliamps, 4 to 20 milliamps, or 0 to 10 volts. In the following
example, a level transmitter monitors the level of liquid in a tank. Depending on
the level transmitter, the signal to the PLC can either increase or decrease as the
level increases or decreases.

2. Outputs:
There are three common categories of outputs: Discrete, Register, and Analog.
Discrete outputs can be pilot lights, solenoid valves, or annunciator Windows
(lamp box). Register output can drive panel meters or displays; analog outputs
can drive signals to variable speed drives or to I/P (current to air) converters and
thus to control valves.
Outputs are devices that await a signal/data from the PLC to perform their
control functions. Lights, horns, motors, and valves are all good examples of
output devices. These devices stay put, minding their own business, until the
PLC says, "You need to turn on now" or "You’d better open up your valve a
little more," etc.

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A discrete output is an output that is either in an ON or OFF condition.

Solenoids, contactor coils, and lamps are examples of actuator devices
connected to discrete outputs. Discrete outputs may also be referred to as digital
outputs. In the following example, a lamp can be turned on or off by the PLC
output it is connected to.

An analog output is a continuous, variable signal. The output may be as simple

as a 0-10 VDC level that drives an analog meter. Examples of analog meter
outputs are speed, weight, and temperature. The output signal may also be used
on more complex applications such as a current-to-pneumatic transducer that
controls an air-operated flow-control valve.

The PLC program is executed as part of a repetitive process referred to as a

scan. A PLC scan starts with the CPU reading the status of inputs. The
application program is executed using the status of the inputs. Once the program
is completed, the CPU performs internal diagnostics and communication tasks.
The scan cycle ends by updating the outputs, and then starts over. The cycle
time depends on the size of the program, the number of I/Os, and the amount of
communication required.

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3. Control Processor Unit (Real Time):

The central processor unit (CPU), or central control unit (CCU), performs the
tasks necessary to fulfill the PLC function. Among these tasks are scanning, I/O
bus traffic control, program execution, peripheral and external device
communications, special function or data handling execution (enhancements),
and self-diagnostics.
One common way of rating how a PLC performs these tasks is its scan time.
Scan time is roughly defined as the time it takes for the programmable controller
to interrogate the input devices, execute the application program, and provide
updated signals to the output devices. Scan times can vary from 0.1 milliseconds
per 1K (1024) words of logic to more than 50 milliseconds per 1 K of logic.
Therefore, when selecting a programmable controller other performance factors
must be considered. The user should take into account the application as well as
the speed of the controller.
4. Memory Unit:
The memory unit of the PLC serves several functions. It is the library where the
application program is stored. It is also where the PLC's executive is stored. An
executive program functions as the operating system of the PLC. It is the
program that interprets, manages, and executes the user's application program.
Finally, the memory unit is the part of the programmable controller where
process data from the input modules and control data for the output modules are
temporarily stored as data tables. Typically, an image of these data tables is used
by the CPU and, when appropriate, sent to the output modules.
Memory can be volatile or nonvolatile. Volatile memory is erased if power is
removed. Obviously, this is undesirable, and most units with volatile memory
provide battery back up to ensure that there will be no loss of program in the
event of a power outage. Nonvolatile memory does not change state on loss of
power and is used in cases in which extended power outages or long
transportation time to job site (after program entry) are anticipated.
The basic programmable controller memory element is the word. A word is a
collection of 4, 8, 16, or 32 bits that is used to transfer data about the
programmable controller. As word length increase more information can be
stored in a memory location.
5. Programmer Units:
The programmer unit provides an interface between the PLC and the user
During Program development, start-up, and troubleshooting. The instruction to
be performed during each scan are coded and inserted into memory with the
programmer.
Programmers vary from small hand-held units the size of a large calculator to
desktop stand-alone intelligent CRT-based units. These units come complete
with documentation, reproduction, I/O status, and on-line and off-line
programming ability. Many PLC manufactures now offer controller models that
can use a personal computer as the programming tool.
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Universal PLC Platform Scientech 2400GN

Under these circumstances, the manufacture will sell a program for the personal
computer that usually allows the computer that module installed in the
programmable controller.
Programming units are the liaison between what the PLC understands (words)
and what the engineer desires to occur during the control sequence. Some
programmers have the ability to store programs on other media, including
cassette tapes and floppy disks. Another desirable feature is automatic
documentation of the existing program. This is accomplished by a printer
attached to the programmer. With off-line programming, the user can write a
control program on the programming unit, then take the unit to the PLC in the
field and load the memory with the new program, all without removing the PLC.
Selection of these features depends on user requirements and budget. On-line
programming allows cautions modification of the program while the PLC is
controlling the process or the machine.

How does a Programmable Logic Controller Works?

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Difference between Computer and PLC

PLCs are often thought of as computers. To certain extent this is true: however, there
are four important differences between PLC and computer.
Real-Time Operation/Orientation:
The PLC is designed to operate in a real-time control environment. Most PLCs have
internal clocks and "watch-dog timers" built into their operations to ensure that some
functional operation does not send the central processor into the "weeds". The first
priority of the CPU is to scan the I/O for status, to make sequential control decisions
(as defined by the program), to implement those decisions, and to repeat this
procedure all within the allotted scan time.
Environmental Considerations:
PLC are designed to operate near the equipment they are meant to control. This means
that they function in hot, humid, dirty, noisy, and dusty industrial environments.
Typical PLCs can operate in temperatures as high as 140 F (60 C) and as low as
320 F (0 C), with tolerable relative humidity’s ranging from 0% to 95% no
condensing. In addition, they have electrical noise immunities comparable with those
required in military specifications. Manufacturers’ experience shows mean time
between failures (MTBF) ranging form 20,000 to 50,000 hours.

Parameters PLC PC

Environment The PLC was specifically designed Common PCs are not
for harsh conditions with electrical designed for harsh
noise, magnetic fields, vibration, environments. Industrial
extreme temperatures or humidity. PCs are available but cost
more.

Ease of Use By design PLCs are friendlier to Operating systems like

technicians since they are in ladder Windows are common.
logic and have easy connections. Connecting I/O to the PC
is not always as easy.

Flexibility PLCs in rack form are easy to Typical PCs are limited by
exchange and add parts. They are the number of cards they
designed for modularity and can accommodate and are
expansion. not easily expandable.

Speed PLCs execute a single program in PCs, by design, are meant

sequential order. The have better to handle simultaneous
ability to handle events in real tasks. They have difficulty
time. handling real time events.

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Reliability A PLC never crashes over long A PC locking up and

periods of time. ("Never" may not crashing is frequent.
be the right word but its close
enough to be true.)

Programming Languages are typically fixed to A PC is very flexible and

languages ladder logic, function block or powerful in what to use for
structured text. programming.

Data Memory is limited in its ability to This is where the PC excels

management store a lot of data. because of it's hard drive.
Any long term data
storage, history and
trending is best done on a
PC.

Just too hard to compare pricing with so many variables like I/O
Cost
counts, hardware needed, programming software, etc.

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General PLC Architecture:

PLC inputs must convert a variety of logic levels to the 5Vdc logic levels used on the
data bus. This can be done with circuits similar to those shown below. Basically the
circuits condition the input to drive an opto coupler. This electrically isolates the
external electrical circuitry from the internal circuitry. Other circuit components are
used to guard against excess or reversed voltage polarity.
PLC outputs must convert the 5Vdc logic levels on the PLC data bus to external
voltage levels. This can be done with circuits similar to those shown below. Basically
the circuits use an opto coupler to switch external circuitry. This electrically isolates
the external electrical circuitry from the internal circuitry. Other circuit components
are used to guard against excess or reversed voltage polarity.
Advantage of PLC:
Small Size
Faster Response
Wiring Reduced up to 80%
On-line Changes
Low Maintenance Cost
Easy for Troubleshooting
Disadvantage of PLC:
Too much work required in connecting wires
Difficulty with change or replacement
Requiring skillful work force finding error
Fixed program application
High initial investment cost
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Types of PLC
Programmable logic controllers (PLCs) has several types. PLC divided into two types:
Based on the size of the module and it can be classified according to its working,
Based on Size
Micro PLC or Small PLC: It is the simplest PLC with the Power Supply
module, CPU, I / O modules and communication ports in a single chassis. This
PLC types are usually limited to a few I / O discrete and can be expanded. There
are various micro PLCs on the market today. The vast majority offer analog I /
O. with just about any micro PLC, or for that matter PLC in general, when the
application requires the monitoring of various analog signals, a separate module
is required for each signal (voltage, current, temperature). Examples of this type
are CP1H Omron, Siemens S7-200, Fuji Electric SPB.
Medium PLC or Mini: It is PLC which has CPU module, I / O or
communication port are separately. Each module is connected by connector or
backplane. It has the capacity more than 2000 I / O. Examples of this type are
Omron CS1, Siemens S7-300.
Large PLC or Rack: This kind of PLC is nearly equal to the medium one but it
has large I/O capacity and more able to be connected with the higher control
systems. Examples of this type are CVM1 Omron, Siemens S7-400.

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Classified according to its Output working:

Relay based: This type of PLC are used for general purpose application.
Transistor based: This type of PLC are used for High speed application.
SCR based: This type of plc are used for heavy load switching.
Different PLC Manufacturers
Siemens
Fatek
Delta
Allen Bradley
Mitsubishi
Omron
ABB
Panasonic
GE Fanuc
LG
Criteria of Choosing PLC
Cost
No. of I/Os
Memory Capacity
Processing Speed of CPU
CPU Capabilities
No. of Timer, Counters
Interface Module
Networking & Communication Facility

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Sensor (Connected to PLC Input)

A Sensor is a device that measures a physical quantity and converts it into a signal
which can be read by an observer or by an instrument. For example, a mercury-in-
glass thermometer converts the measured temperature into expansion and contraction
of a liquid which can be read on a calibrated glass tube. A thermocouple converts
temperature to an output voltage which can be read by a voltmeter. For accuracy,
most sensors are calibrated against known standards. Sensor are two types
Digital Sensor: Digital Sensor have two unique voltage associated them to
represent the two unique digital states of 0 to [Link] voltage are commonly OV
to 24V but there are many also other.
Ex. IR sensor, Proximity sensor, Hall sensor, PIR Sensor
Analog Sensor: Analog sensor are sensor that vary with respect to time.
Ex. Level sensor, Flow sensor, Temperature Sensor, Speed sensor.
Need for Sensors
Sensors are omnipresent. They embedded in our bodies’ automobiles, airplane,
cellular telephone, radio, chemical plant, industrial plant and countless other
application.
Actuator (Connected to PLC Output)
An Actuator is a mechanical device for moving or controlling a mechanism or
System. It is operated by a source of energy, usually in the form of an electric current,
hydraulic fluid pressure or pneumatic pressure, and converts that energy into some
kind of motion.
Ex. Motor, Solenoid valve, seven segments Display, Contactor, Relay, and Buzzer.
Difference between Actuator and Sensor
A sensor controls the variable for example temperature and pressure and transfers a
signal to a indicator or transmitter. The actuator is a machine which knocks a valve or
other machine in accordance with the control signal transferred to the transducer. The
transducer generally transforms the control signal to a relative air signal which works
the actuator with a great diaphragm opposite a spring.
The mainly common actuator is an actuator of electro-servo or an actuator of
hydraulic. These are actuators of linear that transfer a piston rod to a place force and
stroke. It is utilized to pull and push at a force and fixed length (stroke). The actuator
can be utilized to transfer controls through variable geometry for example arcs used in
conjunction with cranks and rods.

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The Actuator of Hydraulic has an internal piston to the housing. The pressure of
hydraulic is docked on one end and pushes the piston to stir to the opposite end,
which forces the rod to enlarge it. Reversing the pressure of hydraulic will cause the
rod to knock back to origin position. The force that is existing is similar to the
pressure of hydraulic times the piston area.
A sensor or detectors is a tool that measures a physical quantity and transforms it into
a signal which can be interpreted by a spectator or by an device. Sensors are utilized
in everyday items for example touch-sensitive buttons of elevator and lamps which
brighten or dim by contacting the base. There are also numerous applications for
sensors of which mainly people are not aware. The appliances consist of machines,
cars, aerospace, manufacturing, robotics and medicine.

Numbering System
Data Types
There are 4 kinds of Data Types supported by most of the PLCs, which are as follows:
Bit (0,1)
Byte (combination of 8bits)
Word (combination of 16bits) = 2B
Double Word (combination of 32bits) = 2W

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Memory Types
There are different memory locations, which is represented by memory types
abbreviations
In Siemens the memory types are :
Description International
Input X
Output Y
Internal Memory M
Timer T
Counter C
Step Relay S
Data Register D
Register R

Addressing Exapmle
• X4 means input no. 4
• Y6 means output no. 6
• M3 means memory bit 3
• T34 means timer 34 (Resolution: 10ms)
• C5 Means counter 5

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Concept of Relay Functioning

What is a relay?
We know that most of the high end industrial application devices have relays for their
effective working. Relays are simple switches which are operated both electrically
and mechanically. Relays consist of a n electromagnet and also a set of contacts. The
switching mechanism is carried out with the help of the electromagnet. There are also
other operating principles for its working. But they differ according to their
applications. Most of the devices have the application of relays.

Why is a relay used?

The main operation of a relay comes in places where only a low-power signal can be
used to control a circuit. It is also used in places where only one signal can be used to
control a lot of circuits. The application of relays started during the invention of
telephones. They played an important role in switching calls in telephone exchanges.
They were also used in long distance telegraphy. They were used to switch the signal
coming from one source to another destination. After the invention of computers they
were also used to perform Boolean and other logical operations. The high end
applications of relays require high power to be driven by electric motors and so on.
Such relays are called contactors.
As the main purpose of the PLC is to reduce real world relays we convert its element
in to 3 basic symbols for develop understanding over relays for CPU.
A relay is an electromagnetically actuated switch. When a voltage is applied to the
solenoid coil, an electromagnetic field results. This causes the armature to be attracted
to the coil core. The armature actuates the relay contacts, either closing or opening
them, depending on a design. A return spring returns the armature to its initial
position when current to the coil is interrupted.

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Relay Logic
There are several kinds of logic that are made with the help of relay.
This smaller logics are the base of all kind of functioning performed in
industries.
As we get command over these types of logics we can handle even complex
functionality of plant or process.
The panel made by the relay is known as relay logic panel.

Sinking and Sourcing

One of the most often misunderstood notions in control engineering is the concept of
the Sinking and Sourcing relationship between I/O devices. This document is meant
to give a solid understanding of these concepts, and clear up the definition issues of
Sinking (NPN), and Sourcing (PNP), from both a technical and terminology
perspective. “Sinking” and “Sourcing” terms are very important in connecting a PLC
correctly with external environment. These terms are applied only for DC modules.
In general, Sinking (NPN) and Sourcing (PNP) are terms that define the control of
direct current flow in a load. They are only pertinent with DC components and should
not be associated with AC control structures. Devices like relay outputs, reed
switches, etc, are typically not affected since they are not current direction dependent
(unless they have an internal polarity sensitive devices like LEDs or unidirectional
spike suppressors.
From an electro-pneumatic control perspective, it is important to understand this
concept because it dictates which solenoid valve type (sinking or sourcing) is required
for proper operation with a specific (sinking or sourcing) output module. The same
issues also apply for inputs and sensor devices.
The following is a detailed explanation of these concepts that, in short, dictate:
“Sinking (NPN) provides a path to 0 VDC (-DC)”
“Sourcing (PNP) provides a path to +24 VDC (+DC)”

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Universal PLC Platform Scientech 2400GN

Note:
Wire all I/O points with a shared common as either sinking or sourcing.
Do not use an AC Power Supply on a DC sink/source I/O point.

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Output Device:
Sinking (NPN) Output: Are outputs that “Sink” or “pull” current through the load.
In this case the common connection to the load is the 24 VDC (+DC) line.
Sinking output modules require the load to be energized by a current, which flows
from +24 VDC (+DC), through the load, through the NPN Output Switch Device to
the 0 VDC (-DC) line. Below is a representation of the circuit connection.

“Positive side {+24 VDC (+DC)} common and Negative side {0 VDC (-DC)}
switched.”

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Sourcing (PNP) Outputs: Are outputs that “Source” or “push” current through the
load.
This means that the common connection to the load is the 0 VDC (-DC) line.
Sourcing output modules require the load to be energized by a current that flows from
+24 VDC (+DC), through the PNP Output Switch device, through the load, to the 0
VDC (-DC) line. Below is a representation of the circuit connection.

“Negative side {0 VDC (-DC)} common and Positive side {+24 VDC (+DC)}
switched.”

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Input Devices:
Sinking (NPN) Inputs: Are inputs that require an external sensor device to “Sink” or
“pull” current from the Input circuitry to 0 VDC (-DC). This means that the external
sensor device provides a current path to the 0 VDC (-DC) common point. Below is a
representation of the circuit connection.

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Universal PLC Platform Scientech 2400GN

Sourcing (PNP) Inputs: Are inputs that require an external sensor device to “Source”
or “push” current from the 24 VDC (+DC) line to the Input Circuitry. This means that
the external sensor device provides a current path from the 24 VDC (+DC) common
point to the Input circuitry. Below is a representation of the circuit connection.

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Universal PLC Platform Scientech 2400GN

Latching

Latching: Latching is the process in which once output or a coil is energized it

remains energized forever. Latching is done by contact of output or coil which we
want to switch ON Permanently.

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CPU FBs-20MA Description

CPU: The CPU executes the program and stores the data for controlling the
automation task or process. Different types of CPU are available in FATEK
PLC series.
Ex. Scientech 2400GN CPU no. is: FBs-20MA
FBs-20MA: FBs means FATEK PLC and 20MA means 12 Digital Inputs and 8
Digital Outputs, relay based PLC.
Input & Output: The inputs and outputs are the system control points: the
inputs monitor the signals from the field devices (such as sensors and switches),
and the outputs control pumps, motors, or other devices in your process.
Communication Port: The communications port allows you to connect the
CPU to a programming device or to other devices.
Status LED’S: Status LED’s provide visual information about the CPU mode (RUN
or STOP), the current state of the local I/O, and whether a system fault has been
detected., for example, the mode switch is set to the RUN position, the green RUN
indicator is lit. When the mode switch is set to the STOP position, the yellow STOP
indicator is lit

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Wiring of PLC:
Digital Input (DI) Circuit:
24VDC Single-End Input Circuit and Wiring for SINK/SRCE input:
The 24VDC single-end digital input circuits of FBS-PLC are available for high,
medium and low speed. They all have the similar circuit structures but with different
response speeds. To save input terminals, the circuit of single-end input is
implemented by connecting one end of all input points (photo coupler) inside the PLC
to the same internal common point labeled as S/S. The other end of each input circuit
is connected to corresponding terminals such as X0, X1, X2, etc. The S/S common
terminal and N single-end inputs comprise of N digital inputs (i.e., only N+1
terminals are used for N terminals). Therefore, we call this type of input structure the
single-end input. The user also needs to do the same thing when making the
connection of external digital input devices. Namely, the one end of all input devices
(e.g., buttons, switches) are connected together and called the external common wire,
while the other ends of input circuits are connected to the input terminals X0, X1, X2,
etc., of PLC. Then finish it by connecting the external common wiring and internal
common terminal S/S to the positive/negative terminals of the 24VDC power. When
connect the internal common terminal S/S to 24V+ (positive) and the external
common wire to 24V- (negative), then the circuit serves as SINK input. On the
contrary, while exchange the wiring of the above internal and external common will
serve as a SRCE input. The above wiring schemes can illustrated below:
● Wiring of single-end common SINK input (internal common terminal S/S .
24V+, external common wiring 24V-)

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● Wiring of single-end common SRCE input (internal common terminal S/S .24V-
, external common wiring 24V+)

Digital Output (DO) Circuit:

The digital outputs of FBS-PLC are available in the single-end output circuit for
saving terminals. Here we are having relays kind of output device for the single-end
output. Since the relay is bilateral, even when used in single-end output, it can serve
as SINK or SRCE output. At the right side of terminal block of FBS-PLC, there is a
place for making SINK or SRCE label. The Figure shown below is labeling examples
of Relay models with no SINK/SRCES polarity:

Indicator of Relay (black and unmarked)

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Single-End Output Circuit:

A single-end output in each digital output (DO) takes up only one terminal. But since
any output device has two ends, the one end of several output devices have to be
connected together to one common point (called output common) for single-end
output.
Then each output point can output via this common point. The more output device
share a same common points, the more terminals are saved, while relatively
increasing the current running through the common point. Combination of any output
common with its individual single-end outputs are called a Common Output Block,
which is available in 2, 4 and 8PTs (high-density module) in FBS-PLC. Each
Common Output Block is separated from one another. The common terminal has a
label initiated with letter “C”, while its numbering is determined by the minimum Yn
number which comprises the output block. In the example of the Figure below, the
number of common terminal of output block Y2 and Y3 is C2, while the number of
common terminal of output Block Y4, Y5, Y6 and Y7 is C4. The various single-end
common output circuits are described below:
Structure and Wiring of Single-End Relay Output Circuit:
Because relay contacts have no polarity, it can be applied for AC or DC load power.
Each relay can provide current up to 2A. The maximum rated current in all output
commons of FBS-PLC is 4A. Its mechanical lifetime can reach up to 2 million times,
while the contacts have a shorter lifetime. The lifetime also varies depending on
working voltage, load type (power factor cos.) and contact current. In the case of pure
resistive load (cos. =1.0) at 120VAC and 2A, the lifetime of contacts is about 250
thousand times. While for high inductive or capacitive load with [Link] to 0.2 and
current within 1A, the lifetime decreases rapidly to about 50 thousand times
(AC200V) or 80 thousand times (AC120V).

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FBS-4A2D Hardware Description

External power input terminal: Power Supply of analogue circuit for FBs-4A2D,
the voltage can be 24VDC ± 20% and should be supplied with 4W of power at least.
1. Protecting ground terminal: Connect to the shielding of signal cable.
2. Expansion input cable: It should be connected to the front Expansion unit, or
the expansion output of main unit.
3. Expansion output connector: provides the connection for next expansion unit.
4. Power indicator: It indicates whether the Power Supply at analogue circuit and
external input power source are normal.
5. AG Ground: No connection is needed in general; except when the common
mode signal is too high. See examples overleaf for details.
6. Output terminal : of CH0.
7. Output terminal : of CH1.
8. Input terminal : of CH0.
9. Input terminal : of CH1.
10. Input terminal : of CH2.
11. Input terminal : of CH3.

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FBS-4A2D Hardware Jumper Setting

Pin Layout in control board (Open Top Cover) Pin Layout on I/O Board
(Remove Control Board)

FBs-4DA/2DA Jumper location

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(Analog Output):
● Output Code Format Selection (JP1):
Users can select between unipolar and bipolar codes. The output range of unipolar
codes and bipolar codes is 0~16383 and –8192~8191, respectively. The two extreme
values of these formats correspond to the lowest and highest output signal values,
respectively (see table below). In general, the output code format is selected according
to the form of output signals; i.e. unipolar codes for unipolar output signals; and
bipolar codes for bipolar output signals. In doing so, their correlations will become
more heuristics. Yet, as the format of output code on all channels is selected from JP1,
it is the user’s choice to select unipolar or bipolar codes if both are used on different
channels. See diagram above for location of JP1:

● Output Signal Form Setup (JPA&JPB):

Users can set the output signal form (voltage/current) of individual channels;
except the polarity and amplitude which are common.

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(Analog Input)
● Input Code Format Selection (JP1):
Users can select between unipolar and bipolar codes. The input range of unipolar
codes and bipolar codes is 0~16383 and –8192~8191, respectively. The two extreme
values of these formats correspond to the lowest and highest input signal values,
respectively (see table below). For example, if the input signal type is set to -10V~
+10V, the unipolar code corresponding to the input is 8192 and the bipolar code
corresponding to the input is 0 for OV input. If the input is 10V, the unipolar code
corresponding to the input is 16383 and the bipolar code corresponding to the input is
8191. In general, the input code format is selected according to the form of input
signals; i.e. unipolar codes for unipolar input signals; and bipolar codes for bipolar
input signals. In doing so, their correlations will become more heuristics. Unless it is
necessary to make a deviation conversion through FUN32; otherwise, do not select
bipolar codes for unipolar input signals (see FUN32 description for details). The
format of input codes of all channels is selected from JP1. See above diagram for the
location of JP1:

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● Input Signal Form Setup (JP3&JP4):

Users can set the input signal form (voltage/current) of individual channels; except
the polarity and amplitude which are common. The location of jumpers is tabulated
below:

● Voltage or Current setting (JP4&JP9):

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FBS-4A2D Analog Input Format Planning:

The Figure below shows the FBs-4A2D analog input format planning screen in Win
Proladder.

FBS-4A2D Input/Output Characteristics:

Users can select the I/O ranges of FBs-4A2D from the jumpers described above, such
as V/I, U/B (I/O codes), U/B (signal form), 5V/10V, etc. The I/O conversion
characteristics of these settings are illustrated below. Users can adjust different I/O
forms by coordinating the conversion curve with various V/I (voltage/current) I/O
settings.
Bipolar 10V (20mA) Span:

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14 bit input/output format:

12 bit input format:

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Bipolar 5V (10mA) Span:

14 bit input/output format:

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12 bit input format:

Unipolar 10V (20mA) Span:

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14 bit input/output format:

12 bit input format

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14 bit input/output format:

12 bit input format:

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Address Allocation of FBS-PLC Analog Inputs/Outputs

FBs-4A2D offers 4 AD points and 2 DA points. The AD points number starts from
the one nearest to the PLC, the number in order is CH0~CH3 (module 1); CH4~CH7
(module 2); CH8~CH11 (module 3); etc, accumulates in serial; i.e. add 4 to each
module, the total is 64 points (CH0~CH63) corresponding top the value IRs inside the
PLC (R3840~R3903), respectively. In DA point numbering, from the one nearest to
the PLC, the number runs from CH0 through to CH63 in serial, the total is 64 points
corresponding top the value ORs inside the PLC (R3904~R3967), respectively. After
connecting FBs-4A2D to the expansion interface on the PLC, FBs-PLC will
automatically detect the number of AD/DA points. WinProladder will automatically
detect and calculate the value IRs/ORs on the system after connecting to the PLC.
● Wiring of PLC:

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How It Works
The ladder program given with this has to be first downloaded in the PLC (for
downloading procedure of ladder program please refer operating manual of PLC
platform along with manual of analog module) and then run.
The default factory settings of 4A2D analogue input/output module are:
● Input code format: Bipolar (-8192~+8191)
● Input signal type and range: Bipolar (-10V ~ +10V)
● Output code format: Bipolar (-8192~+8191)
● Output signal type and range: Bipolar (-10V ~ +10V)
For those applications that require the setting differ than the above default setting
should make some modifications of jumper position according to above tables.
While application, besides the setting of jumper should be conducted, the AI module
configuration of Winproladder also needs to be performed

Programming Languages and Techniques

PLC languages are designed to emulate the popular relay ladder diagram format. This
format is read and understood worldwide by maintenance technicians as well as by
engineers. Unlike computer programming, PLC programming does not require
extensive special training. Applications know-how is much more important. Although
certain special techniques are important to programming efficiency, they are easily
learned. The major goal is the control program performance. Another difference
between computers and PLCs is the sequential operation of the PLC.

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This is an extremely useful feature that allows easy programming of shift registers,
ring counters, drum timers, and other useful indexing techniques for real-time control
applications.
Maintenance and Troubleshooting:
As a plant floor controller, the PLC must be maintained by the plant electrician or the
instrument technician. It would be highly impractical to require computer-type
maintenance service. To this end, PLC manufactures build in self-diagnostics to allow
for easy troubleshooting and repair of problems. Most PLC components are modular
and simple to isolate; remove-and-replace (system modules) diagnostic techniques are
usually implemented.

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Justification for the Use of PLCS

The only consideration of importance in any control system is to get the process
variable effectively and reliably. When control options are available, several factors
can be taken into consideration in making an implementation decision. Some of these
factors include the controller's cost, versatility, flexibility, and expandability.
Cost:
The ideas associated with cost are discussed first because this is usually the first
issue which users consider when selecting a control technology. In most cases,
the two things initially known about a problem are the results desired and the
budget available for fixing the problem.
The danger involved in using the desired results and the budget as the primary
selections criteria is that at the beginning of a project the understanding of the
problem is limited. If the user's focus on the problem is too narrow, the solution
might solve only the perceived symptoms of the problem while the problem
itself many merely reappear in an alternate form at some other point in the
process.
If the budget assigned to solve a problem is based only on the initial investment
required for the programmable controller hardware, this will under estimate the
total cost by neglecting costs associated with labor, maintenance, and downtime.
The effect of this oversight usually fosters a "penny wise but pound foolish"
philosophy and results in the selection of a controller that initially costs less but
does not quite get the job done.
Purchasing a larger and therefore more expensive programmable controller
might in some situations be cost-effective if labor, maintenance, and down time
costs are also considered. Similarly, while programmable controllers are more
expensive than individual solid-state control units, if the indirect costs are also
considered then the PLC becomes a cost-competitive alternative.
Versatility:
The multifunction capability of a PLC allows control logic decision-making,
versatility rarely possible with other systems. The ability to combine discrete
and analog logic is s powerful tool for the controls engineer. This is especially
evident in the control of batch processes. Entire start-up and shut down
sequences can be performed by the sequencer logic, and analog logic can be
brought in during the batch run. Control of critical start-up parameters, such as
temperature and pressure, can be precisely preprogrammed for each start-up
step. Temperature stepping is easily programmed, as are the feed forward
calculations that are used in some polymer reactors. All of these types of PLC
applications are currently in use today and are well documented.

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Flexibility:
As a process goes on-line and is refined, the control equipment should be easily
reconfigured to accommodate such modifications. Because one common device
performs multiple functions in a plant, fewer spare parts are needed, and the
programming language is technician friendly. In addition, the digital nature and
self-diagnostic capabilities are strong additional justification for the PLC.
Expandability:
As a process matures, it is inevitable that enhancements will be added. These
usually require more inputs and outputs. For hand-wired relay systems this
usually necessitates extensive panel changes, which generally are problematic.
A PLC easily accommodates the additional I/O without requiring changes in the
existing wiring: the new points are merely placed in the system.
Another advantage of the PLC is that it allows piecemeal implementation of
projects. System can be brought up on-line quickly and can be gradually
converted over to the PLC to be reprogrammed while operating permits
automation of processes that are too expensive to shut down. This technique is
valuable to new as well as retrofit projects (revamps).

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Applications of PLC
The control of cutting machine with variable length.

3-axes position control.

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Level Control

Batching Process.

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Pick & Place

Conveyor control

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Elevator control

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Software Installation
How to install Fatek WinProladder Software:
Double click on the software icon is shown below.

Icon for the WinProladder setup

After above step Welcome window will open then Click on Next Tab is shown
below.

This window describes that installation process start on clicking next button.
After above step User Information window will open then click on Next tab is
shown below below.

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After above step Choose destination Location window will open then click on
Next tab is shown below.

After above step Select Program Folder window will open then click on Next
tab is shown below.

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After above step Start Copying Files window will open then click on Next tab is
shown below.

After above step Setup Complete window will open then click on Finish tab is
shown below.

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How to Open Win proladder Software

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Working Desk of the WinProladder

Before we proceed to build the first application program, we should first acquaint
with the desk environment of Win Pro ladder. The screen shot shown on below is a
typical working screen of Win Pro ladder.

The screen as you can see is consist of many operating areas, among these areas the
most important are as follows
Main Menu:
Most of the operations can be activated by using the mouse to left click the main
menu and the pull down sub-menu.
Tool Bar:
Most of the major operations can be activated by using the mouse to left click the
button on this area.
Component Pallet:
The buttons in this area are used while perform the ladder program entry or editing.

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Status Bar:
This area provides the information about the PLC connection mode and it's
connecting status, current cursor position, ladder memory utilization, insert or
overwrite mode.
Project Tree:
This area outlines the whole project with hierarchy tree. All the jobs needed to work
out can be activated by direct click the mouse button on the tree object. Which lead an
intuitive working environment.
Ladder Diagram:
User can input or monitor the ladder program in this area. WinProladder allow the
user open multiple ladder windows in this area at same time. The ladder windows can
be tile horizontal or vertical or cascaded. Each window can contain more than one
program unit, while operating can click the tab on the window to bring out the desire
program unit.
How to change PLC Model No. in Win proladder

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First open the “Winprolaader” software, this window will be open. Click on
“File” (in main menu) then click on “New Project” is shown below.

After above step Project information window will open, then click on “Edit”
Tab is shown below.

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After above step “PLC Model” window will open then Select PLC “Series to
FBs-“, “Point to 20” and “Model to MA” is shown below.

After above step click on OK tab is shown below.

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Ladder Program Testing

In this topic we will changed the working mode from off-line to on-line. Because all
the modifications to project will only save in the disk while in off-line operating
mode, so before begin to test the program we must first save the project data to PLC.
The projects data can be transferred to PLC include ladder program, element
comment, table data and configurations while network comment and program unit
comment can only exist in the project file.
Save project data to PLC:
Click the menu items as follows
File -> Save AS -> To PLC then a dialog will pop up as follow

There are three pre-defined connection sessions can be found in the 'Connection
Name' combo list which are RS232, UDP, TCP. In this tutorial we assume to connect
the PLC with serial line so we can pick RS232 or create a new cession with click the
New button which will bring out an wizard to direct you to create a new cession. If
you don't want to create a new cession but the pre-defined session is not exactly what
you want then you can click the Edit button to change it.
After click the OK button the WinPro ladder will try to connect with PLC, if the
connection success then a message box will shown as below

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Click OK button to return to the ladder window.

PLC start and run control:
[Mouse]
Click the menu as follows
PLC -> Run PLC -> OK to start the PLC.
or while PLC is running
PLC -> Stop PLC -> OK to stop the PLC.
[Keyboard]
Press the keys
Ctrl + F9 Enter to Stop the PLC.
F9 Enter to start the PLC.

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Simulation of Winproladder

Note: Simulation process will work for only digital input and outputs.

If you want to simulate a Program, go to PLC button then click on

Simulation button as shown below.

Go to PLC button then click on Run PLC button as shown below.

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Your simulation will start as shown below.

Right click on A Contact icon , then click on ON button as shown

below.

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When X0 (Input ) will on then Y0 (Output) will off as shown

below.

Right click on A Contact icon, and then click on OFF button as

shown below.

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If you want to stop a Simulation , go to PLC button then click on

Stop PLC button as shown below.

Go to PLC button then click on End Simulation as shown below.

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Connection Details
Scientech 2400 Input Output Interface PCB

20 Pin box type connector detail

Terminal Block Connection Detail

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Connection Detail of Terminal Block of Input & Output Side

Input Side Terminal Block Connection Detail

Output Side Terminal Block Connection Detail

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Pushbutton Switch

Toggle Switch

Visual Indicator (LED)

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Terminal Block Connection detail with PLC and Component

Pushbutton Switch

Toggle Switch

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IR Sensor

Limit Switch

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Audio Indicator (Buzzer)

Visual Indicator (LED)

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DC motor

Pilot Lamp

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Scientech 2400GN Input Addressing Detail

PLC Input Address Component Detail
X0 Pushbutton Switch_1 (PB1)
X1 Pushbutton Switch_2 (PB2)
X2 Pushbutton Switch_3 (PB3)
X3 Toggle Switch_1 (TS1)
X4 Toggle Switch_2 (TS2)
X5 Toggle Switch_3 (TS3)
X6 Toggle Switch_4 (TS4)
X7 IR Sensor
X8 Limit Switch
Scientech 2400GN Output Addressing Detail
PLC Output Address Component Detail
Y0 Buzzer
Y1 LED1
Y2 LED2
Y3 LED3
Y4 LED4
Y5 DC Motor
Y6 Pilot Lamp & Realy1
Y7 Realy2

Scientech 2400GN Universal PLC Platform Ferrule No. Detail

Ferrule Input Section Ferrule Output Section
no. no.
17 X0 or I/P 1 or Pushbutton_1 0 Y1 or O/P1 or LED1
18 X1 or I/P 2 or Pushbutton_2 1 Y2 or O/P2 or LED2
19 X2 or I/P 3 or Pushbutton_3 2 Y3 or O/P3 or LED3
20 Pushbutton_4 3 Y4 or O/P4 or LED4
21 Pushbutton_5 4 LED5
22 X3 or I/P 4 or Toggle witch_1 5 LED6
23 X4 or I/P 5 or Toggle witch_2 6 LED7

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24 X5 or I/P 6 or Toggle witch_3 7 LED8

25 X6 or I/P 7 or Toggle witch_4 11 Y0 or O/P1 or Buzzer
26 Toggle witch_5 12 Y5 or O/P6 or DC Motor
27 Toggle witch_6 10 +5V
28 Toggle witch_7 13 Y6 or O/P7 or Relay1
& Pilot Lamp
29 Toggle witch_8 14 Y7 or O/P8 or Relay2
30 X7 or I/P 8 or IR Sensor 15 Relay3
31 X8 or I/P 9 or Limit Switch 16 Relay4
8 +24V DC 33 Analog Output_1
9 GND 34 Line
32 Analog Input_1 35 Neutral
36 Earth
Note: After turning ON the Panel, Please check if the supply (+24V, +5V, Ground
2400GN Input/output interface PCB)is correct at their respective points. if the supply
is not coming the please check the connections. Also if the wiring is loose, use a
screw driver to tight the screws for proper connections.
Note:
We have used 3 push buttons, 4 toggle switches,1 IR sensor, 1 Limit switch, 6 LED’s,
1buzzer,1 dc motor in our experiment. The other 2 push buttons, 4 toggle switches, 2
LED’s have been left for the user to interface any other device if he wants to.
Note:
If the LED continues to glow during operation, then rotate the preset available on the
PCB to turn OFF the LED. Then bring an object in front of the IR Sensor. The LED
should glow and when the object is removed, the LED is OFF.

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Experiment 1
Objective: Study and use the NO (normally open) and NC (normally close)
instruction bit.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
NO (Normally open): Normally Open Contact means at initially the contacts are
open (OFF). So, when an electrical supply is applied to these components is not been
transmitted to other end. The moment you apply an external source (electrical or,
mechanical) to it, the contacts are in close (ON) state and the signal will transmitted to
other end as shown in next figure.

In PLC programming we frequently use these No as one of the input to PLC. While
PLCs are capable of sensing and generating analog values, internally programmable
controllers use signals that are ON or OFF. These ON or OFF conditions correspond
to binary values 1 or 0.
For example, a binary 0, also called logic 0, can used to indicate switch is OFF and a
binary 1, also called logic 1, can used to indicate switch is ON.

NO switch when it is in zero state

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As shown in above figure, NO switch is in normal condition as shown. So, the

electrical supply can’t flow through the circuit.

NO switch when it is in one or high state it will be like NC switch

In above figure, the moment we push NO, it will make contact and ultimately supply
will flow through the circuit (as shown by the red arrow).
NC (Normally Closed):
This is another type of input to PLC; initially the contacts are close (ON). So, when an
electrical supply is applied to these components is being transmitted to other end. The
moment you apply an external source (electrical or, mechanical) to it, the contacts get
open (OFF) and the signal will transmitted to other end as shown in next Figure.

But as shown in next figure, when we push the component or button it will open the
contact and ultimately supply will cut-off from the circuit.

NC switch when it is in low state or zero state, it is like NOT gate

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Status of NC switch after toggle (become NO)

Now, we are going to implement it practically on the Scientech 2403. But by

following the procedure below-
Procedure:
At first Connect mains cord to mains socket of Scientech 2400GN and Turn the
rocker switch in ON Position.
Connect 4 Pin Din connector to Port 0 of PLC and Serial (RS232) connector to
PC COM Port.
Open the “Win Proladder” software to follow the given below path.

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When you open “Win proladder” software this window will open is shown
below.

For open a New Projects, you go to “File” in menu bar and click on “New
Project” is shown below.

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After click on “New Project”, “Project Information” window will open. Then
click on “Edit Tab” is shown below.

After Click on “Edit Tab”, “PLC Model” window will open. You select “Series”
FBs-, “Point” 20, “Model” MA then click OK Tab is shown below.

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After above step click on “OK Tab” is shown below.

After above step “WinProladder” Software Window will open is shown below.

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Click on A Contact (Normally Open Contact) which is encircled in red shown

below.

Software window – how to select a NO switch as an input?

Click on Ladder Programming window (on blue Box) and after that Element
“Edit window” will open, you assign address to “X0” and “Comment” to
Pushbutton_1 then click on “OK” tab is shown below.

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After assigning Input Address and Comment NO contact is shown below.

Click one Coil icon which is encircled in red shown below.

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After above step Click (on blue box), “Element Edit” window will open and
assign “address” to Y0 and “Comment” to Buzzer then click on “OK Tab” is
shown below.

Software window – how to select an output?

Your network 1 (N0000 ) program is complete is shown below.

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Take one B Contact (Normally Closed Contact) which is encircled in red and
assign “Address” to X1 and “Comment” to Pushbutton _2 is shown below.

Software window – how to select a NC switch as an input?

Take one Coil and assign “Address” to Y1 and “Comment” to LED_1 is

shown below.

Software window – how to select an output?

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Your normally open and Normally closed contact program is complete is shown
below.

Use of Input and Output

If you want to comment a program go to “project tree” and Double click on
“Comment” then click on “Program unit comment”. After that “Program unit
comment” window will open is shown below.

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Double click on “Main_unit1 Comment” then enter the comment and click on
“OK tab” is shown below.

After above step click on “OK” tab is shown below.

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If you want to comment each network, go to “Project tree” and click on

“Network No.” then “Network Comment” window will open is shown below.

Double click on “Network Comment” then enter the comment for First Network
(N000) and click on “OK tab” is shown below.

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Double click on “Network Comment” then enter the comment for Second
Network (N001 )and click on “OK tab” is shown below.

Project and Network comment is completed.

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For Run a Program you go to “PLC” in main menu bar and click on “On-Line”
Option is shown below.

After Compilation of Program we have to download the program

After above step click on “Edit Tab” is shown below.

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Select your “COM Port No.” like COM3 then click on “OK Tab” is shown
below.

In “On-Line” window click on “OK Tab” is shown below.

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After above step “Data Receiving” window will open, that means your
downloading process is start shown below.

Window for down loading process in progress

After above step “PLC Status” window will open, then click on “OK Tab” is
shown below.

Window for PLC status

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For Run a PLC go to “PLC” in Main Menu Bar, then click on “Run PLC” option
is shown below.

Window to put the PLC in Run mode

After above step “PLC is Stopped” Window will open, then click on “OK Tab”
is shown below.

After enabling the RUN PLC button it will give another window

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In case of Normally Closed contact X1 (Pushbutton Switch _1) is OFF, your

output Y1 (LED_10 is ON is shown below.

When you press X0 (Pushbutton Switch_1), Output Y0 (Buzzer) will be OFF

then You release the X0 (Pushbutton Switch_1), output Y0 (Buzzer) will be
OFF and You press X1 (PushbutonSwitch_2), output Y1 (LED_1) is OFF is
shown below.

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After enabling the Run, we can check the output by toggling or switching the
input
For stop a PLC you go to “PLC”( in Main Menu Bar) then click on “Stop PLC”
option is shown below.

Window to Stop the PLC

After above step “PLC is Running” window will open and click on “OK Tab” is
shown below.

Confirmation to Stop the PLC

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You want to OFF line the “PLC”, you go to PLC (in main menu bar) and Click
on “OFF” Line is shown below.

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So, after PLC is in stop mode, it will again come into normal window.

Questions:
1. What Normally Open Contact means?
2. What Normally Closed Contact means?
3. What are the functions of left and right vertical lines?
4. 3 switches and 2 bulbs
B1 has to change status is S1 or S2 change the status
B2 has to change status is S2 or S3 change the status

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Experiment 2
Objective: Study the use of Logic Gate (OR Gate).
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
The OR function
Last but not least the OR gate is associated with the following symbol that also can
have any number of inputs but only one output.

The truth table below shows that the output is turned on (1) when any of the inputs are
true (1). An easy way to remember this is OR works like addition.

Input A Input B Output

0 0 0

1 0 1

0 1 1

1 1 1

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Procedure:
Take two A contact (NO) and assign address first NO contact to X0 and
comment to PushbuttonSwitch_1 and second NO contact to X1 and comment to
PushbuttonSwitch_2 and joining a 2 NO contact click on Vertical Line in
(Instruction bar) is shown below.

Use of NO Contact
After above step you take one coil and assign address Y2 (LED_2) is shown
below.

USE of OR Gate Logic

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Compile, Download and Run the program of OR Gate.

When you Press or enable the Input X0 (Pushbutton_1) or Input X1
(PushbuttonSwitch_2) output Y2 (LED_2) is ON is shown below.

Questions:
1. Draw the ladder diagram for NAND Gate?
2. Draw the ladder diagram for XOR Gate?
3. Draw the ladder neither Diagram for NOR Gate?
4. Draw the ladder diagram for XNOR Gate?
5. Draw the ladder diagram for following equation
F= (AB+BC+AC)*ABC+ AC

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Experiment 3
Objective: Study and use of S (Set) and R (Reset) bit instruction.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
In previous experiment we used toggle switches to get the output on. But if we use
momentary push buttons so what will happens? As we push the buttons the output
will ON but as soon as we release the buttons output will OFF. That is not happened
with toggle switches, because they stick to stated position so as to stable the output.
Momentary switches are those who can’t stick to their position as we release the
thumb or finger pressure. So what is the solution for this as we want the output should
be ON after we release our finger from button. There is solution or function for this
type of problem is use of S (Set Bit) and R- (Reset Bit).
S (Set Bit): Set bit is used to set the output high until it is not reset.
R (Reset Bit): Reset bit is used to reset the output low until it is set. As we use in the
next example
Procedure:
Take one NO bit and assign address to X3 and comment to Toggle Switch1 and
take one Set Bit and assign address to Y6 (Pilot Lamp) is shown below.

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Take one NO bit and assign address to X4 and comment to Toggle Switch2 and
take one Reset Bit and assign address to Y6 (Pilot Lamp) is shown below.

Use of set and Reset bit in programming

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Compile, Download and Run the program of Set &Reset bit.

When you enable the X3 (Toggle Switch1) then Output Y6 (Pilot Lamp) will be
ON is shown below.

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When you press or enable input X4 (Toggle Switch2) output Y6 (Pilot Lamp)
will be OFF is shown below.

Questions:
What is set bit?
What is Reset bit?
Build a program using set bit and reset bit, when you ON the switch one 4 LED
Will be ON then second switch is ON 2 LED will be OFF.
Boolean Execution speed Sec. per instruction of FB’s 14MA
PLC_________?(0.33 μs/Sequential instruction in average/0.22 μs/Sequential
instruction in average)
Program Size of FB’s 14MA is __________? (2048/4096)

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Experiment 4
Objective: Study and use of memory bit.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
You can use the bit memory area (M memory) as control relays to store the
intermediate status of an operation or other control information. You can access the
bit memory area in bits, bytes, words, or double words.
Procedure:
Take memory bit and assign X0 (Pushbutton_1) and take set bit and assign M0.
Take another NO bit and assign M0 and take coil and assign Y1 (LED_1).Take
another NO bit and assign X1 (Pushbutton_2) and take reset coil and assign M0
is shown below.

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Compile, Download and run the program of memory bit.

When you enable or ON the X0 (Pushbutton_1) memory bit M0 is ON .When
memory bit M0.0 is ON, Y1 (LED_1) is ON is shown below.

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When you disable or OFF the X0 (Pushbutton_1), Output Y1 (LED_1) will be

ON. When you enable X1 (Pushbutton_2), memory bit M0 will be OFF .When
M0 is OFF then Y1 (LED_1) will be OFF is shown below.

Questions:
What is memory bit?
What is latching?
Draw a ladder diagram for Latching.
What is the function of opto coupler?
PLC was made for replacing ______________ logic. What are the
disadvantages of earlier logic?

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Experiment 5
Objective: Study and use of Timer instruction.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Why to Use timers? We have application where there is requirement of heater. Where
the heating procedure must be on after certain specified period. What we will do now,
yes we will use Timer.
This instruction counts time when the enabling input is on. When the current value is
greater than or equal to the preset value timer bit is on.
The timer current value is cleared when the enabling input is off. This timer is
continues counting after preset is reached, and it stops counting at a maximum value
of 32767.
One precaution must be taken, that we can’t share same number for Timer and can’t
have more than one timer having same number that is if we use T0 in our program, we
can’t use this number for either to any timer having different preset value.
If we take an example in which, if we want a output which may be a LED or any kind
of output motor, valves etc, which will ON after some time delay when an input is
given to it.
In this we can use, timer which will hold the ON state and release or ON output
connected to it after the current value reaches to the preset value.

Tn : Timer Number.
PV : Preset value of the timer.
Timer No. Resolution
T0 – T49 0.01s
T50 – T199 0.1s
T200 – T255 1s

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Procedure:
Take one No bit assign it X6 (Toggle Switch_4) and take timer from either
clicking on T button or on F that is function button in the menu bar which is
encircled in Red and assign “T” to T50 and “PV” to 20 then click on OK tab is
shown below.

After that take output coil after the timer instruction we can place our output
directly, then take output assign it Y6 (Pilot Lamp) is shown below

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Download and run the program of Timer.

When you enable or ON the input X6 (ToggleSwitch_4), Timer T50 will be
Start counting is shown below.

After 2s (T50 = 0.1 (Resolution) X 20 = 2s) output Y6 (LED_6) will be ON is

shown below.

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Questions:
What is TON Timer?
Number of Resolution in TON timer?
Draw a ladder program shows how to trigger staircase lighting. The ON
pushbuttons on the different floors are all connected to input X0. After the ON
button has been pushed, the light (output Y0) is switched on for 30 s. If the ON
button is activated again during the 30-s time interval, the time interval is
restarted. This ensures that the light will not go out until 30 s after the last time
the button is pushed.
Draw the ladder program demonstrates a step sequence in which each step is
followed by certain actions. The steps follow one after another, and a step is
only executed when all of the conditions stipulated for it have been met.
Precondition : Active Outputs
First step : X0 is set. Y2 and Y3
Second step : Timer T37 (5 s) runs out. Y1 and Y4
Third step : Timer T38 (5 s) runs out. Y0 and Y5
Fourth step : X2 is set. Y1 and Y3 and Y5
Fifth step : Timer T39 (5 s) runs out and X3 is set. Y3.
Reset step sequence (X0 is set). None

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Experiment 6
Objective: Study and use of cumulative timer instruction
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
In our earlier discussion we have gone through the simple timer. In this experiment
we will see cumulative timer, so why there need of this particular type of timer when
we already have simple timer. To answer this question, we will consider an example
and see what potential problem in it is.
We have critical heating process, where we have to have precise heating time for a
particular product. If this product gets heat more it is going to damage whole process.
We have asked to do write a program for this. What we will do for this, we will take
Ton as we have take in our earlier example.
We will take scenario, during process by any reason supply gets cut off for small
time, what will happen have you realized or noticed the potential problem in this
program. The Problem is, the product will overheated and process will damaged.
In simple words, the cumulative timer is, timer which can hold or accumulate its
current value when the enable power supply is OFF, and continue counting when the
power supply is regains.

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CV : Register storing elapse time (current value)

PV : Preset value of timer
The operation for this instruction is the same as that for the basic timer (T0~T255),
except that the basic timer only has a "timing control" input - when its input is 1 it
starts timing, and when input is 0 it get clear. Every time the input changes, it starts
timing again and is unable to accumulate. Timing with this instruction is only
permissible when enable control "EN" = 1. With this instruction, when timing control
"TIM" is 1, it is the same as a basic timer, but when "TIM" is 0, it does not clear, but
keeps the current value. If the timer need to clear, then change enable control "EN" to
0. When timing control "TIM" is once again to be 1, it will continue to accumulate
from the previous value when the timer last paused. In addition, this instruction also
has two outputs, "Time up TUP" (when time up it is 1, usually it is 0) and "Time not
up" (usually it is 1, when time is up it is 0). Users can utilize input and output
combinations to produce timers with various different functions.
Procedure:
Take No bit and assign X5 (Toggle Switch_3) and take cumulative timer from
F Function (which is encircled in Red) cumulative timer then click on OK tab
is shown below.

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Take another NO assign it X6 (Toggle switch_4) it will used to enable the timer
is shown below.

Take outputs TUP and NUP assign it Y1(LED_1) and Y2 (LED_2) respectively
is shown below.

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Compile, download and run the cumulative timer program.

When you run the program Y2(LED_2) will be ON is shown below.

You ON or enable the X5 (Toggle Switch_3) timer T0 will not start for counting
is shown below.

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When you enable the X6 (ToggleSwitch_4) timer T0 will start counting is

shown below.

When you OFF or disable the X5 (Toggle Switch_3) timer T0 will stop at
current position is shown below.

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When you again enable the X5 (ToggleSwitch_3) timer will start counting at
previous position. When timer current value is greater than the preset value Y1
(LED_1) will be ON and Y2 (LED_2) will be OFF is shown below.

Questions:
1. What do you mean by input scan?
2. What do you mean by output scan?
3. What is the function of logic scan?

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Experiment 7
Objective: Study and use Special or Pulse memory bit
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
M1922 : This memory bit generate 1s clock pulse.
M1923 : This memory bit generate 60s clock pulse.
Procedure:
Take NO bit and assign M1922 (1s clock pulse) and take coil and assign Y3
(LED_3). Take another NO bit and assign M1923 (60s clock pulse) and take
coil and assign Y4 (LED_4) is shown below.

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Compile. Download and run the program of Pulse memory bit.

M1922 generate 1s clock pulse then output Y3 (LED_3) will be ON or OFF
according to M1922 memory bit and M1923 generate 60s clock pulse then
output Y4 (LED_4) will be ON or OFF according to M1923 is shown below.

Questions:
How to generate pulse 30s ON and 30s OFF.
How to generate a pulse for 0.5s ON and O0.5s OFF.
What is name of communication standard cable are used for FATEK PLC
programming.

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Experiment 8
Objective: Study and use Counter instruction.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Counters used in PLCs Serve functions similar to mechanical counters. They compare
accumulated values with preset values in order to control circuit functions. Control
applications that use counters commonly include the following functions:
Count to a preset value and cause an event to occur
A bottling machine, for example, may use a counter to count bottles into groups of six
for packaging.
Counters, represented by boxes in ladder logic, increment or decrement one count
each time the count input transitions from a logic 0 to a logic 1.
Counter:
The counter counts up from a current value to a preset value (PV).
Input C is the count input. Each time C transitions from logic 0 to logic 1 the
counter increments by 1.
Input R is used to reset the counter to zero.
A preset count value is stored in PV input.
If the current count is equal to or greater than this preset value, the output bit
turns on.

Cn: The Counter number

PV : Preset value
There are total 200 16-Bit counters (C0~C199). The range of preset value is between
0~32767. C0~C139 are Retentive Counters and the CV value will be retained when
the PLC turns on or RUN again after a power failure or a PLC STOP. For Non
Retentive Counters, if a power failure or PLC STOP occurs, the CV value will be
reset to 0 when the PLC turns on or RUN again.
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Procedure:

Take No bit assign X7 (IR Sensor) and take C from counter button or Function
instruction which are encircled in Red and assign it C to C0 and PV to 10 then
click on OK tab is shown below.

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Take another NO bit and assign X0 (Pushbutton_1) connect to CLR of Counter.

Take coil and assign address Y0 (Buzzer) is shown below.

Compile, download and run the program of counter .

When any obstacle infront of X7 (IR SENSOR) counter will start counting is
shown below.

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When counter C0 current value is equal to Preset value, Output Y0 (Buzzer ) will be
ON is shown below.

You want to reset a counter C0, press or enable the input X0 (Pushbutton_1) is
shown below.

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Questions:
1. How Does A PLC Operate?
2. What is the function of PLC?
3. What is the function of counter in PLC?
4. Make a counter actuated input X0 such that when X0 activates ones then LED#1
Glows, after second activation LED#2 Glows & others turns off. Third
activation glows LED#3 & remaining off & lastly on the final activation LED#4
glows only. After fourth activation this sequence is repeated in the continuous
manner for each activation of X0.

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Experiment 9
Objective: Study and use of Compare instruction
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Compare instructions are used where we want compare between one quantity to other.
If suppose, we have an application, where a car parking system is there, we want to
assure that when every ten cars enter the parking lot, the lot full light will turn ON.
So, how we are going to handle this situation? Yes you are correct we are using here
counters in this particular application.
As sensor which will detect the presence of car will give output high or low, which is
input to the counter.
As we can take a counter value ten, so that when six counts are done, compare
instruction will high and output will high.
Compares the data of Sa and Sb when the compare control input "EN" =1 or from 0 to
1. If the data of Sa is equal to Sb, then set FO0 to 1. If the data of Sa>Sb, then set FO1
to 1. If the data of Sa<Sb, then set FO2 to 1. If the data of Sa < Sb, then set the FO2 to
1.

Sa：The register to be compared

Sb：The register to be compared
Sa, Sb may combine with V, Z, P0~P9 to serve indirect addressing

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Procedure:
Select No bit assign X2 (Pushbutton_3) and take Counter from “C” option or,
from function option and assign it C0 as counter no. and set the PV value to
[Link] another NO bit and assign address X0 (Pushbutton_1) and connect to
CLR of counter is shown below.

To select the compare instruction Go to”Function” (which is shown encircled

in Red)”Compare””CMP” and give the values as in upper portion i.e. Sa for
counter no. C0 and in lower portion i.e. Sb as 20 so it will know that it have to
compare between Counter C0 and 20 is shown below.

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Take coil and assign Y4 (LED_4) and connect on a=b (From compare
instruction output) .Take coil and assign Y5 (DC Motor) and connect a>b (from
compare instruction output).Take coil and assign Y6 (Pilot Lamp) and connect
b>a (from compare instruction output) is shown below

Compile, download and Run the program of Compare instruction.

When C0 preset value < Sb (20) output Y 7(DC Motor) will be ON is shown
below.

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When you press or enable X2 (Pushbutton_3) counter C0 start counting .When

C0=20 output Y5 (LED_5 ) will be ON is shown below.

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When C0>21 output Y6 (LED_6) will be ON is shown below.

Question
Draw a ladder diagram for equal and less then instruction. Take one counter ,c
when counter preset value is equal and less than 5 , output Y1 (LED_1) will be
ON .
The maximum clock input frequency for high speed counter is ______?
(0.37μs/10Khz/20Khz/1ms)

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Experiment 10
Objective: Study and use of Math instruction (addition)
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Performs the addition of the data specified at Sa and Sb and writes the results to a
specified register D when the add control input "EN" =1 or from 0 to 1 . If the result
of addition is equal to 0 then set FO0 to 1. If carry occurs (the result exceeds 32767 or
2147483647) then set FO1 to 1. If borrow occurs (adding negative numbers resulting
in a sum less than -32768 or -2147483648), then set the FO2 to 1. All the FO statuses
are retained until this instruction is executed again and overwritten by a new result.

Sa：Augend Sb：Addend D ：Destination register to store the results of the

addition.
Procedure:
Take NO bit and assign address X7 (IR SENSOR) .Click on C icon (in
instruction tool bar) then function window will open assign C to C0 and PV to
10 and click on OK tab. Take one NO bit and assign address X0 (Pushbutton_1)
and connect CLR (from input of counter) is shown below.

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Take NO bit and assign address X8 (Limit Switch) .Click on C icon (in
instruction tool bar) then function window will open assign C to C1 and PV to
15 and click on OK tab. Take one NO bit and assign address X0 (Pushbutton_1)
and connect CLR (from input of counter) is shown below.

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To select the addition instruction Go to”Function” (which is shown encircled

in Red)”Bsic””+” is shown below.

Assign address to addition instruction upper portion i.e. Sa to C0 and in lower

portion i.e. Sb to C1 and D to D0 is shown below.

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Compile, download, run the program of Addition.

When any obstacle infront of X7 (IR Sensor) counter C0start counting. When
you press X8 (Limit Switch) counter C1 start counting. Addition instruction
Add the value of C0 and C1 and see the result in D0 is shown below.

Question
Make a ladder program of subtraction of 2 quantities.
Look the Ladder Diagram & give answers of following-

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Experiment 11
Objective: Study and use of PWM (Pulse Width Modulation) instruction.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
To: Pulse ON width (0~32767mS) Tp : Pulse period (1~32676mS) OT : Pulse
output point When execution control "EN" = 1, will send the pulse to output point
OT with the "ON" state for To ms and period as Tp. OT must be a transistor output
point on the main unit. When "EN" is 0, the output point will be OFF.

The units for Tp and To are mS, resolution is 1 mS. The minimum value for To
is 0 (under such case the output point OT will always be OFF), and its
maximum value is the same as Tp (under such case the output point OT will
always be on). If To > Tp there will be an error, this instruction will not be
carried out, and the error flag "ERR" will set to 1.
This instruction can only be used once.

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Procedure:
Take one NO bit and assign address to X0 .To select the PWM instruction Go
to”Function” (which is shown encircled in Red)”I/0””PWM” and click
on OK tab is shown below.

After above step Function window will open and assign T0 to 100 and Tp to 150
and OT to Y0 then click on OK tab is shown below.

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After above step this window will open is shown below.

When you enable X0 (Pushbutton_1) Output Y0 (Buzzer) will ON or OFF

according to give period in PWM instruction is shown below.

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Questions
What is full name and Function of PWM?
Draw a ladder program using a PWM instruction for 10ms on time and pulse
width 50 ms.
The component of a PLC that makes decision and execute control instruction
based on the input signal is________?(CPU/Input module/Programming
device/Operator interface)
An input that is either on/off is a/an ______ input? (analog/discrete/high
speed/Normally open)

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Experiment 12
Objective: Study and use of MOVE instruction
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Move (write) the data of S to a specified register D when the move control input "EN"
=1 or from 0 to 1

S: Source register number

D: Destination register number

Procedure:
Take NO bit and assign X0 (Pushbutton_1) and take one Counter from
instruction bar and assign C to C0 and PV to 15 and take NO bit and assign X1
(Puhsbutton_2) connect to C0 CLR is shown below.

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Click on F icon (Function) in instruction bar is shown below.

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When you click on Function instruction Function Lookup window will open
then you click on Move Instruction then click on OK Tab is shown below.

After above step Move instruction window will open then assign S (Source) to
C0 and D (Destination) to D0 then click on OK is shown below.

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Compile, download and run the program.

When you press X0 (Pushbutton_1) Counter C0 will start counting .Move

instruction move the value of C0 to D0 is shown below.

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Experiment 13

Objective: Study and use of Jump and Label instruction

Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
JUMP Instruction
When jump control “EN” = 1 or from 0→1, PLC will jump to the location behind the
marked label and continuous to execute the program.
This instruction is especially suit for the applications where some part of the
program will be executed only under certain condition. This can shorter the scan
time while not executes the whole program.
This instruction allows jump backward (i.e. the address of LBL is comes before
the address of JMP instruction). However, care should be taken if the jump
action cause the scan time exceed the limit set by the watchdog timer, the WDT
interrupt will be occurred and stop executing.
The jump instruction allows only for jumping among main program or jumping
among subroutine area, it can’t jump across main/subroutine area.

LBL: The Program Label to be jumped

Label Instruction :
This instruction is used to make a tag on certain address within a program, to provide
a target address for execution of JUMP, CALL instruction and interrupt service. It
also can be used for document purpose to improve the readability and interpretability
of the program.
This instruction serves only as the program address marking to provide the
control of procedure flow or for remark. The instruction itself will not perform
any actions; whether the program contains this instruction or not, the result of
program execution will not be influenced by this instruction.

S: Alphanumeric, 1~6 characters

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Procedure:
Take NO bit and assign X3 (Toggle Switch_1) then click on F icon (from
instruction bar) encircled in red then Function Lookup window will open. Click
on Flow Control option then click on JMP then Click on OK tab is shown
below.

After above step Function window will open then assign LB to 3 and click on
OK tab is shown below.

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Take NO bit and assign X0 (Pushbutton_1) and take coil and assign Y0 (Buzzer)
is shown below.

Click on F icon (from instruction bar) then Function Lookup window will open
.Select Flow control then Click on LBL then click on OK Tab is shown below.

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Function window will open then assign LN to 3 and click on OK tab is shown
below.

Take one NO bit and assign it X1 (Pushbutton_2) and take coil and assign it Y1
(LED_1) is shown below.

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When X3 (Toggle Switch_1) is OFF and you press X0 (Puhbutton_1 ) and X1

(Pushbutton_2) OUTPUT Y0 (Buzzer) and Y1 (LED_1) will be ON is shown
below.

When you Turn ON the X3 (Toggle Switch_1) then you press X0

(Pushbutton_1), Output Y0 (Buzzer) will be OFF. When you press X1
(Pushbutton_2) then Y1 (LED_1) will be ON is shown below.

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Questions
_______________ And _______________ are also common example of ways to
program a PLC.
A PLC program is executed as a part of repetitive process referred to as a
_____________.
When talking about computer or PLC memory, 1k refers to _____________
bits, bytes or words.

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Experiment 14
Objective: Study and use of Subroutine.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Subroutines allow parts of your program code to run selectively, and only when
required. This can substantially reduce the size of the main program routine, improve
scan times, and simplify your program.
One subroutine can be called from multiple locations in the main program
When a subroutine is called the main program is on hold - at the current rung -
waiting for the subroutine to "return"
When a subroutine is not running that subroutine is not scanned, and any coils
unique to that routine do not change
Call instruction:

When call control “EN”=1 or from 0→1, PLC will call (perform) the subroutine
bear the same label name as the one being called. When execute the subroutine,
the program will execute continuous as normal program does but when the
program encounter the RTS instruction then the flow of the program will return
back to the address immediately after the CALL instruction.
All the subroutines must end with one “return from subroutine instruction RTS”
instruction; otherwise it will cause executing error or CPU shut down.
Nevertheless, an RTS instruction can be shared by subroutines (so called as
multiple entering subroutines; even though the entry points are different, they
have a same returning path) as illustrated in the right diagram subroutine SUB1
～3.

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This instruction is used to represent the end of a subroutine. Therefore it can

only appear within the subroutine area. Its input side has no control signal, so
there is no way to serially connect any contacts. This instruction is self sustain,
and is directly connected to the power line.

When PLC encounter this instruction, it means that the execution of a subroutine
is finished. Therefore it will return to the address immediately after the CALL
instruction, which were previously executed and will continue to execute the
program
Procedure:
Click on F icon (function) encircled in red and To select the CALL instruction
Go to”Function” ”Flow Control””CALL” and click on OK tab is shown
below.

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Function window will open then assign LB to SUB1 is shown below.

Take NO bit and assign X0 (Pushbutton_1) and take coil and assign Y1
(LED_1) is shown below.

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Click on Sub_unit1 (encircled in red) is shown below.

Click on F icon (function) encircled in red and To select the LBL instruction Go
to”Function” ”Flow Control””LBL” and click on OK tab is shown
below.

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Function window will open then assign LN to SUB1 is shown below.

Take NO bit and assign X1 (Pushbutton_2) and take coil and assign Y2
(LED_2) is shown below.

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Click on F icon (function) encircled in red and To select the RTS instruction Go
to”Function” ”Flow Control””RTS” and click on OK tab is shown
below.

Subroutine program is completed.

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When you enable the X0 (Pushbutton_1) then output Y1 (LED_1) will be ON is

shown below.

When enable the X1 (Pushbutton_2) then output Y2 (LED_2) will be ON is

shown below. That means subroutine is call in main program.

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Questions
What is the function of subroutine?
The _________contains the system memory and make decision based on
instruction stored in program memory.
___________ is a plc programming language that incorporates programming
function that are graphically displayed to resemble symbol used in hardwire
control diagram.
What is the full name of NEMA ?

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Address Allocation of FBS-PLC Analog Inputs/Outputs

FBs-4A2D offers 4 AD points and 2 DA points. The AD points number starts from
the one nearest to the PLC, the number in order is CH0~CH3 (module 1); CH4~CH7
(module 2); CH8~CH11 (module 3); etc, accumulates in serial; i.e. add 4 to each
module, the total is 64 points (CH0~CH63) corresponding top the value IRs inside
the PLC (R3840~R3903), respectively. In DA point numbering, from the one nearest
to the PLC, the number runs from CH0 through to CH63 in serial, the total is 64
points corresponding top the value ORs inside the PLC (R3904~R3967),
respectively. After connecting FBs-4A2D to the expansion interface on the PLC,
FBs-PLC will automatically detect the number of AD/DA points. WinProladder will
automatically detect and calculate the value IRs/ORs on the system after connecting
to the PLC.
Address Allocation of FBs-4A2D (Analog Output):

Unipolar code output (0~16383), B14, B15 = 00

Bipolar code output (-8192~8191, B14, B15 = B13

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Experiment 15
Objective: Study and use of Analog Input.
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Analog Input Addressing Detail
Analog Input No. Analog Input Address
CH0: Analog Input_1 R3840
CH1: Analog Input_2 R3841
CH2: Analog Input_3 R3842
CH3: Analog Input_4 R3843

Analog Input (ADC)

Converting Analog Data

The analog input circuits are able to monitor voltage signals and convert them to
digital data. There are five terminals assigned to the input channels that provide four
voltage inputs, and a return signal (commons). The following table shows sample
Analog Signal and Data Word values using the nominal transfer function formula:

For example, if an input value of 1200 is in the input image, the calculated

value is as follows:

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Procedure:
Take Mov instruction from Function (F) and assign address S to R3840 (Analog
Input1) and D to D0.

Analog Input program is complete.

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Compile, download and run the program.

When you rotate the knob of Potentiometer then Analog Input value will be
varied is shown below.

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Experiment 16
Objective: Study and use of Analog output
Equipments Needed:
Scientech 2400GN Universal PLC Platform
Serial (RS232) to 4-pin Din cable
USB to Serial Convertor
Mains cord
Theory:
Analog Output Addressing Detail
Analog Output No. Analog Output Address

CH0: Analog Output_1 R3904

CH1: Analog Output _2 R3905

Procedure:
Take Mov Instruction from F (Function icon) and assign S to 0 and D to R3904
(Analog Output).

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Compile, download and run the program. See the analog output voltage at
multimeter.

When you change the Mov instruction S value then your output voltage will be
vary. Change the value of 4096 to 0 an measure a Output voltage on Analog
Output _1 banana socket using digital multimeter.

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Frequently Asked Questions

What is full form of PLC?

Programmable logic controller.
What is the purpose of PLC?
The purpose of a PLC was to directly replace electromechanical relays as logic
elements, substituting instead a solid-state digital computer with a stored
program, able to emulate the interconnection of many relays to perform certain
logical tasks.
What is a PLC?
A Programmable Logic Controller (PLC) is an industrial computer control
system that continuously monitors the state of input devices and makes
decisions based upon a custom program to control the state of output devices.
How Does A PLC Operate?
There are four basic steps in the operation of all PLCs; Input Scan, Program
Scan, Output Scan, and Housekeeping. These steps continually take place in a
repeating loop.
Four Steps In The PLC Operations
1.) Input Scan

Detects the state of all input devices that

are connected to the PLC

2.) Program Scan

Executes the user created program logic

3.) Output Scan

Energizes or de-energize all output devices These steps are continually

that are connected to the PLC. processed in a loop.

4.) Housekeeping

This step includes communications with

programming terminals,
internal diagnostics, etc...

What is the function of PLC?

A PLC consists of a Central Processing Unit (CPU) containing an application
program and Input and Output Interface modules, which is directly connected to
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field I/O devices. The program controls the PLC so that when an input signal
from an input device turns ON, the appropriate response is made. The response
normally involves turning ON an out put signals to some sort of output devices.
What is the function of CPU?
The central processing unit (CPU) is the part of a programmable controller that
retrieves, decodes, stores, and processes information. It also executes the control
program stored in the PLC’s memory.
Explain Execution process of PLC?
All PLC have four basic stages of operations that are repeated many times per
Second. Initially when turned on the first time it will check it’s own hardware
and software for faults. If there are no problems it will copy all the input and
copy their values into memory, this is called the input scan. Using only the
memory copy of the inputs the ladder logic program will be solved once, this is
called the logic scan. While solving the ladder logic the output values are only
changed in temporary memory. When the ladder scan is done the outputs will
updated using the temporary values in memory, this is called the output scan.
The PLC now restarts the process by starting a self check for faults.
What are the advantages of PLC?
Advantages of PLC control
Rugged and designed to withstand vibrations, temperature, humidity, and
noise.
Have interfacing for inputs and outputs already inside the controller.
Easily programmed and have an easily understood programming
language.
What are the disadvantages of PLC?
Disadvantages of PLC control
Too much work required in connecting wires.
Difficulty with changes or replacements.
Difficulty in finding errors; requiring skillful work force.
When a problem occurs, hold-up time is indefinite, usually long.

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What is ladder logic?

Ladder logic can be thought of as a rule-based language, rather than a
procedural language. A "rung" in the ladder represents a rule. When
implemented with relays and other electromechanical devices, the various rules
"execute" simultaneously and immediately. When implemented in a
programmable logic controller, the rules are typically executed sequentially by
software, in a loop. By executing the loop fast enough, typically many times per
second, the effect of simultaneous and immediate execution is obtained.
What are the functions of left and right vertical lines?
The left vertical line of a ladder logic diagram represents the power or energized
conductor. The output element or instruction represents the neutral or return
path of the circuit. The right vertical line, which represents the return path on a
hard-wired control line diagram, is omitted. Ladder logic diagrams are read from
left-to-right, top-to-bottom.
Draw the ladder diagram for NOT function?

Draw the ladder diagram for AND function?

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Draw the ladder diagram for OR function?

Draw the ladder diagram for NAND function?

Draw the ladder diagram for NOR function?

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Draw the ladder diagram for XOR function?

What is statement list?

A statement list (STL) provides another view of a set of instructions. The
operation, what is to be done, is shown on the left. The operand, the item to be
operated on by the operation, is shown on the right.
What is Function Block Diagram?
Function Block Diagrams (FBD) provides another view of a set of instructions.
Each function has a name to designate its specific task. Functions are indicated
by a rectangle. Inputs are shown on the left-hand side of the rectangle and
outputs are shown on the right-hand side.
What are the basic criteria on which Function Block Diagram decision
depends?
This decision will depend upon the basic criteria listed below.
Number of logical inputs and outputs.
Memory - Often 1K and up. Need is dictated by size of ladder logic program. A
ladder element will take only a few bytes, and will be specified in
manufacturer’s documentation.
Number of special I/O modules - When doing some exotic applications, a large
number of special add-on cards may be required.
Scan Time - Big programs or faster processes will require shorter scan times.
And, the shorter the scan time, the higher the cost. Typical values for this are 1
microsecond per simple ladder instruction
Communications - Serial and networked connections allow the PLC to be
programmed and talk to other PLC. The needs are determined by the
application.
Software - Availability of programming software and other tools determines the
programming and debugging ease.

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What is the difference between computer and PLC?

Parameters PLC PC

The PLC was specifically Common PCs are not designed

Environment designed for harsh conditions for harsh environments.
with electrical noise, magnetic Industrial PCs are available
fields, vibration, extreme but cost more.
temperatures or humidity.

By design PLCs are friendlier Operating systems like

Ease of Use to technicians since they are in Windows are common.
ladder logic and have easy Connecting I/O to the PC is
connections. not always as easy.

PLCs in rack form are easy to Typical PCs are limited by the
Flexibility exchange and add parts. They number of cards they can
are designed for modularity and accommodate and are not
expansion. easily expandable.

PLCs execute a single program PCs, by design, are meant to

Speed in sequential order. The have handle simultaneous tasks.
better ability to handle events in They have difficulty handling
real time. real time events.

A PLC never crashes over long A PC locking up and crashing

Reliability periods of time. ("Never" may is frequent.
not be the right word but its
close enough to be true.)

Languages are typically fixed to A PC is very flexible and

Programming ladder logic, function block or powerful in what to use for
languages structured text. programming.

Memory is limited in its ability This is where the PC excels

Data to store a lot of data. because of it's hard drive. Any
management long term data storage, history
and trending is best done on a
PC.

Just too hard to compare pricing with so many variables like I/O
Cost
counts, hardware needed, programming software, etc.

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What Normally Open Contact means?

Normally Open Contact means at normal condition the contacts are open (OFF).
So, if we apply electrical supply in present state, it will not operate. The moment
you apply an external source (electrical or, mechanical) to it, the contacts are in
close (ON) state.
What Normally Closed Contact means?
In normal condition this component will be close (ON), thereby, electrical
supplies flow through the circuit.
What is set bit and reset bit?
S (Set Bit): Set bit is used to set the output high until it is not reset.
R (Reset Bit): Reset bit is used to reset the output low until it is set.
What is the function of TON?
This instruction counts time when the enabling input is on. When the current
value is greater than or equal to the preset value timer bit is on.
The on delay timer current value is cleared when the enabling input is off. This
timer is continues counting after preset is reached.
What is the maximum value of TON?
The maximum value of 32767.
Where TOF is used?
TOF (Off Delay Timer) is used to delay turning an output off for a fixed period
of time after the input turns off. When the enabling input is turns on, the timer
bit is turn on immediately, and the current value is set to 0. When the input turns
off, the timer counts until the elapsed time reaches to preset time.
What is the function of counter in PLC?
Counters used in PLCs Serve functions similar to mechanical counters. They
compare accumulated values with preset values in order to control circuit
functions.
How many types of counters are there?
There are two types of counters which can be used for particular application:
Up Counters (CTU)
Down Counters (CTD)
Why PLC language is designed?
PLC languages are designed to emulate the popular relay ladder diagram format.
This format is read and understood worldwide by maintenance technicians as
well as by engineers.

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What is the function of down counter?

The down counter counts down from the preset value (PV) each time CD
transitions from logic 0 to logic 1.
When the current value is equal to Zero, the counter output bit (Q) turns on. The
counter resets and loads the current value with the preset value (PV) when the
load input (LD) is enabled.
What are various inputs used for PLC?
Examples of inputs are push buttons, switches, toggle switches, limit switches,
proximity switches, and contact closures, sensors.
What are various outputs used from PLC?
Lights, horns, motors, and valves are all good examples of output devices
Which types of scanning is used in Execution process of PLC?
Self Test, Input Scan, Logic Solve/Scan, Output Scan
What do you mean by input scan?
When the inputs to the PLC are scanned the physical input values are copied
into memory.
What do you mean by output scan?
When the outputs to a PLC are scanned they are copied from memory to the
physical outputs.
What is the function of logic scan?
The ladder logic scan begins at the top rung. At the end of the rung it interprets
the top output first, and then the output branched below it. On the second rung it
solves branches, before moving along the ladder logic rung.
What is the function of opto coupler?
This electrically isolates the external electrical circuitry from the internal
circuitry.
What is the internal structure of PLC?
PLCs have internal clocks and "watch-dog timers" built into their operations to
ensure that some functional operation does not send the central processor into
the "weeds". The first priority of the CPU is to scan the I/O for status, to make
sequential control decisions (as defined by the program), to implement those
decisions, and to repeat this procedure all within the allotted scan time.
What is the operating temperature and humidity range of PLC?
PLCs can operate in temperatures as high as 140 F (60 C) and as low as 320 F
(0 C), with tolerable relative humidity’s ranging from 0% to 95% no
condensing.
What is difference between PLC and DCS?
PLC is a completely industrial automation system, where as DCS as
computerized control system.
PLC is economically low cost, but the DCS cost High.
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Warranty
We guarantee this product against all manufacturing defects for 12 months from
the date of sale by us or through our dealers.
The guarantee will become void, if
a. The product is not operated as per the instruction given in the Learning
Material.
b. The agreed payment terms and other conditions of sale are not followed.
c. The customer resells the instrument to another party.
d. Any attempt is made to service and modify the instrument.
The non-working of the product is to be communicated to us immediately giving
full details of the complaints and defects noticed specifically mentioning the
type, serial number of the product and date of purchase etc.
The repair work will be carried out, provided the product is dispatched securely
packed and insured. The transportation charges shall be borne by the customer.
Hope you enjoyed the Scientech Experience.

List of Accessories
USB to Serial Convertor .............................................................................1 No.
RS232 USB Converter ................................................................................1 No.
Mains Cord..................................................................................................1 No.
Patch Cord ..................................................................................................5 Nos.

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