Buku Sistem Kontrol Terprogram Kelas 11 SMK

Materi Sistem Kontrol Terprogram

PENULIS ................................ ................................ ................................ ............................... i
KATA PENGANTAR ................................ ................................ ................................ .......... ii
DAFTAR ISI ................................ ................................ ................................ ........................ iii
DAFTAR GAMBAR ................................ ................................ ................................ ........... vi
DAFTAR TABEL ................................ ................................ ................................ ................. x

BAB I ................................ ................................ ................................ ................................ .... 1
PENDAHULUAN ................................ ................................ ................................ ................. 1
A. Deskripsi Bahan Ajar ................................ ................................ ................................ ...... 1
B. Prasyarat ................................ ................................ ................................ .......................... 1
C. Petunjuk Penggunaan Bahan Ajar ................................ ................................ ................... 1
D. Tujuan Akhir ................................ ................................ ................................ ................... 2
KOMPETENSI INTI DAN KOMPETENSI DASAR ................................ ...................... 2
SEKOLAH MENENGAH KEJURUAN /MADRASAH ALIYAH KEJURUAN .......... 2
KELAS XI ................................ ................................ ................................ ............................ 2
SILABUS MATA PELAJARAN ................................ ................................ ........................ 5
Kompetensi Inti: ................................ ................................ ................................ ............. 5
E. Rencana Pembelajaran ................................ ................................ ................................ ... 26

BAB II ................................ ................................ ................................ ................................ . 27
PEMBELA JARAN ................................ ................................ ................................ ............. 27
Kegiatan Belajar 1 ................................ ................................ ................................ ............... 27
SISTEM KONTROL DAN PLC ................................ ................................ ......................... 27
Kompete nsi Dasar ................................ ................................ ................................ ............... 27
Informasi ................................ ................................ ................................ ............................. 27
Tujuan ................................ ................................ ................................ ................................ .. 27
Kemampuan Awal ................................ ................................ ................................ ............... 27
Materi Pembelajaran ................................ ................................ ................................ ........... 28
Persyaratan Lulus ................................ ................................ ................................ ................ 28
Uraian Materi Pembelajaran 1 ................................ ................................ ............................. 29
A. Sistem Kontrol ................................ ................................ ................................ ............... 29
B. Programmable Logic Controller (PLC) ................................ ................................ ......... 33
Rendah ................................ ................................ ................................ ................................ . 38
Tugas: ................................ ................................ ................................ ................................ .. 60

Kegiatan Belajar 2 ................................ ................................ ................................ ............... 61
PERANGKAT KERAS PLC ................................ ................................ .............................. 61
Informasi ................................ ................................ ................................ ............................. 62
Kemampuan Awal ................................ ................................ ................................ ............... 62
Persyaratan Lulus ................................ ................................ ................................ ................ 62
Uraian Materi Pembelajaran 2 ................................ ................................ ............................. 63
A. Sistem Konfigurasi PLC (OMRON) ................................ ................................ ............. 63
B. Konfigurasi Sistem PLC SIEMENS ................................ ................................ ............. 66
E. Spesifikasi Hardware Jenis CPU CPM1A (OMRON) ................................ ................... 72
F. Spesifikasi Hardware Jenis CPU S7 -200 (SIEMENS) ................................ .................. 80
G. Spesifikasi Hardware Jenis CPU FX1N (MITSUBISHI) ................................ ............. 86
H. Spesifikasi Hardware Jenis CPU SLC 5/03 (ALLEN BRADL EY) .............................. 89
Program File ................................ ................................ ................................ ................ 95
Tugas: ................................ ................................ ................................ ................................ .. 98

Kegiatan Belajar 3 ................................ ................................ ................................ ............. 100
Sistem Memory dan Interaksi I/O ................................ ................................ ..................... 101
Kompetensi Dasar ................................ ................................ ................................ ............. 101
Persyaratan Lulus ................................ ................................ ................................ .............. 101
Uraian Materi Pembelajaran 3 ................................ ................................ ........................... 101
A. Memori ................................ ................................ ................................ ........................ 102
B. Struktur dan Kapasitas Memori ................................ ................................ ................... 108
C. O rganisasi Memori dan Interaksi I/O ................................ ................................ .......... 110
D. Konfigurasi Memori PLC ................................ ................................ ........................... 120
Tugas: ................................ ................................ ................................ ................................ 125

Kegiatan Belajar 4 ................................ ................................ ................................ ............. 126
Sistem Input/Output Diskrit ................................ ................................ .............................. 126
Kompetensi Dasar ................................ ................................ ................................ ............. 126
Informasi ................................ ................................ ................................ ........................... 126
Tujuan ................................ ................................ ................................ ................................ 126
Kemampuan Awal ................................ ................................ ................................ ............. 127
Persyaratan Lulus ................................ ................................ ................................ .............. 127
Uraian Materi Pembelajaran 4 ................................ ................................ ........................... 127
A. Pengenalan Sistem I/O Diskrit ................................ ................................ .................... 127
B. Rak I/O dan Pemetaan Tabel ................................ ................................ ....................... 128
C. Instruksi PLC Untuk Input Diskrit ................................ ................................ .............. 132
D. Jenis -jenis Input Diskrit ................................ ................................ ............................... 135
E. Instruksi PLC Untuk Output Diskrit ................................ ................................ ............ 141
F. Output Diskrit ................................ ................................ ................................ .............. 144
Tugas: ................................ ................................ ................................ ................................ 14 8

Kegiatan Belajar 5 ................................ ................................ ................................ ............. 149
PEMROGRAMAN PLC ................................ ................................ ................................ ... 150
Kompetensi Dasar ................................ ................................ ................................ ............. 150
Informasi ................................ ................................ ................................ ........................... 150
Tujuan ................................ ................................ ................................ ................................ 150
Kema mpuan Awal ................................ ................................ ................................ ............. 151
Persyaratan Lulus ................................ ................................ ................................ .............. 151
Uraian Materi Pembelajaran 5 ................................ ................................ ........................... 152
A. Bahasa Pemrograman ................................ ................................ ................................ .. 153
B. Instruksi Lader Rele Pada PLC ................................ ................................ .................. 160
C. Pemrograman Input Normally Closed (NC) ................................ ................................ 167
D. Pemrograman Timer dan Counter ................................ ................................ ............... 174
N : TC number ................................ ................................ ................................ ............... 185
SV : Set value (word, BCD) ................................ ................................ .......................... 185
SV : Set value (word, BCD) ................................ ................................ .......................... 190
N : TC number ................................ ................................ ................................ ............... 190
Tugas: ................................ ................................ ................................ ................................ 194

Kegiatan Belajar 6 ................................ ................................ ................................ ............. 199
PERANGKAT LUNAK PEMROGRAMAN PLC ................................ ........................... 199
Kompetensi Dasar ................................ ................................ ................................ ............. 199
Informasi ................................ ................................ ................................ ........................... 199
Persyaratan Lulus ................................ ................................ ................................ .............. 200
Uraian Materi Pembelajaran 6 ................................ ................................ ........................... 201
A. Pendahuluan ................................ ................................ ................................ ................ 201
B. Pengalamatan Dalam CX -Programmer ................................ ................................ ....... 201
C. Perangkat Lunak Pemrograman CX -Programmer ................................ ....................... 203
Tugas: ................................ ................................ ................................ ................................ 217

BAB III ................................ ................................ ................................ .............................. 225
EVALUASI ................................ ................................ ................................ ....................... 225
A. Evaluasi Program ................................ ................................ ................................ ........ 225
B. Uji Kompetensi ................................ ................................ ................................ ............ 225
BAB IV ................................ ................................ ................................ ............................. 226
PENUTUP ................................ ................................ ................................ ......................... 226
DAFTAR PUSTAKA ................................ ................................ ................................ ....... 227

DAFTAR GAMBAR
Gambar 2. 1 Sistem kontrol ................................ ................................ ................................ 30
Gambar 2. 2 Komponen input ................................ ................................ ........................... 30
Gambar 2. 3 Kompoen Output ................................ ................................ .......................... 31
Gambar 2. 4 Diag ram kontrol loop terbuka ................................ ................................ ....... 32
Gambar 2. 5 Diagram kontrol loop tertutup ................................ ................................ ........ 33
Gambar 2. 6 Diagram sistem kontrol PLC ................................ ................................ ......... 34
Gambar 2. 7 Struktur blok PLC ................................ ................................ ......................... 39
Gambar 2. 8 Prosesor PLC Allen Bradly. ................................ ................................ .......... 40
Gambar 2. 9 Konfigurasi multiprosesor. ................................ ................................ ............ 41
Gambar 2. 10 (a) Modul pemposisian sumbu -tunggal dan ................................ ................ 42
Gambar 2. 11 Diagram blok Prosesor PLC ................................ ................................ ........ 44
Gambar 2. 12 Eksekusi program ................................ ................................ ........................ 45
Gambar 2. 13 Kecepatan Scan ................................ ................................ ........................... 46
Gambar 2. 14 Pengaruh scan program terhadap respon waktu. ................................ ......... 47
Gambar 2. 15 Pengaruh urutan scan pada alur logika program ................................ ......... 48
Gambar 2. 16 Subsistem konfigurasi PLC ................................ ................................ ......... 49
Gambar 2. 17 ( a) data transmisi 16 bit ................................ ................................ ............... 50
Gambar 2. 18 Blok pemeriks aan karakter pada akhir dari blok. ................................ ........ 52
Gambar 2. 19 Operasi siklus pemeriksaan penjumlahan eksklusif -OR. ............................ 54
Gambar 2. 20 Transf ormator tegangan konstan yang dihubungkan ke .............................. 56
Gambar 2. 21 Alat pemrogram -mini. ................................ ................................ ................. 57
Gambar 2. 22 Kartu memori untuk pemrogram -mini. ................................ ....................... 58
Gambar 2. 23 Diagram ladder PLC yang ditampilkan di komputer pribadi. ..................... 58
Gambar 2. 24 Komputer pribadi yang dihubung kan ke PLC melalui jaringan LAN. ....... 59
Gambar 2. 25 Komputer pribadi sebagai jembatan antara jaringan PLC dengan mainframe............................... ................................ ............. 59
Gam bar 2. 26 Komponen -komponen PLC ................................ ................................ ......... 64
Gambar 2. 27 Komunikasi 1:1 ................................ ................................ ........................... 65
Gambar 2. 28 Komunikasi serial RS -232C ................................ ................................ ........ 66
Gambar 2. 29 Komponen -komponen PLC ................................ ................................ ......... 67
Gambar 2. 30 Hubungan kabel multi -master RS -232/PPI ................................ ................. 68
Gambar 2. 31 Komponen -komponen PLC ................................ ................................ ......... 68
Gambar 2. 32 Hubungan kabel komunikasi RS -422 ................................ .......................... 69
Gambar 2. 33 Hubungan ka bel komunikasi RS -232 ................................ .......................... 69
Gambar 2. 34 Konfigurasi PLC SLC 500 ................................ ................................ .......... 70
Gambar 2. 35 Kanal komunikasi ................................ ................................ ........................ 71
Gambar 2. 36 Interface converter 1747 -PIC ................................ ................................ ...... 72
Gambar 2. 37 Komunikasi PLC dengan PC ................................ ................................ ....... 72
Gamb ar 2. 38 Alamat byte, bit. ................................ ................................ .......................... 82
Gambar 2. 39 Membandingkan akses Byte, Word dan ................................ ...................... 83
Gambar 2. 40 Pengaksesan Bit Timer atau nila i saat ini (current value) dari Timer ......... 85
Gambar 2. 41 Pengaksesan Bit Conter atau nilai saat ini (current value) dari Counter. .... 86
Gambar 2. 42 PLC jenis modular ................................ ................................ ....................... 90
Gambar 2. 43 Catu daya PLC ................................ ................................ ............................. 91
Gambar 2. 44 Komponen CPU SLC 6/03 ................................ ................................ .......... 92
Gambar 2. 45 Processor File ................................ ................................ .............................. 96
Gambar 2. 46 Diagram blok yang disederhanakan dari system memori PLC. ................ 102
Gambar 2. 47 Memori RAM ................................ ................................ ............................ 105
Gambar 2. 48 Memori EPROM. ................................ ................................ ....................... 106
Gambar 2. 49 Unit memory PLC: bit, byte, dan word. ................................ .................... 108
Gambar 2. 50 Ilustrasi blok dari (a) lokasi penyimpanan 8 bit (b) lokasi penyimpanan 16 bit. ................................ .................... ...... 109
Gambar 2. 51 Pemet aan memori yang disederhanakan ................................ ................... 111
Gambar 2. 52 Pemetaan memori aplikasi. ................................ ................................ ........ 113
Gambar 2. 53 Saklar batas yang terhubung ke sebu at bit pada tabel input. ..................... 114
Gambar 2. 55 Bagian area penyimpanan dari tabel data. ................................ .................. 116
Gambar 2. 55 Saklar batas (terbuka) yang tersambung ke internal output. ..................... 117
Gambar 2. 56 Saklar batas dalam keadaan tertutup yang tersabung ke internal output. .. 118
Gam bar 2. 57 Pemetan memori. ................................ ................................ ....................... 118
Gambar 2. 58 Solusi untuk contoh 2 -2 ................................ ................................ ............. 119
Gambar 2. 59 Tabel I/O dan memori pengguna. ................................ .............................. 121
Gambar 2. 60 Area penyimpanan register. ................................ ................................ ....... 122
Gambar 2. 61 Sebuah rangkaian rele dengan saklar batas yang digunakan ..................... 123
Gambar 2. 62 Modul input/output yang terhubung ke peralatan eksternal ...................... 124
Gambar 2. 63 Implementasi ladder PLC dari gambar 2 -62 meggunakan s ebuah bit output internal. .............................. .............................. 124
Gambar 2. 64 Diagram blok sebuah CPU PLC dan sistem I/O. ................................ ...... 128
Gambar 2. 65 Sistem I/O diskrit. ................................ ................................ ...................... 128
Gambar 2. 66 Contoh sebuah rak I/O ................................ ................................ ............... 129
Gambar 2. 67 Saklar internal yang digunakan untuk menetapkan alamat I/O. ................ 129
Gambar 2. 68 Rak master (a) tanpa modul I/O dan (b) dengan modul I/O. ..................... 130
Gambar 2. 69 Konfigurasi rak lokal ................................ ................................ ................. 130
Gambar 2. 70 Konfugurasi rak jauh (remote) ................................ ................................ .. 131
Gambar 2. 71 Table input 8 -bit ................................ ................................ ........................ 134
Gambar 2. 72 Transfer blok dan perolehan data input ................................ ..................... 134
Gambar 2. 73 Konfigurasi rak. ................................ ................................ ......................... 135
Gambar 2. 74 Alamat peralatan input ................................ ................................ .............. 135
Gambar 2. 75 Diagram blok rangkaian input DC/AC. ................................ ..................... 137
Gambar 2. 76 Rangkaian input AC/DC. ................................ ................................ .......... 138
Gambar 2. 77 Hubungan peralatan untuk (a) sebuah modul input AC dan ..................... 138
Gambar 2. 78 Arus untuk (a) modul input sinking/peralatan input sourcing dan ............ 140
Gambar 2. 79 Sambungan peralatan input untuk modul input DC sink/source ............... 140
Gambar 2. 80 Rangkaian pengubah antarmuka modul out put sinking dengan modul input sourcing  ................................ ............................. 141
Gambar 2. 81 Tabel output 8 -bit. ................................ ................................ ..................... 142
Gambar 2. 82 Instruksi blok fungsi yang memin dahkan isi register ke modul. ............... 142
Gambar 2. 83 Konfigurasi rak untuk contoh 3 -1. ................................ ............................ 143
Gambar 2. 84 Alamat peralatan output untu k output contoh 2 -3 ................................ ..... 143
Gambar 2. 85 Diagram blok rangkaian output AC. ................................ ......................... 145
Gambar 2. 86 Fungsi saklar sebuah antarmuka output. ................................ ................... 145
Gambar 2. 87 Rangkaian output AC. ................................ ................................ ............... 146
Gambar 2. 88 Diagram hubungan modul output AC ................................ ....................... 146
Gambar 2. 89 Rangkaian output DC sourcing. ................................ ................................ 147
Gambar 2. 90 Diagram sambungan peralatan output untuk modul output sinking/sourcing.. ................................ ................................ 148
Gambar 2. 91 Diagram hubungan modul output TTL ................................ ..................... 148
Gambar 2. 92 Logika kontrol rele dan representasi Grafcet -nya ................................ ..... 155
Gambar 2. 93 Penterjemahan dari bahasa pemrograman Grafcet ke bahasa Ladder. ...... 156
Gambar 2. 94 Diagram ladder rele ................................ ................................ ................... 157
Gambar 2. 95 Rele industri ................................ ................................ .............................. 157
Gambar 2. 96 Simbol kontak rele ................................ ................................ ..................... 158
Gambar 2. 97 Simbol rele output ................................ ................................ ..................... 159
Gambar 2. 98 Insruksi Utama pada logika ladder rele ................................ ..................... 159
Gambar 2. 99 Kontrol dan logika ladder rele untuk operasi Boolean AN D .................... 160
Gambar 2. 100 (a) Instruksi NO dengan logika „0? dan (b) Instruksi NO dengan logika „1?................................ ........... 162
Gambar 2. 101 (a) Instruk si NC dengan logika „0? dan (b) Instruksi NC dengan logika „1? ................................ ........... 163
Gambar 2. 102 Kumparan output ................................ ................................ ..................... 163
Gambar 2. 103 (a) Instru ksi kumparan output dengan logika „0? dan ............................ 164
Gambar 2. 104 Kontak NO dan NC yang mengendalikan kumparan output riil dan internal. ................................ ......................................... 165
Gambar 2. 105 Rung dari ladder untuk contoh 2 -5 ................................ .......................... 166
Gambar 2. 106 Implementasi gambar 2.105 dengan menggunakan kumparan NOT ...... 166
Gambar 2. 107 Implementasi logika NOT Y tanpa kumparan NOT ............................... 167
Gambar 2. 108 Rangkaian kontrol rele ................................ ................................ ............ 168
Gambar 2. 109 Implementasi logika dengan PB1 yang diprogram sebagai kontak NC. . 168
Gambar 2. 110 Implementasi logika dengan PB1 diprogram sebagai kontak NO. ......... 168
Gambar 2. 111 Daya mengalir melalui rangkaian seperti ditunjukkan pada gambar (b) . 169
Gambar 2. 112 Daya mengalir melalui rangkaian seperti ditunjukkan pada gambar (a) . 169
Gambar 2. 113 Logika kontrol rele untuk contoh 2 -6 ................................ ...................... 171
Gambar 2. 114 Implementasi NO dari gambar 2.113 ................................ ...................... 171
Gambar 2. 115 Implementasi NC pada dari gambar 2.113 ................................ .............. 172
Gambar 2. 116 Tombol stop kontak NC ................................ ................................ .......... 173
Gambar 2. 117 Tombol stop ditekan ................................ ................................ ................ 173
Gambar 2. 118 Motor tetap ON ................................ ................................ ....................... 173
Gambar 2. 119 Kabel penghubung kon tak NC putus ................................ ........................ 173
Gambar 2. 120 Tombol tekan stop NC diprogram sebagai NO ................................ ....... 173
Gambar 2. 121 Tombol start ditekan ................................ ................................ ................ 174
Gambar 2. 122 Motor tetap ON ketika tombol start dilepas ................................ ............ 174
Gambar 2. 123 Kabel penghubung kontak NO putus ................................ ...................... 174
Gambar 2. 124 (a) Instruksi timer format blok dan (b) Instruksi timer format ladder .... 177
Gambar 2. 125 Instruksi timer ON -delay energize ................................ .......................... 178
Gambar 2. 126 Diagram waktu untuk (a) timer ON -delay energize dan ....................... 179
Gambar 2. 127 Instruksi timer OFF -delay energize ................................ ......................... 180
Gambar 2. 128 Diagram waktu untuk (a) timer OFF -delay energize dan ...................... 180
Gambar 2. 129 Timer Delay -ON ................................ ................................ ...................... 182
Gambar 2. 130 Timer Delay -OFF ................................ ................................ .................... 183
Gambar 2. 131 Timer retentive delay -ON ................................ ................................ ........ 184
Gambar 2. 132 Instruksi timer CPM1A ................................ ................................ ........... 185
Gambar 2. 133 (a) Instruksi counter format blok dan (b) Instruksi counter format ladder ................................ ................................ ........... 186
Gambar 2 . 134 Instruksi down -counter di PLC S7 -200 ................................ .................... 189
Gambar 2. 135 Instruksi counter di PLC OMRON CPM1A ................................ .......... 190
Gambar 2. 136 Blok fung si instruksi dengan counter up, down, dan reset ...................... 191
Gambar 2. 137 Instruksi counter blok fungsi ................................ ................................ ... 191
Gambar 2. 138 Me -reset cou nter secara otomatis ................................ ............................ 192
Gambar 2. 139 Solusi dari contoh 2 -8 ................................ ................................ .............. 193
Gambar 2. 140 Pengalamatan dalam CX -Programmer ................................ .................... 202
Gambar 2. 141 Program manager ................................ ................................ ................... 204
Gambar 2. 142 Layar CX -Prorammer ................................ ................................ .............. 204
Gambar 2. 143 Menu membuat proyek baru ................................ ................................ .... 205
Gambar 2. 144 Pemilihan jenis PLC ................................ ................................ ................ 206
Gambar 2. 145 Pemilihan jenis CPU ................................ ................................ ............... 207
Gambar 2. 146 Pengaturan komunikasi ................................ ................................ ........... 207
Gambar 2. 147 Ruang kerja proyek ................................ ................................ ................. 208
Gambar 2. 148 Program ladder ................................ ................................ ........................ 211

DAFTAR TABEL
Tabel 2. 1 Perbandingan sistem kontrol ................................ ................................ ............. 38
Tabel 2. 2 Tabel kebenaran eksklusif -OR. ................................ ................................ ......... 53
Tabel 2. 3 Indikator Status PLC ................................ ................................ ......................... 64
Tabel 2. 4 Spesifi kasi umum CPU ................................ ................................ ...................... 73
Tabel 2. 5 Karakteristik CPU_CPM1A ................................ ................................ .............. 74
Tabel 2. 6 Struktur Area Memori CPU -CPM1A ................................ ................................ 76
Tabel 2. 7 Perbandingan CPU S7 -200 ................................ ................................ ................ 80
Tabel 2. 8 Rentang Memori CPU S7 -200 ................................ ................................ .......... 81
Tabel 2. 9 Rentang Desimaldan Hexadesimal untuk Ukuran Data yang Berbeda ............. 82
Tabel 2. 10 Spesifikasi Hardware FX1N ................................ ................................ ........... 87
Tabel 2. 11 Struktu r Memori ................................ ................................ .............................. 87
Tabel 2. 12 Status indicator LED ................................ ................................ ....................... 92
Tabel 2. 13 Konstanta dan variabel yang tersimpan dalam area penyimpanan regis ter/word. ................................117
Tabel 2. 14 Peralatan input diskrit ................................ ................................ ................... 132
Tabel 2. 15 Standar rating untuk antarmuka input diskrit ................................ ................ 136
Tabel 2. 16 Peralatan output. ................................ ................................ ............................ 144
Tabel 2. 17 Rating standar output. ................................ ................................ ................... 144
Tabel 2. 18 Kode bahasa pemrograman instruction list ................................ ................... 154
Tabel 2. 19 Instruksi rele ladder ................................ ................................ ....................... 160
Tabel 2. 20 Dasar waktu ................................ ................................ ................................ ... 175
Tabel 2. 21 Instruksi Timer ................................ ................................ .............................. 176
Tabel 2. 22 Resolusi dan Jumlah Timer ................................ ................................ ........... 182
Tabel 2. 23 Instruksi Counter ................................ ................................ ........................... 186