Basic PLC

Basic PLC

Description
This training introduces the basic hardware and software components of a Programmable Controller (PLC). It details the architecture and basic instruction set common to all PLCs. Basic programming techniques and logic designs are co ered. This training describes the operating features of the PLC! the ad antages of the PLC o er hard"wired control s#stems! practical applications! troubleshooting and maintenance of PLCs.

Basic PLC

Objectives
$t the end of the training the participants should be able to% &escribe the ma'or components of a common PLC. Interpret PLC specifications. $ppl# troubleshooting techniques. Con ert con entional rela# logic to a PLC language. (perate and program a PLC for a gi en application.

Basic PLC

Course Contents
)istor# of Programmable Controllers *ela# Ladder Logic Central Processing +nit Input,(utput -#stem Programming and Peripheral &e ices Programming Concepts $pplications Troubleshooting and .aintenance

Basic PLC

IN !OD"C ION O PLC#

Advantages of PLCs / Less wiring. / 0iring between de ices and rela# contacts are done in the PLC program. / 1asier and faster to ma2e changes. / Trouble shooting aids ma2e programming easier and reduce downtime. / *eliable components ma2e these li2el# to operate for #ears before failure.

Basic PLC

PLC Origin
/" &e eloped to replace rela#s in the late 3456s /" Costs dropped and became popular b# 3476s /" 8ow used in man# industrial designs

Basic PLC

%istorica& Bac'ground
The %(dra)atic Division of the *enera& +otors Corporation specified the design criteria for the first programmable controller in 1,-. Their primar# goal o e&i)inate t/e /ig/ costs associated 0it/ inf&e1ib&e2 re&a(3contro&&ed s(ste)s.

Basic PLC

%istorica& Bac'ground
/ The controller had to be designed in modular form! so that sub"assemblies could be remo ed easil# for replacement or repair. / The control s#stem needed the capabilit# to pass data collection to a central s#stem. / The s#stem had to be reusable. / The method used to program the controller had to be simple! so that it could be easil# understood b# plant personnel.

Basic PLC

Progra))ab&e Contro&&er Deve&op)ent

3457 3454 34;< Programmable concept de eloped )ardware CP+ controller! with logic instructions! 3 9 of memor# and 3:7 I,( points +se of se eral (multi) processors within a PLC " timers and counters= arithmetic operations= 3: 9 of memor# and 36:< I,( points *emote input,output s#stems introduced .icroprocessors " based PLC introduced

34;5 34;;

Basic PLC

Progra))ab&e Contro&&er Deve&op)ent

3476 Intelligent I,( modules de eloped 1nhanced communications facilities 1nhanced software features (e.g. documentation) +se of personal microcomputers as programming aids Low " cost small PLCs introduced 8etwor2ing of all le els of PLC! computer and machine using -C$&$ software.

347> 347? on

14

Basic PLC

Progra))ab&e Logic Contro&&ers

5 Definition according to N6+A standard IC#331,$.7

$ digitall# operating electronic apparatus which uses a programming memor# for the internal storage of instructions for implementing specific functions such as logic! sequencing! timing! counting and arithmetic to control through digital or analog modules! arious t#pes of machines or process.

11

Basic PLC

Leading Brands Of PLC

$.1*IC$8 3. :. >. <. ?. 5. ;. 1+*(P1$8 3. :. >. <. $llen Bradle# @ould .odicon TeAas Instruments @eneral 1lectric 0estinghouse Cutter )ammer -quare & -iemens 9loc2ner B .ouller Cesto Telemechanique
12

Basic PLC

Leading Brands Of PLC

D$P$81-1 3. :. >. <. Toshiba (mron Canuc .itsubishi

13

Basic PLC

Areas of App&ication

.anufacturing , .achining Cood , Be erage .etals Power .ining Petrochemical , Chemical

14

Basic PLC

PLC #i9e
3. -.$LL " it co ers units with up to 3:7 I,(s and memories up to : 9b#tes. " these PLCs are capable of pro iding simple to ad ance le els or machine controls. :. .1&I+. " ha e up to :6<7 I,(s and memories up to >: 9b#tes. >. L$*@1 " the most sophisticated units of the PLC famil#. The# ha e up to 734: I,(s and memories up to ;?6 9b#tes. " can control indi idual production processes or entire plant.
18

Basic PLC

an' "sed to +i1 0o Li:uids

+O O!

A
;#

;LOA #<I C%

#OL6NOID#

#OL6NOID
I+6!

1 3+IN" 6

1-

Basic PLC

an' "sed to +i1 0o Li:uids

$ tan2 is used to miA two liquids. The control circuit operates as follows% 3. 0hen the start button is pressed! solenoids $ and B energiEe. This permits the two liquids to begin filling the tan2. :. 0hen the tan2 is filled! the float switch trips. This de" energiEes solenoids $ and B and starts the motor used to miA the liquids together. >. The motor is permitted to run for one minute. $fter one minute has elapsed! the motor turns off and solenoid C energiEes to drain the tan2.
1$

Basic PLC

an' "sed to +i1 0o Li:uids

<. 0hen the tan2 is empt#! the float switch de"energiEes solenoid C. ?. $ stop button can be used to stop the process at an# point. 5. If the motor becomes o erloaded! the action of the entire circuit will stop. ;. (nce the circuit has been energiEed it will continue to operate until it is manuall# stopped.

1.

Basic PLC

+ajor Co)ponents of a Co))on PLC

PO<6! #"PPL=

;ro) #6N#O!#
Pus/buttons2 contacts2 &i)it s0itc/es2 etc?

I + N O P D " " L 6

O + P!OC6##O! " O D P " " L 6

o O" P"
#o&enoids2 contactors2 a&ar)s etc?

P!O*!A++IN* D6>IC6

1,

Basic PLC

+ajor Co)ponents of a Co))on PLC

PO<6! #"PPL= Pro ides the oltage needed to run the primar# PLC components I@O +OD"L6# Pro ides signal con ersion and isolation between the internal logic" le el signals inside the PLC and the fields high le el signal.

24

Basic PLC

+ajor Co)ponents of a Co))on PLC

P!OC6##O! Pro ides intelligence to command and go ern the acti ities of the entire PLC s#stems. P!O*!A++IN* D6>IC6 used to enter the desired program that will determine the sequence of operation and control of process equipment or dri en machine.

21

Basic PLC

Progra))ing Device
$lso 2nown as%

Industrial Terminal ( $llen Bradle# ) Program &e elopment Terminal ( @eneral 1lectric ) Programming Panel ( @ould .odicon ) Programmer ( -quare & ) Program Loader ( Idec"IEumi ) Programming Console ( 9e#ence , (mron )
22

Basic PLC

Progra))ing Device
T#pes%

)and held unit with L1& , LC& displa# &es2top t#pe with a C*T displa# Compatible computer terminal

23

Basic PLC

I@O +odu&e
/ The I,( interface section of a PLC connects it to eAternal field de ices. / The main purpose of the I,( interface is to condition the arious signals recei ed from or sent to the eAternal input and output de ices. / Input modules con erts signals from discrete or analog input de ices to logic le els acceptable to PLCs processor. / (utput modules con erts signal from the processor to le els capable of dri ing the connected discrete or analog output de ices.
24

Basic PLC

I@O +odu&e
DC INP" +OD"L6
+-1 T( &*(P T)1 F(LT$@1 T( L(@IC L1F1L I- 811&1& T(% Pre ent oltage transients from damaging the processor. )elps reduce the effects of electrical noise

;!O+ INP" D6>IC6

Current Limiting *esistor

OP OI#OLA O!

Buffer! Cilter! h#steresis Circuits

O P!OC6##O!

28

Basic PLC

I@O +odu&e
AC INP" +OD"L6
C(8F1*T- T)1 $C I8P+T T( &C $8& &*(P- T)1 F(LT$@1 T( L(@IC L1F1L I- 811&1& T(% Pre ent oltage transients from damaging the processor. )elps reduce the effects of electrical noise

;!O+ INP" D6>IC6

*ectifier! *esistor 8etwor2

OP OI#OLA O!

Buffer! Cilter! )#steresis Circuits

O P!OC6##O!

2-

Basic PLC

27

Basic PLC

28

Basic PLC

29

Basic PLC

I@O +odu&e
DC @ AC O" P" +OD"L6
I- 811&1& T(% Pre ent oltage transients from damaging the processor. )elps reduce the effects of electrical noise

;!O+ P!OC6##O!

TTL Circuits

OP OI#OLA O!

$mplifier *1L$G T*I$C H-I-T(*

O O" P" D6>IC6

34

Basic PLC

31

Basic PLC

I@O Circuits
DI;;6!6N =P6# O; I@O CI!C"I # 3. Pilot &ut# (utputs (utputs of this t#pe t#picall# are used to dri e high"current electromagnetic loads such as solenoids! rela#s! al es! and motor starters. These loads are highl# inducti e and eAhibit a large inrush current. Pilot dut# outputs should be capable of withstanding an inrush current of 36 times the rated load for a short period of time without failure.
32

Basic PLC

I@O Circuits
:. @eneral " Purpose (utputs These are usuall# low" oltage and low"current and are used to dri e indicating lights and other non"inducti e loads. 8oise suppression ma# or ma# not be included on this t#pes of modules. >. &iscrete Inputs Circuits of this t#pe are used to sense the status of limit switches! push buttons! and other discrete sensors. 8oise suppression is of great importance in pre enting false indication of inputs turning on or off because of noise.

33

Basic PLC

I@O Circuits
<. $nalog I,( Circuits of this t#pe sense or dri e analog signals. $nalog inputs come from de ices! such as thermocouples! strain gages! or pressure sensors! that pro ide a signal oltage or current that is deri ed from the process ariable. -tandard $nalog Input signals% <":6m$= 6"36F $nalog outputs can be used to dri e de ices such as oltmeters! H"G recorders! ser omotor dri es! and al es through the use of transducers. -tandard $nalog (utput signals% <":6m$= 6"?F= 6"36F
34

Basic PLC

I@O Circuits
?. -pecial " Purpose I,( Circuits of this t#pe are used to interface PLCs to er# specific t#pes of circuits such as ser omotors! stepping motors PI& (proportional plus integral plus deri ati e) loops! high"speed pulse counting! resol er and decoder inputs! multipleAed displa#s! and 2e#boards. This module allows for limited access to timer and counter presets and other PLC ariables without requiring a program loader.

38

Basic PLC

(+TP+TI8P+TC(8T$CT(* L$.P P+-)B+TT(8.(T(*

PLC

36

Basic PLC

A%%&n/B*+$%&0 1716/1A16 L1 L2 I= In !" I:2

P. B SWITCH

M#$!%& '%#" ( )n *+,-

M#$!%& T&*.)n+% ( Address I:2.0/0

LADDER PROGRAM INPUT MODULE WIRING DIAGRAM

37

Basic PLC

L2

L1

CONTACTOR N.O

L2 L1 2IELD WIRING

MOTOR /SOLENOID /3AL3ES /LAMP /BU44ER

OUTPUT MODULE WIRING L1

O:1

L2

CONTACTOR

0
38

LADDER PROGRAM

Basic PLC

&iscrete Input $ discrete input also referred as digital input is an input that is either (8 or (CC are connected to the PLC digital input. In the (8 condition it is referred to as logic 3 or a logic high and in the (CC condition ma#be referred to as logic o or logic low.
N#*.+%%0 O &n P!'56!""#n N#*.+%%0 C%#'&$ P!'56!""#n N#*.+%%0 O &n '7)",5 N#*.+%%0 C%#'&$ '7)",5 N#*.+%%0 O &n ,#n"+," N#*.+%%0 ,%#'&$ ,#n"+,"
39

Basic PLC

IN

O;; Logic 4

PLC Input +odu&e

24 > dc

IN

O;; Logic 1

PLC Input +odu&e

24 > dc

<6

Basic PLC

Ana&og Input $n analog input is an input signal that has a continuous signal. T#pical inputs ma# ar# from 6 to :6m$! < to :6m$ or 6 to36F. Below! a le el transmitter monitors the le el of liquid in the tan2. &epending on the le el TA! the signal to the PLC can either increase or decrease as the le el increases or decreases.
Le el Transmitter
IN

Tan2

PLC Ana&og Input +odu&e

11

Basic PLC

&igital (utput $ discrete output is either in an (8 or (CC condition. -olenoids! contactors coils! lamps are eAample of de ices connected to the &iscrete or digital outputs. Below! the lamp can be turned (8 or (CC b# the PLC output it is connected to.
O"

PLC Digita& Output +odu&e

Lamp

12

Basic PLC

$nalog (utput $n analog output is an output signal that has a continuous signal. T#pical outputs ma# ar# from 6 to :6m$! < to :6m$ or 6 to36F.
6&ectric to pneu)atic transducer
O" 6

PLC Ana&og Output +odu&e

4 to 14>

#upp&( air

Pneu)atic contro& va&ve

13

Basic PLC

Processor
The processor module contains the PLCs microprocessor! its supporting circuitr#! and its memor# s#stem. The main function of the microprocessor is to anal#Ee data coming from field sensors through input modules! ma2e decisions based on the users defined control program and return signal bac2 through output modules to the field de ices. Cield sensors% switches! flow! le el! pressure! temp. transmitters! etc. Cield output de ices% motors! al es! solenoids! lamps! or audible de ices. The memor# s#stem in the processor module has two parts% a system memory and an application memory.
44

Basic PLC

+e)or( +ap Organi9ation

/-#stem memor# includes an area called the 1H1C+TIF1! composed of permanentl#"stored programs that direct all s#stem acti ities! such as eAecution of the users control program! communication with peripheral de ices! and other s#stem acti ities. /The s#stem memor# also contains the routines that implement the PLCs instruction set! which is composed of specific control functions such as logic! sequencing! timing! counting! and arithmetic. /-#stem memor# is generall# built from read"onl# memor# de ices.

#=# 6+

APPLICA ION /&ata Table /+ser Program

/The application memor# is di ided into the data table area and user program area. /The data table stores an# data associated with the users control program! such as s#stem input and output status data! and an# stored constants! ariables! or preset alues. The data table is where data is monitored! manipulated! and changed for control purposes. /The user program area is where the programmed instructions entered b# the user are stored as an application control program.

48

Basic PLC

+e)or( Designs
>OLA IL6. $ olatile memor# is one that loses its stored information when power is remo ed. 1 en momentar# losses of power will erase an# information stored or programmed on a olatile memor# chip. Common T#pe of Folatile .emor# !A+? !andom Access +emor#(*ead,0rite) *ead,write indicates that the information stored in the memor# can be retrie ed or read! while write indicates that the user can program or write information into the memor#.
4-

Basic PLC

+e)or( Designs
The words rando) access refer to the abilit# of an# location (address) in the memor# to be accessed or used. *am memor# is used for both the user memor# (ladder diagrams) and storage memor# in man# PLCs. *$. memor# must ha e batter# bac2up to retain or protect the stored program.

4$

Basic PLC

+e)or( Designs
-e eral T#pes of *$. .emor#% 3..(:.).(>.C.(The C.(-"*$. (Complimentar# +etal OAide #emiconductor) is probabl# one of the most popular. C.(-" *$. is popular because it has a er# low current drain when not being accessed (3?microamps.)! and the information stored in memor# can be retained b# as little as :Fdc.

4.

Basic PLC

+e)or( Designs
NON3>OLA IL6 )as the abilit# to retain stored information when power is remo ed! accidentall# or intentionall#. These memories do not require batter# bac2"up. Common T#pe of 8on"Folatile .emor# !O+2 !ead Onl# +emor# *ead onl# indicates that the information stored in memor# can be read onl# and cannot be changed. Information in *(. is placed there b# the manufacturer for the internal use and operation of the PLC.

4,

Basic PLC

+e)or( Designs
(ther T#pes of 8on"Folatile .emor# P!O+2 Programmable !ead Onl# +emor# $llows initial and,or additional information to be written into the chip. P*(. ma# be written into onl# once after being recei ed from the PLC manufacturer= programming is accomplish b# pulses of current. The current melts the fusible lin2s in the de ice! pre enting it from being reprogrammed. This t#pe of memor# is used to pre ent unauthoriEed program changes.
84

Basic PLC

+e)or( Designs
6P!O+2 6rasable Programmable !ead Onl# +emor# Ideall# suited when program storage is to be semi" permanent or additional securit# is needed to pre ent unauthoriEed program changes. The 1P*(. chip has a quartE window o er a silicon material that contains the electronic integrated circuits. This window normall# is co ered b# an opaque material! but when the opaque material is remo ed and the circuitr# eAposed to ultra iolet light! the memor# content can be erased. The 1P*(. chip is also referred to as ">P!O+?
81

Basic PLC

+e)or( Designs
66P!O+! 6lectricall# 6rasable Programmable !ead Onl# +emor# $lso referred to as 1:P*(.! is a chip that can be programmed using a standard programming de ice and can be erased b# the proper signal being applied to the erase pin. 11P*(. is used primaril# as a non" olatile bac2up for the normal *$. memor#. If the program in *$. is lost or erased! a cop# of the program stored on an 11P*(. chip can be down loaded into the *$..

82

Basic PLC

PLC Operation
Basic Cunction of a T#pical PLC *ead all field input de ices ia the input interfaces! eAecute the user program stored in application memor#! then! based on whate er control scheme has been programmed b# the user! turn the field output de ices on or off! or perform whate er control is necessar# for the process application. This process of sequentiall# reading the inputs! eAecuting the program in memor#! and updating the outputs is 2nown as scanning.

83

Basic PLC

0hile the PLC is running! the scanning process includes the following four phases! which are repeated continuousl# as indi idual c#cles of operation%
P%A#6 1

!ead Inputs #can

P%A#6 2

Progra) 61ecution
P%A#6 3

Diagnostics@ Co))
P%A#6 4

Output #can
84

Basic PLC

P%A#6 1 A Input #tatus scan

$ PLC scan c#cle begins with the CP+ reading the status of its inputs. P%A#6 2A Logic #o&ve@Progra) 61ecution The application program is eAecuted using the status of the inputs P%A#6 3A Logic #o&ve@Progra) 61ecution (nce the program is eAecuted! the CP+ performs diagnostics and communication tas2s
88

Basic PLC

P%A#6 4 3 Output #tatus #can

/$n output status scan is then performed! whereb# the stored output alues are sent to actuators and other field output de ices. The c#cle ends b# updating the outputs.

8-

Basic PLC

$s soon as Phase < are completed! the entire c#cle begins again with Phase 3 input scan. The time it ta2es to implement a scan c#cle is called -C$8 TI.1. The scan time composed of the program scan time! which is the time required for sol ing the control program! and the I,( update time! or time required to read inputs and update outputs. The program scan time generall# depends on the amount of memor# ta2en b# the control program and t#pe of instructions used in the program. The time to ma2e a single scan can ar# from 3 ms to 366 ms.

8$

Basic PLC

PLC Co))unications
Co))on "ses of PLC Co))unications Ports Changing resident PLC programs " uploading,downloading from a super isor# controller (Laptop or des2top computer).

Corcing I,( points and memor# elements from a remote terminal.

Lin2ing a PLC into a control hierarch# containing se eral siEes of PLC and computer.

.onitoring data and alarms! etc. ia printers or (perator Interface +nits ((I+s).

8.

Basic PLC

PLC Co))unications
#eria& Co))unications PLC communications facilities normall# pro ides serial transmission of information. Common -tandards !# 232 +sed in short"distance computer communications! with the ma'orit# of computer hardware and peripherals. )as a maAimum effecti e distance of approA. >6 m at 4566 baud.

8,

Basic PLC

PLC Co))unications
Loca& Area Net0or' 5LAN7 Local $rea 8etwor2 pro ides a ph#sical lin2 between all de ices plus pro iding o erall data eAchange management or protocol! ensuring that each de ice can Ital2J to other machines and understand data recei ed from them. L$8s pro ide the common! high"speed data communications bus which interconnects an# or all de ices within the local area. L$8s are commonl# used in business applications to allow se eral users to share costl# software pac2ages and peripheral equipment such as printers and hard dis2 storage.
-4

Basic PLC

PLC Co))unications
!# 422 @ !# 4.8 +sed for longer"distance lin2s! often between se eral PCs in a distributed s#stem. *- <7? can ha e a maAimum distance of about 3666 meters.

-1

Basic PLC

PLC Co))unications
Progra))ab&e Contro&&ers and Net0or's &edicated 8etwor2 -#stem of &ifferent .anufacturers
+anufacturer $llen"Bradle# @ould .odicon @eneral 1lectric .itsubishi -quare & TeAas Instruments Net0or' &ata )ighwa# .odbus @1 8et Cactor# L$8 .elsec"81T -G,81T TI0$G

-2

Basic PLC

#pecifications
-e eral factors are used for e aluating the qualit# and performance of programmable controllers when selecting a unit for a particular application. These are listed below. 8+.B1* (C I ,( P(*TThis specifies the number of I,( de ices that can be connected to the controller. There should be sufficient I,( ports to meet present requirements with enough spares to pro ide for moderate future eApansion.

-3

Basic PLC

#e&ecting a PLC
Criteria B / / / / / 8umber of logical inputs and outputs. .emor# 8umber of special I,( modules -can Time Communications -oftware

Basic PLC

A Detai&ed Design Process 1? +nderstand the process :. )ardware,software selection >. &e elop ladder logic <. &etermine scan times and memor# requirements

Basic PLC

#pecifications
(+TP+T"P(*T P(01* *$TI8@1ach output port should be capable of suppl#ing sufficient oltage and current to dri e the output peripheral connected to it. -C$8 TI.1 This is the speed at which the controller eAecutes the rela#" ladder logic program. This ariable is usuall# specified as the scan time per 3666 logic nodes and t#picall# ranges from 3 to :66 milliseconds.
--

Basic PLC

#pecifications
.1.(*G C$P$CITG The amount of memor# required for a particular application is related to the length of the program and the compleAit# of the control s#stem. -imple applications ha ing 'ust a few rela#s do not require significant amount of memor#. Program length tend to eApand after the s#stem ha e been used for a while. It is ad antageous to a acquire a controller that has more memor# than is presentl# needed.

-$

Basic PLC

PLC -tatus Indicators /Power (n /*un .ode /Programming .ode /Cault

Basic PLC

roub&es/ooting 1. Loo2 at the process :. PLC status lights )$LT " something has stopped the CP+ *+8 " the PLC thin2s it is (9 (and probabl# is) 1**(* " a ph#sical problem has occurred with the PLC >. Indicator lights on I,( cards and sensors <. Consult the manuals! or use software if a ailable. ?. +se programming terminal , laptop.

Basic PLC

List of ite)s re:uired 0/en 0or'ing 0it/ PLCsC 1. Programming Terminal " laptop or des2top PC. :. PLC -oftware. PLC manufacturers ha e their own specific software and license 2e#. >. Communication cable for connection from Laptop to PLC. <. Bac2up cop# of the ladder program (on dis2ette! C&*(.! hard dis2! flash memor#). If none! upload it from the PLC. ?. &ocumentation" (PLC manual! -oftware manual! drawings! ladder program printout! and -eq. of (perations manual.)

Basic PLC

61a)p&es of PLC Progra))ing #oft0areC 1. $llen"Bradle# K *oc2well -oftware *-LogiA?66 :. .odicon " .odsoft >. (mron " -#swin <. @1"Canuc -eries 5 K Logic.aster5 ?. -quare &" PowerLogic 5. TeAas Instruments K -imatic 5. Telemecanique K .odicon T-H .icro

Basic PLC

P*(@*$..I8@ 8ormall# Closed (8C)

8ormall# (pen (8()

Power flows through these contacts when the# are closed. The normall# open (8() is true when the input or output status bit controlling the contact is 3. The normall# closed (8C) is true when the input or output status bit controlling the contact is 6.

72

Basic PLC

C#)%'

Coils represent rela#s that are energiEed when power flows to them. 0hen a coil is energiEed it causes a corresponding output to turn on b# changing the state of the status bit controlling the output to 3. That same output status bit ma#be used to control normall# open or normall# closed contact an#where in the program.

73

Basic PLC

BoAes

BoAes represent arious instructions or functions that are 1Aecuted when power flows to the boA. -ome of these Cunctions are timers! counters and math operations.

71

Basic PLC

$8& (P1*$TI(8 A *ung B C

1ach rung or networ2 on a ladder program represents a logic operation. In the rung abo e! both inputs $ and B must be true (3) in order for the output C to be true (3).

78

Basic PLC

(* (P1*$TI(8 A *ung B C

In the rung abo e! it can be seen that either input $ or B is be true (3)! or both are true! then the output C is true (3).

76

Basic PLC

8(T (P1*$TI(8 A *ung C

In the rung abo e! it can be seen that if input $ is be true (3)! then the output C is true (6) or when $ is (6)! output C is 3.

77