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    Basic PLC 1

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    Basic PLC 2 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 PLC’s. Basic programming techniques and logic designs are covered. This training describes the oper...

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    Basic PLC 3 Objectives At the end of the training the participants should be able to:  Describe the major components of a common PLC.  Interpret PLC specifications.  Apply troubleshooting techniques.  Convert conventional relay logic to a PLC language.  Operate and program a PLC f...

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    Basic PLC 4 Course Contents History of Programmable Controllers  Relay Ladder Logic  Central Processing Unit  Input/Output System  Programming and Peripheral Devices  Programming Concepts  Applications  Troubleshooting and Maintenance

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    Basic PLC Advantages of PLCs • Less wiring. • Wiring between devices and relay contacts are done in the PLC program. • Easier and faster to make changes. • Trouble shooting aids make programming easier and reduce downtime. • Reliable components make these likely to operate for years bef...

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    Basic PLC PLC Origin •- Developed to replace relays in the late 1960s •- Costs dropped and became popular by 1980s •- Now used in many industrial designs

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    Basic PLC 7 Historical Background The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968 Their primary goal To eliminate the high costs associated with inflexible, relay-controlled systems.

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    Basic PLC 8 Historical Background • The controller had to be designed in modular form, so that sub-assemblies could be removed easily for replacement or repair. • The control system needed the capability to pass data collection to a central system. • The system had to be reusable. • Th...

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    Basic PLC 9 Programmable Controller Development 1968 Programmable concept developed 1969 Hardware CPU controller, with logic instructions, 1 K of memory and 128 I/O points 1974 Use of several (multi) processors within a ...

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    Basic PLC 10 Programmable Controller Development 1980 Intelligent I/O modules developed Enhanced communications facilities Enhanced software features (e.g. documentation) Use of personal microcomputers as programming aids 1983 Low - cost small PLC’s intr...

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    Basic PLC 11 Programmable Logic Controllers ( Definition according to NEMA standard ICS3-1978) A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and ar...

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    Basic PLC 12 Leading Brands Of PLC AMERICAN 1. Allen Bradley 2. Gould Modicon 3. Texas Instruments 4. General Electric 5. Westinghouse 6. Cutter Hammer 7. Square D EUROPEAN 1. Siemens 2. Klockner & Mouller 3. Festo 4. Telemechanique

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    Basic PLC 13 Leading Brands Of PLC JAPANESE 1. Toshiba 2. Omron 3. Fanuc 4. Mitsubishi

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    Basic PLC 14 Areas of Application  Manufacturing / Machining  Food / Beverage  Metals  Power  Mining  Petrochemical / Chemical

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    Basic PLC 15 PLC Size 1. SMALL - it covers units with up to 128 I/O’s and memories up to 2 Kbytes. - these PLC’s are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/O’s and memories up to 32 K...

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    Basic PLC 17 Tank Used to Mix Two Liquids A tank is used to mix two liquids. The control circuit operates as follows: 1. When the start button is pressed, solenoids A and B energize. This permits the two liquids to begin filling the tank. 2. When the tank is filled, the float switch trips. Th...

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    Basic PLC 4. When the tank is empty, the float switch de-energizes solenoid C. 5. A stop button can be used to stop the process at any point. 6. If the motor becomes overloaded, the action of the entire circuit will stop. 7. Once the circuit has been energized it will continue to operate unti...

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    Basic PLC 19 Major Components of a Common PLC PROCESSOR POWER SUPPLY I M N O P D U U T L E O M U O T D P U U L T E PROGRAMMING DEVICE From SENSORS Pushbuttons, contacts, limit switches, etc. To OUTPUT Solenoids, contactors, alarms etc.

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    Basic PLC 20 Major Components of a Common PLC POWER SUPPLY Provides the voltage needed to run the primary PLC components I/O MODULES Provides signal conversion and isolation between the internal logic- level signals inside the PLC and the field’s high level signal.

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    Basic PLC 21 Major Components of a Common PLC PROCESSOR Provides intelligence to command and govern the activities of the entire PLC systems. PROGRAMMING DEVICE used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machin...

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    Basic PLC 22 Programming Device Also known as:  Industrial Terminal ( Allen Bradley )  Program Development Terminal ( General Electric )  Programming Panel ( Gould Modicon )  Programmer ( Square D )  Program Loader ( Idec-Izumi )  Programming Console ( Keyence / Omro...

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    Basic PLC 23 Programming Device Types:  Hand held unit with LED / LCD display  Desktop type with a CRT display  Compatible computer terminal

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    Basic PLC 24 I/O Module • The I/O interface section of a PLC connects it to external field devices. • The main purpose of the I/O interface is to condition the various signals received from or sent to the external input and output devices. • Input modules converts signals...

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    Basic PLC 25 I/O Module DC INPUT MODULE OPTO- ISOLATOR IS NEEDED TO:  Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise Current Limiting Resistor FROM INPUT DEVICE USE TO DROP THE VOLTAGE TO LOGIC LEVEL Buffer, Filter, hysteresis Circu...

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    Basic PLC 26 I/O Module AC INPUT MODULE OPTO- ISOLATOR IS NEEDED TO:  Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise Rectifier, Resistor Network FROM INPUT DEVICE CONVERTS THE AC INPUT TO DC AND DROPS THE VOLTAGE TO LOGIC LEVEL Buff...

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    Basic PLC 27

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    Basic PLC 28

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    Basic PLC 29

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    Basic PLC 30 I/O Module DC / AC OUTPUT MODULE OPTO- ISOLATOR IS NEEDED TO:  Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise FROM PROCESSOR TTL Circuits Amplifier RELAY TRIAC X’SISTOR TO OUTPUT DEVICE

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    Basic PLC 31

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    Basic PLC 32 I/O Circuits DIFFERENT TYPES OF I/O CIRCUITS 1. Pilot Duty Outputs Outputs of this type typically are used to drive high-current electromagnetic loads such as solenoids, relays, valves, and motor starters. These loads are highly inductive and exhibit a large inrush current. Pil...

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    Basic PLC 33 I/O Circuits 2. General - Purpose Outputs These are usually low- voltage and low-current and are used to drive indicating lights and other non-inductive loads. Noise suppression may or may not be included on this types of modules. 3. Discrete Inputs Circuits of this type are used to...

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    Basic PLC 34 I/O Circuits 4. Analog I/O Circuits of this type sense or drive analog signals. Analog inputs come from devices, such as thermocouples, strain gages, or pressure sensors, that provide a signal voltage or current that is derived from the process variable. Standard Analog Input sig...

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    Basic PLC 35 I/O Circuits 5. Special - Purpose I/O Circuits of this type are used to interface PLCs to very specific types of circuits such as servomotors, stepping motors PID (proportional plus integral plus derivative) loops, high-speed pulse counting, resolver and decoder inputs, multiplexed ...

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    Basic PLC 37 L1 L2 P. B SWITCH INPUT MODULE WIRING DIAGRAM LADDER PROGRAM I:2 0 I= Input Module slot # in rack Module Terminal # Allen-Bradley 1746-1A16 Address I:2.0/0

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    Basic PLC 39 Discrete Input A discrete input also referred as digital input is an input that is either ON or OFF are connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a logic high and in the OFF condition maybe referred to as logic o or logic low. Normally Op...

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    Basic PLC 40 OFF Logic 0 IN PLC Input Module 24 V dc OFF Logic 1 IN PLC Input Module 24 V dc

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    Basic PLC 41 IN PLC Analog Input Module Tank Level Transmitter An analog input is an input signal that has a continuous signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level transmitter monitors the level of liquid in the tank. Depending on the level Tx, the signal...

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    Basic PLC 42 OUT PLC Digital Output Module Lamp A discrete output is either in an ON or OFF condition. Solenoids, contactors coils, lamps are example of devices connected to the Discrete or digital outputs. Below, the lamp can be turned ON or OFF by the PLC output it is connected to. Digital...

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    Basic PLC 43 OUT PLC Analog Output Module An analog output is an output signal that has a continuous signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Analog Output E P Pneumatic control valve Supply air Electric to pneumatic transducer 0 to 10V

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    Basic PLC 44 Processor The processor module contains the PLC’s microprocessor, its supporting circuitry, and its memory system. The main function of the microprocessor is to analyze data coming from field sensors through input modules, make decisions based on the user’s defined control progr...

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    Basic PLC 45 Memory Map Organization SYSTEM •System memory includes an area called the EXECUTIVE, composed of permanently-stored programs that direct all system activities, such as execution of the users control program, communication with peripheral devices, and other system activities. •The...

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    Basic PLC 46 Memory Designs VOLATILE. A volatile memory is one that loses its stored information when power is removed. Even momentary losses of power will erase any information stored or programmed on a volatile memory chip. Common Type of Volatile Memory RAM. Random Access Memory(Read/Wri...

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    Basic PLC 47 Memory Designs The words random access refer to the ability of any location (address) in the memory to be accessed or used. Ram memory is used for both the user memory (ladder diagrams) and storage memory in many PLC’s. RAM memory must have battery backup to retain or protect t...

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    Basic PLC 48 Memory Designs Several Types of RAM Memory: 1.MOS 2.HMOS 3.CMOS The CMOS-RAM (Complimentary Metal Oxide Semiconductor) is probably one of the most popular. CMOS-RAM is popular because it has a very low current drain when not being accessed (15microamps.), and the information sto...

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    Basic PLC 49 Memory Designs NON-VOLATILE Has the ability to retain stored information when power is removed, accidentally or intentionally. These memories do not require battery back-up. Common Type of Non-Volatile Memory ROM, Read Only Memory Read only indicates that the information stored i...

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    Basic PLC 50 Memory Designs Other Types of Non-Volatile Memory PROM, Programmable Read Only Memory Allows initial and/or additional information to be written into the chip. PROM may be written into only once after being received from the PLC manufacturer; programming is accomplish by pulses o...

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    Basic PLC 51 Memory Designs EPROM, Erasable Programmable Read Only Memory Ideally suited when program storage is to be semi-permanent or additional security is needed to prevent unauthorized program changes. The EPROM chip has a quartz window over a silicon material that contains the electron...

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    Basic PLC 52 Memory Designs EEPROM, Electrically Erasable Programmable Read Only Memory Also referred to as E2PROM, is a chip that can be programmed using a standard programming device and can be erased by the proper signal being applied to the erase pin. EEPROM is used primarily as a...

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    Basic PLC 53 PLC Operation Basic Function of a Typical PLC Read all field input devices via the input interfaces, execute the user program stored in application memory, then, based on whatever control scheme has been programmed by the user, turn the field output devices on or off, or perform wh...

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    Basic PLC 54 While the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation: PHASE 2 Program Execution PHASE 3 Diagnostics/ Comm PHASE 4 Output Scan PHASE 1 Read Inputs Scan

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    Basic PLC 55 PHASE 1 – Input Status scan  A PLC scan cycle begins with the CPU reading the status of its inputs. PHASE 2– Logic Solve/Program Execution  The application program is executed using the status of the inputs PHASE 3– Logic Solve/Program Execution  Once the prog...

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    Basic PLC 56 PHASE 4 - Output Status Scan •An output status scan is then performed, whereby the stored output values are sent to actuators and other field output devices. The cycle ends by updating the outputs.

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    Basic PLC 57 As soon as Phase 4 are completed, the entire cycle begins again with Phase 1 input scan. The time it takes to implement a scan cycle is called SCAN TIME. The scan time composed of the program scan time, which is the time required for solving the control program, and the I/O update...

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    Basic PLC 58 PLC Communications Common Uses of PLC Communications Ports  Changing resident PLC programs - uploading/downloading from a supervisory controller (Laptop or desktop computer).  Forcing I/O points and memory elements from a remote terminal.  Linking a PLC into a control h...

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    Basic PLC 59 PLC Communications Serial Communications PLC communications facilities normally provides serial transmission of information. Common Standards RS 232  Used in short-distance computer communications, with the majority of computer hardware and peripherals.  Has a maximum eff...

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    Basic PLC 60 PLC Communications Local Area Network (LAN) Local Area Network provides a physical link between all devices plus providing overall data exchange management or protocol, ensuring that each device can “talk” to other machines and understand data received from them. LANs provide t...

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    Basic PLC 61 PLC Communications RS 422 / RS 485  Used for longer-distance links, often between several PCs in a distributed system. RS 485 can have a maximum distance of about 1000 meters.

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    Basic PLC 62 PLC Communications Programmable Controllers and Networks Dedicated Network System of Different Manufacturers ManufacturerNetworkAllen-BradleyData HighwayGould ModiconModbusGeneral ElectricGE Net Factory LANMitsubishiMelsec-NETSquare DSY/NETTexas InstrumentsTIWAY

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    Basic PLC 63 Specifications Several factors are used for evaluating the quality and performance of programmable controllers when selecting a unit for a particular application. These are listed below. NUMBER OF I /O PORTS This specifies the number of I/O devices that can be connected to the cont...

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    Basic PLC Selecting a PLC Criteria • Number of logical inputs and outputs. • Memory • Number of special I/O modules • Scan Time • Communications • Software

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    Basic PLC A Detailed Design Process 1. Understand the process 2. Hardware/software selection 3. Develop ladder logic 4. Determine scan times and memory requirements

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    Basic PLC 66 Specifications OUTPUT-PORT POWER RATINGS Each output port should be capable of supplying sufficient voltage and current to drive the output peripheral connected to it. SCAN TIME This is the speed at which the controller executes the relay-ladder logic program. This variable is usu...

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    Basic PLC 67 Specifications MEMORY CAPACITY The amount of memory required for a particular application is related to the length of the program and the complexity of the control system. Simple applications having just a few relays do not require significant amount of memory. Program length ten...

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    Basic PLC PLC Status Indicators •Power On •Run Mode •Programming Mode •Fault

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    Basic PLC Troubleshooting 1. Look at the process 2. PLC status lights HALT - something has stopped the CPU RUN - the PLC thinks it is OK (and probably is) ERROR - a physical problem has occurred with the PLC 3. Indicator lights on I/O cards and sensors 4. Consult the manuals, or use software if ...

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    Basic PLC List of items required when working with PLCs: 1. Programming Terminal - laptop or desktop PC. 2. PLC Software. PLC manufacturers have their own specific software and license key. 3. Communication cable for connection from Laptop to PLC. 4. Backup copy of the ladder program (...

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    Basic PLC Examples of PLC Programming Software: 1. Allen-Bradley – Rockwell Software RSLogix500 2. Modicon - Modsoft 3. Omron - Syswin 4. GE-Fanuc Series 6 – LogicMaster6 5. Square D- PowerLogic 6. Texas Instruments – Simatic 6. Telemecanique – Modicon TSX Micro

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    Basic PLC 72 PROGRAMMING Normally Open (NO) Normally Closed (NC) Power flows through these contacts when they are closed. The normally open (NO) is true when the input or output status bit controlling the contact is 1. The normally closed (NC) is true when the input or output status bit contro...

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    Basic PLC 73 Coils Coils represent relays that are energized when power flows to them. When a coil is energized it causes a corresponding output to turn on by changing the state of the status bit controlling the output to 1. That same output status bit maybe used to control normally open or norm...

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    Basic PLC 74 Boxes Boxes represent various instructions or functions that are Executed when power flows to the box. Some of these Functions are timers, counters and math operations.

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    Basic PLC 75 AND OPERATION Each rung or network on a ladder program represents a logic operation. In the rung above, both inputs A and B must be true (1) in order for the output C to be true (1). Rung A B C

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    Basic PLC 76 OR OPERATION In the rung above, it can be seen that either input A or B is be true (1), or both are true, then the output C is true (1). Rung A B C

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    Basic PLC 77 NOT OPERATION In the rung above, it can be seen that if input A is be true (1), then the output C is true (0) or when A is (0), output C is 1. Rung A C