PLC

BASIC 1

1
 Genesis of Automation
• Operation sheets
– May date back to the 1830s
• Listing of:
– All machining operations
– The machine tools employed
– Tools, jigs, fixtures, and gauges
• Organization and flow of work
Purpose of Automation
• Increase productivity
• Standardize
components or
processes
• Free workers from
repetitive, and
sometime dangerous,
tasks
Industrial Revolution
• High-volume production
• Interchangeable parts
• Transportation system
• Inexpensive energy (coal)
• Frederick W. Taylor
– Scientific management
• Henry Ford
Early Automation Applications
• 1869 – Refineries in
Pennsylvania
automatically covert
crude oil to kerosene
• 1937 – Pictured is the
loading and unloading of
stators via an overhead
conveyor for dipping in
continuous process oven
2
 Automobile body line system
1. Introduction 3. System configuration

Forces Driving Automation - Front Longi welding line application in automobile line
1) Installation: 2001/12
2) Field: Automobile
Ethernet (10BASE5)

A 1 A A A A A A A to A A A B A A A A A A C
3) Type: GM1/GM2 (DI/DO, Enet) A2P MG UEE 82D Y4R 4YR R8T 82D Y4R Sl IDF A2P 82D R8T 82D 28D 82D Y4R 4YR Y4R RIF
공

• Lower costs 2. Process

A A A A A A A A A C
A2P 82D 28D 82D 28D 4YR Y4R 4YR Y4R RIF
A A B A A C
A2P 82D R8T 82D 28D RIF

Handler OP OP
Robot Sub operation Sub operation panel A A A A A A ty yt ty C A A A A to C
A2P Y4R 4YR Y4R 4YR Y4R pm pm pm RIF A2P 4YR Y4R 4YR Sl RIF
• Faster production (ABB) panel Storage
E E E 공

A A A A A B B B B C
A2P 82D 28D 82D 28D 8RT R8T 8RT R8T RIF
• Better quality control Part
Load
Slide
JIG
OP Welding Welding Welding
4. Main functions
gun gun gun
Main 1) Automobile type grading
operation - Manual input for grading data (automotive type,
panel steering wheel, domestic/foreign demand, etc)
Storage
- Shift table operation
2) Robot control and interlock
- Work complete detection and robot operation
- Welding condition detection
3) Main/sub operation panel control (total/each process)
- Line operation mode setup (manual/automatic)
Welding Welding Welding Welding
OP gun gun gun gun
- Utility status lamp (power, air, cooling water, etc)
- Error status display (robot, pneumatic, valve, etc)
Sub
OP OP
- Emergency stop
operation
panel
4) Line status/automobile type display (TR output)
Sub operation panel Sub operation panel - Production state display
(production/inferior goods number, cycle time)
- Present/next automobile type display

Zeolite production system Wastewater treatment system

1. Introduction 4. Main functions 1. Introduction 3. System configuration
- Process control and total monitoring system for Zeolite 1) Various measuring data detection (analog input: 4~20mA) - Wastewater treatment control using Modbus communication Ethernet (10BASE5, Dual)
production process - temperature/pressure/flow rate/tank level/weight between GLOFA GMR (Cnet) and ViMac/ViPam
2) Valve control
1) Installation: 2002/02 - on/off valve (digital output) 1) Installation: 2002/03
A A A R F R A A A
2) Field: PA (water treatment) - analog valve (analog output: 4~20mA) 2) Field: PA (water treatment) A2P IDF UEE MG ID MG UEE IDF A2P
3) Type: GM4 (DI/DO, AI/AO, Enet, Fnet), IS5, IH5, CIMON 3) System integration and HMI monitoring using Ethernet. 3) Type: GMR/GM4 (DI/DO, AI/AO, Enet, Cnet), CIMON RS-422 (Modbus)
4) Others - monitoring (PLC -> HMI): Temperature, pressure, flow rate,
weight, level, etc.
2. Process
- control (HMI -> PLC): Valve On/Off, analog value setting, 2. Process 2AA A2A EAU AEU EAU AEU 4A2 A42 4A2 A24 ICR ICR
ViMac ViMac ViPam ViPam
PID setup value change P P C C C C D D D D F F A Sewage Pumping Lot
4) Measuring data sharing between PLCs and Interlock control
3~4km
using Fnet P A Sewage Pumping Lot 2AA 4M EAU A22 2AY 2AD
Raw
Dissolution/ Mixing 2nd Drying 5) Inverter (IS5) frequency control using Fnet P G C D R A
1st filtration filtration
Mater
ial
6) Drier control using PID function (2nd filtration & drying)
- setup value (SV) = Temperature in the drier P B Sewage Pumping Lot B Sewage Pumping Lot
- when the temperature is low -> Increase liquid input volume A2 A2 A4 A4 A4 A4 A4 A4 A2 A2 CI CI A2 4 AE A2 A2 A2
- when the temperature is high -> Decrease liquid input volume AP AP 2D 2D 2D 2D 2D 2D YR YR RF RF 3~4km AP MG UC 2D YR DA
Packing Wastewater
3. System configuration (zeolite) Treatment
system
Blower
C Sewage Pumping Lot
Y Y
Enet PV Sewage 2AA A2A 4AY A4Y 4AY B4D 4BB I3A MM MM ICR ICR 2AA 4M EAU A22 2AY 2AD
Ethernet (10Base5) value P storage NaOH P P R R R A A D UD DU F F Modem P G C D R A
Stirrer Aerator Re-
aerator
T T
4 E E D T I I
4 E C Sewage
W W
P M
G N N I
P P M
G N
E A A
CCR
CCR
E F
PV value
Pumping Lot
P P P 4. Main functions
(temperature) Return 1) CPU and communication (Ethernet) redundancy
Ethernet 4~20mA
(10BaseT) MV Fnet
sludge 2) Analog input processing (4~20mA): level, flow rate,
value PUMP water quality (pH), etc.
Ethernet
Treatment
3) Pump and valve control
Filter water tank - DO: pump run/stop and valve on/off
Motor Various Sludge
SV = Temperature in the drier (120℃) equipments collector
- AO: analog valve control
COSA COSA
Fnet
COSA
Discharge
4) TM/TC and monitoring
-DIDO -AIAO -CTR
- PLC
HMI PC: pump status, valve status, tank level,
Heater
COSA-MCC (500℃)
Drier Sludge flow rate, water quality
HTP-2K
Sludge Dehydrator - HMI PC
PLC: operation mode setup (automatic/manual),
cake pump run/stop, monitoring level change (HH,H,L,LL)
5) Modbus communication
Dissolution/1st filtration & mixing 2nd filtration & drying
- Current/voltage/power/frequency input from ViMac/ViPam

3
 Building air conditioning system
1. Introduction 3. Main functions
- Building air conditioning system application using 1) Inverter operation parameter control using RS-485
Course Contents
PMU-600 and iH communication of PMU-600
1) Installation: 2002/02 2) Building air conditioning by controlling inverter frequency
2) Field: Electric/electronic/semiconductor and its operation
(building airconditioning)
3) Type: PMU-600, iH
History of Programmable Controllers
2. System configuration
 Relay Ladder Logic
 Central Processing Unit

Blower  Input/Output System

Air in  Programming and Peripheral Devices

Air out
 Programming Concepts

 Applications

5
8
Air in 4
-
S
R

Air out

PMU-600

14

INTRODUCTION TO PLCS PLC Origin

Advantages of PLCs

• Less wiring. •- Developed to replace relays in the late 1960s

• Wiring between devices and relay contacts are done in •- Costs dropped and became popular by 1980s
the PLC program.
• Easier and faster to make changes. •- Now used in many industrial designs
• Trouble shooting aids make programming easier and
reduce downtime.
• Reliable components make these likely to operate for
years before failure.

4
Historical Background Historical Background
The Hydramatic Division of the General Motors • The controller had to be designed in modular form, so that
Corporation specified the design criteria for the first sub-assemblies could be removed easily for replacement or
programmable controller in 1968 repair.

Their primary goal • The control system needed the capability to pass data
collection to a central system.
To eliminate the high costs associated with inflexible,
relay-controlled systems. • The system had to be reusable.

• The method used to program the controller had to be simple,

so that it could be easily understood by plant personnel.

17 18

Programmable Controller Development 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
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976 Remote input/output systems introduced
1977 Microprocessors - based PLC introduced
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 introduced
1985 on Networking of all levels of PLC, computer
and machine using SCADA software.

19 20

5
Programmable Logic Controllers Leading Brands Of PLC
( Definition according to NEMA standard ICS3-1978)
AMERICAN 1. Allen Bradley
A digitally operating electronic apparatus which uses a 2. Gould Modicon
programming memory for the internal storage of instructions 3. Texas Instruments
for implementing specific functions such as logic, 4. General Electric
sequencing, timing, counting and arithmetic to control 5. Westinghouse
through digital or analog modules, various types of machines 6. Cutter Hammer
or process. 7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

21 22

Leading Brands Of PLC Areas of Application

JAPANESE 1. Toshiba  Manufacturing / Machining
2. Omron
3. Fanuc  Food / Beverage
4. Mitsubishi
 Metals

 Power

 Mining

 Petrochemical / Chemical

23 24

6
 PLC Size Tank Used to Mix Two Liquids
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes. MOTOR
- these PLC’s are capable of providing A
FS FLOAT SWITCH
simple to advance levels or machine
controls. SOLENOIDS B
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s and
SOLENOID
memories up to 750 Kbytes. C
- can control individual production TIMER

processes or entire plant. 1 -MINUTE

25 26

Tank Used to Mix Two Liquids Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control
4. When the tank is empty, the float switch de-
circuit operates as follows:
energizes solenoid C.
MOTOR
1. When the start button is pressed, solenoids A
5. A stop button can be used to stop the
A and B energize. This permits the two liquids to MOTOR

FS FLOAT SWITCH A
process at any point.
B
begin filling the tank. FS FLOAT SWITCH

SOLENOIDS
SOLENOIDS
B
6. If the motor becomes overloaded, the action
2. When the tank is filled, the float switch trips.
of the entire circuit will stop.
This de-energizes solenoids A and B and starts
SOLENOID
the motor used to mix the liquids together.
TIMER
C
C
SOLENOID
7. Once the circuit has been energized it will
TIMER
continue to operate until it is manually stopped.
1 -MINUTE 3. The motor is permitted to run for one minute. 1 -MINUTE
After one minute has elapsed, the motor turns off
and solenoid C energizes to drain the tank.

27 28

7
Major Components of a Common PLC Major Components of a Common PLC
POWER POWER SUPPLY
SUPPLY

Provides the voltage needed to run the primary PLC

I M O M components
N O U O
P D T D
U U PROCESSOR P U
T L U L
From E T E
To I/O MODULES
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts,
limit switches,
contactors, Provides signal conversion and isolation between the
alarms
etc.
PROGRAMMING
etc. internal logic- level signals inside the PLC and the field’s
DEVICE high level signal.

29 30

Major Components of a Common PLC Programming Device

Also known as:
PROCESSOR
 Industrial Terminal ( Allen Bradley )
Provides intelligence to command and govern the activities
of the entire PLC systems.  Program Development Terminal ( General Electric )

 Programming Panel ( Gould Modicon )

PROGRAMMING DEVICE
 Programmer ( Square D )
used to enter the desired program that will determine the
sequence of operation and control of process equipment or  Program Loader ( Idec-Izumi )
driven machine.
 Programming Console ( Keyence / Omron )
31 32

8
Programming Device I/O Module
Types: • The I/O interface section of a PLC connects it to
external field devices.
 Hand held unit with LED / LCD display
• The main purpose of the I/O interface is to condition the
various signals received from or sent to the external input
 Desktop type with a CRT display
and output devices.
 Compatible computer terminal
• Input modules converts signals from discrete or analog
input devices to logic levels acceptable to PLC’s processor.

• Output modules converts signal from the processor to

levels capable of driving the connected discrete or analog
output devices.

33 34

I/O Module I/O Module

DC INPUT MODULE AC INPUT MODULE
IS NEEDED TO: IS NEEDED TO:
USE TO • Prevent voltage CONVERTS THE AC • Prevent voltage
DROP THE transients from INPUT TO DC AND transients from
VOLTAGE damaging the DROPS THE VOLTAGE damaging the
TO LOGIC processor. TO LOGIC LEVEL processor.
LEVEL •Helps reduce the •Helps reduce the
effects of electrical effects of electrical
noise noise

Current Buffer, Buffer,

Rectifier,
FROM Limiting Filter, Filter,
OPTO- TO FROM Resistor
hysteresis OPTO- TO
INPUT Resistor ISOLATOR
PROCESSOR INPUT Network ISOLATOR Hysteresis
DEVICE Circuits PROCESSOR
DEVICE Circuits

35 36

9
Dual opto-coupler IC in Basic DC input 37 3-Input circuit diagram 38
8 DIP IC

I/O Module
Input Connection
Block Isolation
Terminal Barrier
DC / AC OUTPUT MODULE
IS NEEDED TO: Input
• Prevent voltage
components 1
transients from
damaging the 2
processor.
•Helps reduce the 3
effects of electrical
L1 4
noise
5 P
Amplifier
L1 6 L
RELAY 7
FROM
PROCESSOR
TTL
Circuits
OPTO-
ISOLATOR TRIAC
X’SISTOR
TO
OUTPUT
DEVICE
8 C
9
10
L2 COM

39

10
 Output Connections
Isolation Terminal I/O Circuits
Barrier Block
Output DIFFERENT TYPES OF I/O CIRCUITS
components
OUT 1 L1
CR
OUT 1 L2 1. Pilot Duty Outputs
OUT 2 Outputs of this type typically are used to drive high-current
OUT 2
electromagnetic loads such as solenoids, relays, valves, and
motor starters.
P OUT 3 L1
OUT 3 L2
L OUT 4
These loads are highly inductive and exhibit a large inrush
current.
C OUT 4
OUT 5 Pilot duty outputs should be capable of withstanding an
OUT 5 inrush current of 10 times the rated load for a short period of
OUT 6 time without failure.
OUT 6
42

I/O Circuits 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 sense the status of limit
switches, push buttons, and other discrete sensors. Noise
suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.
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 signals: 4-20mA; 0-10V
Analog outputs can be used to drive devices such as
voltmeters, X-Y recorders, servomotor drives, and valves
through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V

43 44

11
 I/O Circuits OUTPUTS
5. Special - Purpose I/O
INPUTS MOTOR
Circuits of this type are used to interface PLCs to very specific
types of circuits such as servomotors, stepping motors PID CONTACTOR
(proportional plus integral plus derivative) loops, high-speed LAMP
pulse counting, resolver and decoder inputs, multiplexed
displays, and keyboards. PUSHBUTTONS
PLC
This module allows for limited access to timer and counter
presets and other PLC variables without requiring a program
loader.

46
45

CONTACTOR
L2 L1 N.O
Allen-Bradley 1746-1A16

L1 L2 I= Input MOTOR
Module L2
C •SOLENOID
L1
I:2 slot # in rack •VALVES
FIELD WIRING •LAMP
•BUZZER

P. B SWITCH 0 Module
Terminal # OUTPUT MODULE
Address I:2.0/0 WIRING

LADDER PROGRAM L1 O:4 L2

INPUT MODULE
WIRING DIAGRAM
CONTACTOR 0
LADDER PROGRAM
47 48

12
Discrete Input
A discrete input also referred as digital input is an input that is
IN
either ON or OFF are connected to the PLC digital input. In the
OFF PLC
ON condition it is referred to as logic 1 or a logic high and in the Logic 0
OFF condition maybe referred to as logic o or logic low. Input
Module
24 V dc
Normally Open Pushbutton

Normally Closed Pushbutton IN

OFF PLC
Normally Open switch Logic 1
Input
Normally Closed switch Module
24 V dc

Normally Open contact

Normally closed contact 49 50

Analog Input Digital Output

An analog input is an input signal that has a continuous
signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA A discrete output is either in an ON or OFF condition. Solenoids,
or 0 to10V. Below, a level transmitter monitors the level of contactors coils, lamps are example of devices connected to the
liquid in the tank. Depending on the level Tx, the signal to the Discrete or digital outputs. Below, the lamp can be turned ON or
PLC can either increase or decrease as the level increases OFF by the PLC output it is connected to.
or decreases. OUT
Level Transmitter IN
PLC
PLC Lamp
Analog Digital
Tank Input Output
Module Module

51 52

13
Analog Output Processor
An analog output is an output signal that has a continuous The processor module contains the PLC’s microprocessor,
signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA its supporting circuitry, and its memory system.
or 0 to10V.
The main function of the microprocessor is to analyze data
Electric to pneumatic transducer
coming from field sensors through input modules, make
OUT
E
decisions based on the user’s defined control program and
Supply air
PLC 0 to 10V P
return signal back through output modules to the field
devices. Field sensors: switches, flow, level, pressure, temp.
Analog
Output transmitters, etc. Field output devices: motors, valves,
Module
Pneumatic control valve
solenoids, lamps, or audible devices.

The memory system in the processor module has two parts:

a system memory and an application memory.
53
54

Memory Map Organization Memory Designs

•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,
VOLATILE.
communication with peripheral devices, and other system A volatile memory is one that loses its stored information
SYSTEM activities.
•The system memory also contains the routines that implement the when power is removed.
PLC’s instruction set, which is composed of specific control
functions such as logic, sequencing, timing, counting, and
arithmetic.
•System memory is generally built from read-only memory devices.
Even momentary losses of power will erase any information
stored or programmed on a volatile memory chip.
APPLICATION
•The application memory is divided into the data table area and Common Type of Volatile Memory
•Data Table user program area.
•The data table stores any data associated with the user’s control
•User Program program, such as system input and output status data, and any
stored constants, variables, or preset values. The data table is
RAM. Random Access Memory(Read/Write)
where data is monitored, manipulated, and changed for control Read/write indicates that the information stored in the
purposes.
•The user program area is where the programmed instructions memory can be retrieved or read, while write indicates that
entered by the user are stored as an application control program.
the user can program or write information into the memory.

55 56

14
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
the stored program.
57
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 in memory
can be read only and cannot be changed. Information in ROM
is placed there by the manufacturer for the internal use and
operation of the PLC.
59
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
stored in memory can be retained by as little as 2Vdc.
58
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 of current.
The current melts the fusible links in the device, preventing it
from being reprogrammed. This type of memory is used to
prevent unauthorized program changes.
60
15
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 electronic integrated circuits. This
window normally is covered by an opaque material, but
when the opaque material is removed and the circuitry
exposed to ultra violet light, the memory content can be
erased.
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 non-volatile backup for the
normal RAM memory. If the program in RAM is lost or erased,
a copy of the program stored on an EEPROM chip can be
down loaded into the RAM.

The EPROM chip is also referred to as UVPROM.

61 62

PLC Operation While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as
Basic Function of a Typical PLC individual cycles of operation:

Read all field input devices via the input interfaces, execute PHASE 1
Read Inputs
the user program stored in application memory, then, based
Scan
on whatever control scheme has been programmed by the
PHASE 2
user, turn the field output devices on or off, or perform Program
whatever control is necessary for the process application. Execution
PHASE 3
This process of sequentially reading the inputs, executing Diagnostics/
the program in memory, and updating the outputs is known Comm
as scanning. PHASE 4
Output
Scan

63 64

16
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 program is executed, the CPU performs
diagnostics and communication tasks
65
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 time, or time required to read inputs and
update outputs. The program scan time generally depends on
the amount of memory taken by the control program and type
of instructions used in the program. The time to make a single
scan can vary from 1 ms to 100 ms.
67
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.
66
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 hierarchy containing several
sizes of PLC and computer.
Monitoring data and alarms, etc. via printers or Operator
Interface Units (OIUs).
68
17
PLC Communications PLC Communications
Serial Communications Local Area Network (LAN)

PLC communications facilities normally provides serial Local Area Network provides a physical link between all
transmission of information. devices plus providing overall data exchange management or
protocol, ensuring that each device can “talk” to other
Common Standards machines and understand data received from them.

RS 232 LANs provide the common, high-speed data communications

 Used in short-distance computer communications, with the
majority of computer hardware and peripherals.
 Has a maximum effective distance of approx. 30 m at
9600 baud.
69
bus which interconnects any or all devices within the local
area.
LANs are commonly used in business applications to allow
several users to share costly software packages and
peripheral equipment such as printers and hard disk storage.
70

PLC Communications PLC Communications

RS 422 / RS 485 Programmable Controllers and Networks

 Used for longer-distance links, often between several PCs Dedicated Network System of Different Manufacturers
in a distributed system. RS 485 can have a maximum
distance of about 1000 meters. Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY

71 72

18
 Selecting a PLC
Specifications
Several factors are used for evaluating the quality and
Criteria
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.
• Number of logical inputs and outputs.
• Memory
NUMBER OF I /O PORTS
• Number of special I/O modules
• Scan Time
This specifies the number of I/O devices that can be
• Communications
connected to the controller. There should be sufficient I/O
• Software
ports to meet present requirements with enough spares to
provide for moderate future expansion.

73

A Detailed Design Process Specifications

OUTPUT-PORT POWER RATINGS
1. Understand the process
2. Hardware/software selection Each output port should be capable of supplying sufficient
3. Develop ladder logic voltage and current to drive the output peripheral connected
to it.
4. Determine scan times and memory requirements
SCAN TIME

This is the speed at which the controller executes the relay-

ladder logic program. This variable is usually specified as the
scan time per 1000 logic nodes and typically ranges from 1 to
200 milliseconds.

76

19
 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
tend to expand after the system have been used for a while. It
is advantageous to a acquire a controller that has more
memory than is presently needed.
77
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 available.
5. Use programming terminal / laptop.
PLC Status Indicators
•Power On
•Run Mode
•Programming Mode
•Fault
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 (on diskette, CDROM,
hard disk, flash memory). If none, upload it from the PLC.
5. Documentation- (PLC manual, Software manual, drawings,
ladder program printout, and Seq. of Operations manual.)
20
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
7. Telemecanique – Modicon TSX Micro

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