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Table of Contents
Introduction to PLC ................................................................................................................................. 4
PLC HISTORY............................................................................................................................................ 5
PLC Manual ............................................................................................................................................. 6
PLC OPERATION ...................................................................................................................................... 8
PLC COMMUNICATION ........................................................................................................................... 9
RS-232 COMMUNICATION .................................................................................................................... 12
ISO/OSI MODEL ..................................................................................................................................... 13
TCP/IP PROTOCOL ................................................................................................................................. 15
SINK SOURCING I/O............................................................................................................................... 18
PLC INPUT UNIT..................................................................................................................................... 20
PLC OUTPUT UNITS ............................................................................................................................... 21
PLC NETWORKS ..................................................................................................................................... 23
Plc programming ................................................................................................................................... 24
Plc instructions ...................................................................................................................................... 27
PLC INSTRUCTION TIMERS .................................................................................................................... 28
Fault detection techniques ................................................................................................................... 51
Applications........................................................................................................................................... 52
PLC LAN Applications ............................................................................................................................ 57
Introduction to PLC
What does PLC mean?
A PLC (Programmable Logic Controllers) is an industrial computer used to
monitor inputs, and depending upon their state make decisions based on
its program or logic, to control (turn on/off) its outputs to automate a
machine or a process.
NEMA defines a PROGRAMMABLE LOGIC CONTROLLER as:
A digitally operating electronic apparatus which uses a programmable
memory for the internal storage of instructions by implementing specific
functions such as logic sequencing, timing, counting, and arithmetic to
control, through digital or analog input/output modules, various types of
machines or processes.
Traditional PLC Applications
*In automated system, PLC controller is usually the central part of a
process control system.
*To run more complex processes it is possible to connect more PLC
controllers to a central computer.
Disadvantages of PLC control
- Too much work required in connecting wires.
- Difficulty with changes or replacements.
- Difficulty in finding errors; requiring skillful work force.
- When a problem occurs, hold-up time is indefinite, usually long.
Advantages of PLC control
* Rugged and designed to withstand vibrations, temperature, humidity,
and noise.
* Have interfacing for inputs and outputs already inside the controller.
* Easily programmed and have an easily understood programming
language.
PLC HISTORY
PLC development began in 1968 in response to a request from an US car
manufacturer (GE). The first PLCs were installed in industry in 1969.
Communications abilities began to appear in approximately 1973. They
could also be used in the 70s to send and receive varying voltages to
allow them to enter the analog world.
The 80s saw an attempt to:
standardize communications with manufacturing automation protocol
(MAP), reduce the size of the PLC, and making them software
programmable through symbolic programming on personal computers
instead of dedicated programming terminals or handheld programmers.
The 90s have seen a gradual reduction in the introduction of new
protocols, and the modernization of the physical layers of some of the
more popular protocols that survived the 1980s.
The latest standard IEC 1131-3 has tried to merge plc programming
languages under one international standard. We now have PLCs that are
programmable in function block diagrams, instruction lists, C and
structured text all at the same time.
PLC Manual
Hardware Components of a PLC System
Processor unit (CPU), Memory, Input/output, Power supply unit,
Programming device, and other devices.
internal devices. EPROM for ROMs that can be programmed and then the
program made permanent.
I/O Sections
Inputs monitor field devices, such as switches and sensors.
Outputs control other devices, such as motors, pumps, solenoid valves,
and lights.
Power Supply
Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC
controllers have electrical supply as a separate module, while small and
medium series already contain the supply module.
Programming Device
The programming device is used to enter the required program into the
memory of the processor.
The program is developed in the programming device and then
transferred to the memory unit of the PLC.
PLC OPERATION
Input Relays
These are connected to the outside world. They physically exist and
receive signals from switches, sensors, etc. Typically they are not relays
but rather they are transistors.
Internal Utility Relays
These do not receive signals from the outside world nor do they physically
exist. They are simulated relays and are what enables a PLC to eliminate
external relays.
There are also some special relays that are dedicated to performing only
one task.
Counters
These do not physically exist. They are simulated counters and they can
be programmed to count pulses.
Typically these counters can count up, down or both up and down. Since
they are simulated they are limited in their counting speed.
Some manufacturers also include high speed counters that are hardware
based.
Timers
These also do not physically exist. They come in many varieties and
increments.
The most common type is an on-delay type.
Others include off-delay and both retentive and non-retentive types.
Increments vary from 1ms through 1s.
Output Relays
These are connected to the outside world. They physically exist and send
on/off signals to solenoids, lights, etc.
They can be transistors, relays, or triacs depending upon the model
chosen.
Data Storage
Typically there are registers assigned to simply store data. Usually used
as temporary storage for math or data manipulation.
They can also typically be used to store data when power is removed from
the
PLC.
PLC COMMUNICATION
Extension modules
PLC I/O number can be increased through certain additional modules by
system extension through extension lines. Each module can contain
extension both of input and output lines.
Extension modules can have inputs and outputs of a different nature from
those on the PLC controller. When there are many I/O located
considerable distances away from the PLC an economic solution is to use
I/O modules and use cables to connect these, over the long distances, to
the PLC.
Remote I/O connections
When there are many I/O located considerable distances away from
the PLC an economic solution is to use I/O modules and use cables to
connect these, over the long distances, to the PLC.
Remote PLCs
In some situations a number of PLCs may be linked together with a
master PLC unit sending and receiving I/O data from the other units.
Cables
Twisted-pair cabling, often routed through steel conduit. Coaxial cable
enables higher data rates to be transmitted and does not require the
shielding of steel conduit.
Fibre-optic cabling has the advantage of resistance to noise, small size
and flexibility.
Parallel communication
Parallel communication is when all the constituent bits of a word are
simultaneously transmitted along parallel cables. This allows data to be
transmitted over short distances at high speeds. Might be used when
connecting laboratory instruments to the system.
Parallel standards
The standard interface most commonly used for parallel communication is
IEEE-488, and now termed as General Purpose Instrument Bus (GPIB).
Parallel data communications can take place between listeners , talkers ,
and controllers. There are 24 lines: 8 data (bidirectional), 5
status & control, 3 handshaking, and 8 ground lines.
Serial communication
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forms of parity are: None, Even, and Odd. During transmission, the
sender calculates the parity bit and sends it. The receiver calculates parity
for the character and compares the result to the parity bit received. If the
calculated and real parity bits dont match, an error occurred and we act
appropriately.
Baud rate
it is the number of bits per second that are being transmitted or received.
Common values (speeds) are 1200, 2400, 4800, 9600, 19200, and
38400.
RS232 data format
RS232 data format (baud rate-data bitsparity-stop bits). 9600-8-N-1
means a baud rate of 9600, 8 data bits, parity of None, and 1 stop bit.
Software handshaking
Software handshaking (flow control) is used to make sure both devices
are ready to send/receive data. The most popular character flow control
is called XON/XOFF. The receiver sends the XOFF character when
it wants the transmitter to pause sending data. When its ready to receive
data again, it sends the transmitter the XON character.
STX & ETX
Sometimes an STX and ETX pair is used for transmission/reception as
well. STX is start of text and ETX is end of text. The STX is sent before
the data and tells the external device that data is
coming. After all the data has been sent, an ETX character is sent.
ACK / NAK Pair
The transmitter sends its data. If the receiver gets it without error, it
sends back an ACK character. If there was an error, the receiver sends
back a NAK character and the transmitter resends the data.
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RS-232 COMMUNICATION
RS-232 is an asynchronous communications method (a marching band
must be in sync
with each other so that when one steps they all step. They are
asynchronous in that they follow the band leader to keep their timing).
We use a binary system to transmit our data in the ASCII format. PLCs
serial port is used for transmission/reception of the data, it works by
sending/receiving a voltage, With RS232, normally, a 1 bit is represented
by a voltage -12 V, and a 0 by a voltage +12 V. (The voltage between +/3 volts is considered There are 2 types of RS-232 devices.)
DTE Data Terminal Equipment and a common example is a computer.
DCE Data Communications Equipment and a common example is a
modem.
PLC may be either a DTE or DCE device.
When plc and external device are both DTE, (and both DCE) devices they
cant talk to each other. The solution is to use a null-modem connection.
Usually, the plc is DTE and the external device is DCE.
Using RS-232 with PLC
Some manufacturers include RS-232 communication capability in the
main processor. Some use the programming port for this. Others
require a special module to talk RS-232 with an external device.
External device may be an operator interface, an external computer, a
motor controller, a robot, a vision system, etc.
To communicate via RS-232 we have to setup:
1. Where, in data memory, will we store the data to be sent?
2. Where, in data memory, will we put the data we receive from the
external device?
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ISO/OSI MODEL
Interconnecting several devices can present problems because of
compatibility problems. In order to facilitate communications between
different devices the International Standard Organization (ISO) devised a
ISO/OSI model to be used for standardization for Open System
Interconnection (OSI).
A communication link between items of digital equipment is defined in
terms of:
* physical,
* electrical,
* protocol and
* user standards.
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Each layer is self contained and only deals with the interfaces of the layer
immediately above and below. It performs its tasks and transfers its
results to the layer above or the layer below.
It enables manufacturers of products to design products operable in a
particular layer that will interface with the hardware of other
manufacturers.
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TCP/IP PROTOCOL
ControlNet
The ControlNet network uses the Common Industrial Protocol (CIP) to
combine the functionality of an I/O network and a peer-to-peer network.
ControlNet take precedence over program uploads and downloads and
messaging. Supports a maximum of 99 nodes.
DeviceNet
DeviceNet is mainly used in industrial and process automation. It is based
on CAN technology.
It is a low-cost communication link to connect industrial devices to a
network and eliminate expensive hard wiring. Power and communication
supplied over a 4-wire bus. Supports up to 62 devices on the same bus
network.
ModBus
ModBus is an open, serial communication protocol based on the
master/slave architecture. The bus consists of a master station,
controlling the communication, and of a number of slave stations.
MODBUS is an application layer messaging protocol, positioned at level 7
of the OSI model, that provides client/server communication between
devices connected on different types of buses or networks. MODBUS is
used to monitor and program devices; to communicate intelligent devices
with sensors and instruments; to monitor field devices using PCs and
HMIs. MODBUS is an ideal protocol for RTU applications where wireless
communication is required.
Modbus offers two basic communication mechanisms:
* Question/answer (polling): The master sends an inquiry to any of the
stations, and waits for the answer.
* Broadcast: The master sends a command to all the stations on the
network, and these execute the command without providing feedback.
Serial Transmission Modes of MODBUS Networks
The transmission mode defines the bit contents of the message bytes
transmitted along the network, and how the message information is to be
packed into the message stream and decoded. The mode of transmission
is usually selected with other serial port communication parameters as
part of the device configuration.
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transmitting on the cable, the computer will wait and try again when the
line is clear.
TCP/IP PROTOCOL
Most manufacturers who offer Ethernet compatibility to implement
supervisory functions over equipment controlling plant floor functions use
a transmission control protocol/internet protocol (TCP/IP) for layers 3 and
4 of the OSI model. Some PLC manufacturers offer programmable
controllers with TCP/IP over-Ethernet protocol built into the PLC
processor. This allows the PLC to connect directly to a supervisory
Ethernet network. Note that the PLC can also have a control network with
other PLCs.
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Sinking I/O circuits on the I/O modules receive (sink) current from
sourcing field devices. Sinking output modules used for interfacing
with electronic equipment.
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Typically an AC input takes longer than a DC input for the PLC to see.
In most cases it doesnt matter to the programmer because an AC input
device is typically a mechanical switch and mechanical devices are slow.
Its quite common for a plc to require that the input be on for 25 ms (or
more) before its seen. This delay is required because of the filtering
which is needed by the PLC internal circuit.
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PLC NETWORKS
As control systems become more complex, they require more effective
communication schemes between the system components. Some machine
and process control systems require that programmable controllers be
interconnected, so that data can be passed among them
easily to accomplish the control task.
Other systems require a plantwide communication system that centralizes
functions, such as data acquisition, system monitoring, maintenance
diagnostics, and management production reporting, thus providing
maximum efficiency and productivity.
Local Area Networks
The term local area network (LAN) is used to describe a communication
network designed
to link computers and their peripherals within the same building or site. A
LAN is a high-speed, mediumdistance communication system.
For most LANs, the maximum distance between two nodes in the network
is at least one mile, and the transmission speed ranges from 1 to 20
mega baud. Also, most local networks support
at least 100 stations, or nodes.
Industrial Network
A special type of LAN, the industrial network, is one which meets the
following criteria:
1. Capable of supporting real-time control.
2. High data integrity (error detection).
3. High noise immunity.
4. High reliability in harsh environments.
5. Suitable for large installations.
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Plc programming
Programming Languages
A program loaded into PLC systems in machine code, a sequence of
binary code numbers to represent the program instructions.
Assembly language based on the use of mnemonics can be used, and a
computer program called an assembler is used to translate the
mnemonics into machine code.
High level Languages (C, BASIC, etc.) can be used.
Programming Devices
PLC can be reprogrammed through an appropriate programming device:
Programming Console
PC
Hand Programmer
Introduction to Ladder Logic
Ladder logic uses graphic symbols similar to relay schematic circuit
diagrams.
Ladder diagram consists of two vertical lines representing the power rails.
Circuits are connected as horizontal lines between these two verticals.
Ladder diagram features
Power flows from left to right.
Output on right side can not be connected directly with left side.
Contact can not be placed on the right of output.
Each rung contains one output at least.
Each output can be used only once in the program.
A particular input a/o output can appear in more than one rung of a
ladder.
The inputs a/o outputs are all identified by their addresses, the notation
used depending on the PLC manufacturer.
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Example
please note:
LD: load
O: or
AN: and not (and a normally closed contact)
ALD: AND the first LD with second LD
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Plc instructions
Instructions
Relay-type (Basic) instructions: I, O, OSR, SET, RES, T, C
Data Handling Instructions:
Data move Instructions: MOV, COP, FLL, TOD, FRD, DEG, RAD
(degrees to radian).
Comparison instructions: EQU (equal), NEQ (not equal), GEQ (greater
than or equal), GRT (greater than).
Mathematical instructions.
Continuous Control Instructions ( PID instructions ).
Program flow control instructions: MCR (master control reset), JMP, LBL,
JSR, SBR, RET, SUS, REF
Specific instructions:
BSL, BSR (bit shift left/right), SQO (sequencer output), SQC (sequencer
compare), SQL (sequencer load).
High speed counter instructions: HSC, HSL, RES, HSE
Communication instructions: MSQ, SVC
ASCII instructions: ABL, ACB, ACI, ACL, CAN
Internal Relays
Auxiliary relays, markers, flags, coils, bit storage.
Used to hold data, and behave like relays, being able to be switched on or
off and switch other devices on or off. They do not exist as real-world
switching devices but are merely bits in the storage memory.
Internal Relays Use
In programs with multiple input conditions or arrangements. For latching
a circuit and for resetting a latch circuit. Giving special built-in functions
with PLCs.
Retentive relays (battery-backed relays)
Such relays retain their state of activation, even when the power supply is
off. They can be used in circuits to ensure a safe shutdown of plant in the
event of a power failure and so enable it to restart in an appropriate
manner.
Latch Instructions (Set and Reset)
The set instruction causes the relay to self-hold,, i.e. latch. It then
remains in that condition until the reset instruction is received.
The latch instruction is often called a SET or OTL (output latch).
The unlatch instruction is often called a RES (reset), OTU (output
unlatch) or RST (reset).
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Software Errors
Input error depending upon when the timer input turns on during the
scan cycle.
Output error depending upon when in the ladder the timer actually
times out and when the plc finishes executing the program to get to the
part of the scan when it updates the outputs.
Total software error is the sum of both the input and output errors.
Hardware Error
There is a hardware input error as well as a hardware output error. The
hardware input error is caused by the time it takes for the plc to actually
realize that the input is on when it scans its inputs. Typically this duration
is about 10ms (to eliminate noise or bouncing inputs).
The hardware output error is caused by the time it takes from when the
plc tells its output to physically turn on until the moment it actually does.
Typically a transistor takes about 0.5ms whereas a mechanical relay takes
about 10ms.
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ADWANCE INSTRUCTIONS
Data Handling Instructions
Timers, counters and individual relays are all concerned with the handling
of individual bits, i.e. single on-off signal. PLC operations involve blocks of
data representing a value, such blocks being
termed words.
Data handling consists of operations involving moving or transferring
numeric information stored in one memory word location to another word
in a different location, comparing data values and carrying out simple
arithmetic operations.
A register is where data can be stored.
Each data register can store a binary word of usually 8 or 16 bits.
The number of bits determines the size of the number that can be stored
(2n 1).
4-bit register can store a positive number between 0 and +15.
8-bit: 0 and +255.
16-bit: 0 and +65535.
Data movement instructions
There are typically 2 common instruction sets:
The single instruction is commonly called MOV (move) copies a value
from one address to another.
The MOV instruction needs to know 2 things:
Source where the data we want to move is located.
Destination the location where the data will be moved to.
We write an address here. Allso, the data can be moved to the physical
outputs.
Data comparison
The data comparison instruction gets the PLC to compare two data
values.
Thus it might be to compare a digital value read from some input device
with a second value contained in a register.
PLCs generally can make comparisons for:
less than (< or LESS),
equal to (= or EQU),
less than or equal to (<= or LEQ),
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ADWANCE INSTRUCTION-2
Continuous control (PID Instruction)
Continuous control of some variable can be achieved by comparing the
actual value of the variable with the desired set value and then giving an
output depending on the control law required. Many PLCs provide the PID
calculation to determine the controller output as a standard routine. All
that is then necessary is to pass the desired parameters, i.e. the values of
Kp, Ki, and KD, and input/output locations to the routine via the PLC
program.
Control instructions are used to enable or disable a block of logic
program or to move execution of a program from one place to another
place.
The control instructions include:
Master Control instruction (MC/MCR)
Jump to label instruction (JMP)
Label instruction (LBL)
Jump to Subroutine instruction (JSR)
Subroutine instruction (SBR)
Return from Subroutine instruction (RET)
Shift Registers
Master Control/ Master Control Reset (MC/MCR)
When large numbers of outputs have to be controlled, it is sometimes
necessary for whole sections of program to be turned on or off when
certain criteria are realized. This could be achieved by including a MCR
instruction. A MCR instruction is an output instruction.
The master control instruction typically is used in pairs with a master
control reset. Different formats are used by different manufacturers:
MC/MCR (master control/master control reset),
MCS/MCR (master control set/master control reset) or
MCR (master control reset).
The zone being controlled begins with a rung that has the first MC
instruction, which status depends on its rung condition. This zone ends
with a rung that has the second MCR instruction only.
When the rung with the first MCR instruction is true, the first MCR
instruction is high and the outputs of the rung in the controlled zone can
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PROGRAMMING EXAMPLE
Example 1:
Write a program (instruction list) to put the number (4000) in a memory
location, and the number (41) in another location. divide the first one by
the second and put the result in a memory location.
solution:
Example 2:
Make a program to increase the counter by one with each pulse from the
pulse generator SM0.4 (on rising edge) , and decrease another counter by
the same pulse.
Solution:
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when we press the PLC input button (I0.0), the PLC will put the value
(980) inside memory location vw200, and when the rising edge of the
pulse arrives, the contents of memory location will be shifted to
the left for one bit (the instruction SLW = shift left word). we could put 2
after # to shift two bits to left. If we put 7 after the #, the overflow
indicator will be activated (SM1.1=1) which will activate the output in
question.
here is the ladder diagram:
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Example 4:
Using two timers, write a program so we have a pulse on PLC output with
(TON = 10 sec.) and (TOFF = 10 sec.)
*TON: timer output on, TOFF: timer output off.
Solution:
Example 5:
Using up-counter (CTU), make the PWM algorithm.
solution:
there is inside the PLC places for generating a series of pulses with fixed
durations, one of these places is SM0.5, it generates a pulse of 1 second
(on time is 0.5 sec and off time is 0.5 sec). another one is SM0.4, it
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Example 6:
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In the next figure we want to fill the two tanks with water by a pump. The
pump is operating manually by a push-button Start. When the first tank
becomes full, the circuit should automatically start to fill the second tank
by closing the first valve, and opening the second valve, and when the
second tank is full, the pump disconnects automatically and a sign lamp
is turned on to show that 2nd tank is full.
solution:
We need first to identify the inputs and outputs of the system, so
we can set relations between the outside world and the inputs/outputs of
the programmable logic controller.
This table makes it clear: (remember NC: normally closed, NO:normally
open)
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.. and here is the ladder diagram and instruction list for the system:
Example A:
Use the instructions (set, reset) with the timer (SM0.4) to turn an output
on/off after several pulses from the SM0.4 timer.
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Example B:
The next figure represents the process of making tea every day in the
morning for seven days (water in the tank is enough for 7 days only)
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Procedure:
When pressing the start button, the valve 1 (V1) opens,so the water
pass through the valve to the heating tank. And when the water level
reaches the float switch (FS), the valve should close and heating must
begin.
When the temperature reach the required level the thermostat
disconnects the heater and opens valve 2 (V2) for 10 seconds then the
alarm bell is activated (as a sign that the tea jug is filled now with hot
water)
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VENDOR SECTION
The range of PLC suppliers is vast and many offer a number of
alternative product ranges with any number of modules, boasting special
features.
Our choice must meet the application requirements, provide extra
capacity for future development and provide a cost-effective solution.
Price is the most commonly stated reason for making a choice, but the
true price of a PLC to meet the requirements of a particular application is
often much the same over a wide range of supplier equipment.
The final choice of supplier for our PLC will depend upon functionality,
support available, customer preferences, user knowledge and price.
These are the issues that must be addressed:
- Functionality: We have to match the application requirements with the
features of each of the contending suppliers equipment to identify the
one that best meets our requirements.
- Support: Before any purchase is made the following points should be
confirmed with any manufacturer:
*Training;
*Technical support (on site and over the phone);
*Application support to configure and design a system;
*Rapid exchange/repair of failed equipment;
*Guaranteed support for any products for at least 10 years from
purchase
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Grounding guidelines.
Power considerations.
Safety considerations.
Checking that all cable connections between the PLC and the plant
are complete, safe, and to the required specification and meeting
local standards.
Checking that all the incoming power supply matches the voltage
setting for which the PLC is set.
Checking that all protective devices are set to their appropriate trip
settings.
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Applications
Conveyor system
this simple application is for a conveyor (moving material machine) and
how we implement it using ladder diagram and instruction list.
System requirements:
1. A plc is used to start and stop the motors of a segmented conveyor
belt, this allows only belt sections carrying a copper plate to move.
2. The system have three segmented conveyor belts, each segment runs
by a motor.
3. A proximity switch located at the end of each segment to detect the
position of the plate.
4. The first conveyor segment is always on.
5. The second conveyor segment turns on when the proximity switch in
the first segment detects the plate.
6. when the proximity switch at the second conveyor detects the
plate, the third segment conveyor turns ON.
7. the second conveyor is stopped, when the plate is out of detection
range of the second proximity switch, after 20 seconds.
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Troubleshooting
Program troubleshooting
There are several causes off alteration to the user
program:
extreme environmental conditions,
electromagnetic Interference (EMI),
improper grounding,
improper wiring connections, and Unauthorized tampering.
If you suspect the memory has been altered, check the program against a
previously saved program on an EEPROM, UVPROM or flash EPROM
module.
Hardware troubleshooting
Tips for troubleshooting control system
If installation and start-up procedures were followed closely, controller
will give reliable service.
If a problem should occur, the first step in the troubleshooting procedure
is to
identify the problem and its source.
Do this by observing your machine or process and by monitoring the
diagnostic LED indicators on the CPU, Power Supply and I/O modules.
By observing the diagnostic indicators on the front of the processor unit
and I/O modules, the majority of faults can be located and corrected.
These indicators, along with error codes identified in the programming
device user manual and programmers monitor, help trace the source of
the fault to the users input/output devices, wiring, or the controller.
Troubleshooting Controller
In identifying the source of the controllers operation problem use
troubleshooting considerations table including status indication, trouble
description, probable causes and recommended action.
To receive the maximum benefit, follow these steps:
Identify Power Supply and CPU LED status indicators;
Match processor LEDs with the status LEDs located in troubleshooting
tables;
Once the status LEDs are matched to the appropriate table, simply
move across the table identifying error description and probable causes;
Follow the recommended action steps for each probable cause until
the cause is identified;
If recommended actions do not identify the cause, contact manufacturer
or distributor for assistance.
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Have all personnel remain clear of the controller and equipment when
power is applied.
The problem may be intermittent and sudden unexpected machine
motion could result in injury.
Have someone ready to operate an emergency-stop switch in case it
becomes necessary to shut off power to the controller equipment.
Never reach into a machine to actuate a switch since unexpected
machine motion can occur and cause injury.
Remove all electrical power at the main power disconnects switches
before checking electrical connections or inputs/outputs causing machine
motion.
Never alter safety circuits to defeat their functions. Serious injury or
machine damage could result.
Calling for assistance
If you need to contact manufacturer or local distributor for assistance, it
is helpful to obtain the following (prior to calling):
Processor type, series letter
Processor LED status
Processor error codes
Hardware types in system (I/O modules, chassis)
Revision of programming device (HHT or APS).
System documentation
The documentation is the main guide used by the users and for
troubleshooting and fault finding with PLCs.
The documentation for a PLC installation should include:
A description of the plant.
Specification of the control requirements.
Details of the programmable logic controller.
Electrical installation diagrams.
Lists of all inputs and outputs connections.
Application program with full commentary on what it is achieving.
Software back-ups.
Operating manual, including details of all start up and shut down
procedures and alarms.