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CONTROLLER
input device(s)
a controller and
output device(s)
CPU of the PLC are digital devices and must have an input of digital signals of a particular
size, normally 0 to 5 volts. The output from CPU will be digital normally 0 to 5Volts.
Input devices(sensors) may give either digital or analogue signals of varying magnitude.
Output devices(actuators) may need either an analogue or digital signal of varying magnitude
to operate.
Thus there is a need to manipulate (modify)
1. the input signals from the sensors and
2. the output signals to the actuators
so that they are compatible with the input and output of the processor of PLC.
Signal conditioning (sizing) for analog and digital signals from sensors and signal
conversion for only analog signals from sensors are done in input modules.
Signal conditioning (sizing) for analog and digital output signals required for actuators
and signal conversion of digital PLC output into analog signals required for actuators are
done in output modules.
Programmes for PLC have to be written in a language and converted into a machine code, this being a
sequence of binary code numbers to represent the program instructions.
A software is used to translate the program into machine code for use by the processor.
Programming can be made much easier by use of high level languages like
C,BASIC,PASCAL,FORTRAN,COBOL but writing programs with these languages requires skill in
programming
IEC 61131-3 currently defines five programming languages for programmable control systems: FBD
(Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming
language), IL (Instruction list, similar to assembly language) and SFC (Sequential function chart). These
techniques emphasize logical organization of operations
The most common format for programming are Ladder Diagram and Instruction List. FBD and SFC can
also be brought down to Ladder diagram and Instruction list formats to be fed to PLC
SELF TEST(SANITY SCAN) Checks to see if all the cards are error free, reset watch-dog
timers. A watchdog timer will energise and initiate an alarm and shut down the PLC in the event
of a fault in the system.
INPUT SCAN Reads input values from the chips in the input cards, and copies their present
values to memory by using an input image table. The time taken for the input scan depends on
the number of inputs, the clock speed of the CPU etc
LOGIC SOLVE/PROGRAM SCAN Based on the input table in memory, the program is
executed, as per instructions in the memory, one step at a time and updates out put and stores
them in an output image table in the memory. The program execution time depends on the
length of the program. A 20-30 rungs program may take an execution time of few milliseconds.
OUTPUT SCAN The output image table is copied from the memory to the output chips,
These chips then drive the output devices.
During program scan, the inputs are taken from the memory and not from their physical states.
If the input has a short time, there is a possibility of it being missed out during the scanning
process.
Fig 1(b) shows how the above program and its program
instruction list would appear with a Mitsubishi PLC
Check the integrity of the PLC's power and ground. The integrity of the ground can be
electrically checked by measuring the voltage between the PLC ground terminal and a known
ground. Using a digital meter set on the lowest scale, both the AC and DC voltages should be
zero.
The power supply also can be tested electrically. If the PLC processor has an AC power
source, check the input voltage; it should be within the manufacturer's recommended range.
PLC processors actually operate on DC power, so that also must be checked. Measure each
of the outputs of the DC power supply and check if the voltages are within the
recommended ranges.
Also check the DC supplies for AC ripple. This can be done using a digital meter set on a low
AC range, and the value measured should be well below the manufacturer's specifications.
Excess ripple has drastic effects on the operation of the microprocessors and memory
devices typically found in PLC processors.
The final power check is to measure the voltage of any batteries in the system. Battery
power is often used to prevent a PLC from losing its program during power outages, and
battery voltages should be within recommended values.
a. Timing checks A watchdog is used for a timing check that is carried out by the
PLC to check that some function has been carried out within the normal time. If
the function is not carried out within the normal time, then a fault is assumed to
have occurred and the watchdog timer trips setting off an alarm or closing down
the PLC. Alarm is set off if the function is not carried out in the normal time.
b. Last output check involves the use of status lamps to indicate each output as
it occurs. The program is designed to turn off the previous status lamps and turn
on a new status lamp as each new output is turned on. The program indicates at
which point in the sequence the fault has occurred.
c. Replication- The system repeats every operation twice and if it gets the same
result, it is assumed that there is no fault.
d. Expected value checks Software errors can be detected by checking whether
an expected value is obtained when a specific input occurs. If the expected value is
not obtained, then a fault is assumed to be occuring