A Basic Starter Guide for Students

 A relay is an electromechanical device that when

powered, changes the states of the electrical
connections passing through its contacts.
 A normally open contact creates an open circuit
across the contact when the coil is unpowered.
When the coil becomes powered, the circuit
across the contact becomes closed.
 A normally closed contact creates a closed circuit
across the contact when the coil is unpowered.
When the coil becomes powered, the circuit
across the contact becomes open.
 Contacts on a relay are defined by a number.

A simple
relay
 PLC stands for Programmable Logic
Controller. A PLC is an industrial computer
control system. It continuously monitors the
state of electrical input signals and computes
outputs based on a custom program.
 PLC’s are generally modular, meaning that
input, output, and communication cards can
be added or removed as necessary.

A mounted
ControlLogix
PLC Rack
 Most PLC programming is done using ladder
diagrams. Other formats for writing logic are
sequential charts and structured text.
 Each rung of the ladder powers a coil or executes
an instruction.
 The program is downloaded to the PLC from the
computer.
 Programs already loaded into a PLC can be
uploaded to your computer.
 While communicating with a PLC, you can go
online with it and monitor inputs, outputs, and
internal logic on your computer.
 There are various software platforms to
program and go online with PLC’s.
 Rockwell/Allen Bradley PLC’s are
programmed in Studio5000 or RSLogix5000.
 Older models of Allen Bradley PLC are
programmed in RsLogix500 or RSLogix5.
 RSLinx is required to communicate with Allen
Bradley PLC’s.
 Siemens PLC’s are programmed on various
platforms of Step 7, including MicroWin and
TIA Portal. There is a large, often confusing
variety of Siemens software
 Step 5 is the predecessor to Step 7.
 Note that when installing Siemens PLC
software, particular attention should be paid
to order of installation otherwise the software
may not work correctly.
 Toyopuc PLCs are used by Toyota.
 Information and training on Toyopuc PLCs
can be found here:

\\phfiles\Engineering\Miscellaneous\Custom
er Engineering Standards & Forms\Toyota
 Variables in PLC programming are called tags
Most variables are Boolean (BOOL), but they
can also be integers (INT), or others.
 A tag can be an alias for another tag. An alias
will take on the value of the tag it is pointing
to. Aliasing can be used for creating
meaningful tag names.
 A timer is an example of a basic PLC
instruction other than a coil. You can
examine whether or not the timer is done
before activating contacts.
 Mathematical comparisons can be performed,
such as greater than, less than, equal to, and
more.
 A one-shot contact only closes for a single
scan cycle on the rising or falling edge of its
coil becoming powered.
 For more on the basics of PLC logic
and programming, see:

“Basic Level 1-PLC Theory.ppt”

(add hyperlink)
 Before programming or downloading to a
PLC, the hardware configuration should be
setup to match the physical hardware. This is
required in order for the program to
determine where to look for processors,
inputs, outputs, and communications.
 The models of the PLC hardware can be found
on their label or in drawings. When you are
selecting hardware, ensure it is the correct
model.
 HMI stands for Human-Machine Interface. It
acts as an intermediary for operators to
interact with the control system.
 HMI’s provide visual feedback of the system
and a means to adjust parameters, monitor
I/O, and manually control movement.
 The HMI reads and writes tags to the PLC.
 Some HMI’s require a runtime file to run, but
a project file to create/modify.
 Allen Bradley HMI’s are created mostly using
FactoryTalk View ME (Machine Edition).
 Tags can be imported from RSLogix PLC
Programs to be used in the HMI.
 In order to work on an .apa HMI file, it must
first be restored by using FactoryTalk
Application Manager.
 To export the project file for uploading to the
server, use the Application Manager to
backup the project.
 A Virtual Machine (VM) is an emulation of a
computer system.
 VM’s are kept on the server on the “images”
and “images4review” network drives. They
should be copied to the local computer
before being used.
 Some legacy software requires Windows XP or
older operating systems to work properly.
VM’s provide a convenient way to run older
operating systems.
 VMWare Player is the preferred virtualization
software.
 VM’s require a .vmdk (virtual disk) and .vmx
(configuration) file. The configuration file will
start the VM if the .vmdk is in the same
directory.
 Files can easily be shared between the host
(native) computer and the guest (virtual)
computer by copy-pasting or enabling shared
folders.
 CAD stands for Computer Aided Design. It is
used in the creation of electrical schematics
and panel layouts.
 At Powerhouse, drawings are done in
AutoCAD, Promis-e, or E-Plan.
 All sheets of a drawing set are given unique
page numbers and a drawing set should
contain all or most of the following: Title
Sheet, Contents, Legend, Single-Line,
Mechanicals, Lamacoids, Power Distribution,
Inputs/Outputs.
 The Cover Sheet, Table of Contents, Revison
Record, Drawing Standards, and Legend are
the first sheets of a drawing set. They contain
drawing metadata, a list of the drawings, and
relevant symbol information.
 Single Line drawings show the system at a
high level. They show the inter-connections
between panels and devices. An
Ethernet/communications diagram may be
included.
 Mechanical drawings refer to the physical
layout of hardware as it will be built. It
includes information such as panel size, cut-
outs, connectors, and hardware model
numbers.
 Lamacoid drawings are for labels placed on
panels are used for connectors, pushbuttons,
lamps, switches, and more.

An example of a
lamacoid used for
an E-Stop pushbutton
 Wire Numbers and Device ID’s are determined
using the page and line number that they are
found.
 For example, The wire number 16073 could
be found on sheet 16, line 07, and is the
third unique wire found on that line.
 The device number LC5514 could be found
on sheet 55, line 14, and is a LC (Light
Curtain) type of device.
 Depending on the standard used, wire
numbering may follow a different format.
 Files created in E-Plan, Promis-e, and AutoCAD
are not convenient for viewing. When a new or
revised drawing set is completed, it should be
made into a PDF.
 Document control is very important to keep track
of design changes. If changes must be made to a
drawing that has been released, use a red pen,
initial the mark-up, and include the date. Do not
create multiple working copies of drawings for
the same project. This leads to higher chances of
miscommunication and undocumented changes.
 A Variable Frequency Drive (VFD), sometimes
just called a “drive”, is an electric motor
controller. It varies the frequency and voltage
supplied to a motor, providing a means to
control the speed and torque. VFD’s can
output either AC or DC voltages.
 A Transformer is used to step-up (increase)
or step-down (decrease) AC voltages. For
example, customer supply may be 600VAC or
higher, so a transformer could be used to
“step it down” to the standard 120VAC.
 A Line Reactor is used to reduce transient
noise on power fed to VFD’s. It provides
“cleaner” 3-phase power and helps to reduce
nuisance trips and extend motor life.
 A Thermocouple is a sensor used to measure
temperature. They are composed of two
different metals that produce a temperature-
dependant voltage that can be re-interpreted
to measure temperature.
 A Proximity Sensor is used to detect the
presence of objects without any physical
contact. Proximity Sensor’s can use
capacitors, inductors, sonar, electromagnetic
radiation, or more. Different types of sensor
have different advantages and disadvantages.
 When powered, a Power Supply provides a
specified voltage (usually 24VDC) for use in
controls and powering devices.
 A sinking digital I/O provides a grounded
connection to the load. Current flows into the
sink.
 A sourcing digital I/O provides a voltage source
to the load. Current flows out of the source.
 A sinking I/O must be paired with a sourcing
module on the PLC to allow current flow and
vice-versa. If this is not the case, a PNP or NPN
transistor can be used to bias the components in
a way which will allow current to flow.
 A Contactor works like a relay but handles
higher voltages and currents.
 Motor Starter Protector (MSP) is used to
switch and protect single phase and three-
phase induction motors of up to 75 HP at 480
VAC and for loads with rated currents of up
to 100 Amps. MSP’s have 3 poles.
 A Terminal Block (TB) is an electrical
connector that clamps down on wires on each
side of it, providing electrical continuity
between the wires on either side. Terminals
can be jumpered together to provide
branching of a circuit.

A typical
terminal strip
 A Gland is a device designed to allow the
entry of cable into electrical equipment
that provides sealing and retention.
 Glands come in both metric and imperial
sizes. Metric glands might be referred to as
“M12”, “M16”, “M20” or other sizes.
 A Connector is found on the outside of a
panel. It is essentially a plug. A connector can
have any number of pins, with
corresponding leads on the
inside of the panel.
 The Male end of a connector or cable is the
end where the wire is exposed.
 The Female end of a connector or cable is the
end where the wire is not exposed.
 A Distribution Block is used as an economical
means to branch circuits and reduce the total
number of wires in an electrical panel.

A typical Distribution
Block for 3 Phases
 Many modern control systems communicate
using Ethernet. This means that each Node or
device requires a unique IP address.
 This also means that you cannot
communicate with the devices unless you set
a static IP address. (More information on this
on the next slide).
 Some Ethernet devices require that you set
their IP address using BOOTP. (“Bootstrap
Protocol”)
 Go to: Control Panel  Network and Sharing
Centre  Change Adaptor Settings.
 Right-click on the adaptor you are using and
choose “Properties”.
 Select “Internet Protocol Version 4 (TCP/IPv4) and
click “Properties”.
 Select “Use the following IP Address:” and enter
an IP address as required.
 NOTE: You cannot use the internet through the
modified adaptor until you return the settings to
“Obtain an IP address automatically”.
 Ethernet is the highest level for networking
and provides the information layer for data
collection and program maintenance.
 ControlNet is the middle network that supplies
the automation
layer for real-time
input/output control.
ControlNet is highly
deterministic and
repeatable.
 DeviceNet is the lowest level of networking
and free to use. DeviceNet components are
widely manufactured making it an economical
network.
 DataHighway provides simple communication
and simple implementation. Devices and PLCs
are wired to the trunk line to form a
connection.
 ProfiBus sub-nets:
 Profibus-DP is a device level bus that
supports both analog and discrete signals.
 Profibus-PA is a full-function fieldbus that is
generally used for process control and
process-level instrumentation.
 Profibus-FMS is a control bus generally used
for communications between DCS
(Distributed Control Systems) and PLCs.
 ProfiNet is Siemens' version of Ethernet
networking. It can be used for virtually any
function required in automation. i.e. discrete,
process motion, peer-to-peer integration,
vertical integration, safety and more.
 Serial communication transfers only one bit
of data at a time while Parallel
communication can transfer a number of bits
simultaneously depending on the bus size
(common sizes: 32-bit, 64-bit)