fundamentals of plcs review
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1: Review of PLCProgramming and Logi
FundamentalsMTR 335 Advanced PLCs and Integration
Fall 2015
Dr. enni!er "il#$rn
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Outline
Revie% o! PLCs Ladder Logic F$nda&ental Circ$its
Me&or' and Pro(ect )rgani*ation
+it,Level Progra&&ing
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Review of PLCs
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What is a PLC?
Progra&&a#le Logic Controllers -PLCs is an ind$strial,gradeco&/$ter $sed to /er!or& control !$nctions.
PLCs %ere originall' develo/ed to re/lace co&/le rela' logic controlcirc$its.
Te ca/a#ilities o! PLCs are ever,e/anding &eaning tat PLCs are#eing $sed to control increasingl',co&/le s'ste&s. Te' are nolonger li&ited to si&/le digital in/$to$t/$t s'ste&s.
PLC Progra&&ing is designed to #e readil' accessi#le to 4eldengineers and tecnicians %o &a' not necessaril' #e !a&iliar %itco&/$ter /rogra&&ing.
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Advantages of PLCs Increased relia#ilit'
P'sical contacts on electro&agnetic rela's %ear o$t &$c !aster tan PLCs a&e /rogra& can #e do%nloaded to &an' PLCs no cance o! &is%iring
More 6ei#ilit' 7asier to &a8e logic canges in te PLC /rogra& tan te rela' circ$it
7/anded !$nctionalit' not ($st digital I)
ec$rit' !eat$res
Lo%er cost Rela'sContactors are not cea/.
PLCs do not ave to go o$t o! service to /rocess logic canges.
Co&&$nications ca/a#ilit' $/ervisor' control data gatering &onitoring devices and /rocess /ara&eters re&ote I)
Faster res/onse ti&e Designed !or ig,s/eed and real,ti&e a//lications
Rela' circ$its do not res/ond 9$ic8l' eno$g !or s'ste&s tat /rocess to$sands o! /arts /er second
7asier to tro$#lesoot Diagnostic ca/a#ilities si&$late in/$ts cec8 logic %atc /rogra& eec$te in real,ti&e
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Parts of a PLC
Mod$lar Fied
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Principle of Operations
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Principle of Operations - Example
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Principle of Operations - Example1. Te /ress$re s%itc te&/erat$re
s%itc and /$s#$tton in/$ts areea&ined and teir stat$sesrecorded in te controller:s &e&or'.
a. Closed ; 1 o/en ; 0
2. Te ladder diagra& is eval$ated#ased on tese in/$t states.Activated r$ngs assign a logic val$e
o! 1 to teir o$t/$t coil:s &e&or'location.
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Typical PLC InstructionsSiemens SIMATIC STEP 7 Allen-Bradley RSLogix 5000
Normally-Open Contact XIC Examine If Closed
Normally-Closed Contact XIO Examine If Open
Positive Signal Edge OSR One-Shot Rising
Assignment Coil OTE Output Energize
Set Coil OTL Output Latch
Reset Coil OTU Output Unlatch
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Typical PLC InstructionsSiemens SIMATIC STEP 7 Allen-Bradley RSLogix 5000
TOF Timer Off Delay TOF Timer Off Delay
TON Timer On Delay TON Timer On Delay
CTD Count Down CTD Count Down
CTU Count Up CTU Count Up
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Addressing
ie&ens
I In/$t
= )$t/$t
M Me&or'
Process I&age> )nl' %a' to to access I)#its +ool ?I 0.0@ ?= 0.0@
+'te ?I+ 10@ ?=+ 10@
"ord ?I" 1@ ?=" 1@
Do$#le "ord ?ID 2B@ ?=D 2B@
Ti&ers> T3B
Co$nters> C23
Local> L0.0 L+1 L"2 LDB
Pointer> P !ollo%ed #' an address li8eP2.0 or PIB.1
Allen,+radle'
I In/$t
) )$t/$t
M Me&or'
For&at>
)0>0100 File t'/e ) ; o$t/$t I ; in/$t
> , 4le deli&iter
0 rac8 n$er
1 gro$/ -0,E gro$/s in a rac
, #it deli&iter
00 ter&inal n$er -#it addres
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Types of PLCs
Co&/act
o&eti&es called ?Co&/act@ or?Micro@ PLCs
Li&ited n$er o! I) /orts
I) /orts are integrated into te #od'o! te PLC %it te CPG &e&or' and
co&&$nications ?
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I/O Modules Discrete I)
Analog I)
/ecial I) Mod$les> Jig,/eed Co$nter Mod$le
T$%eel Mod$le
TTL Mod$le
7ncoder,Co$nter Mod$le
+AIC or ACII Mod$le te//er,Motor Mod$le
+CD,)$t/$t Mod$le
Pro/ortional,Integral,Derivative -PID Control Mod$le
Motion and Position Control Mod$le
Co&&$nication Mod$les
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Discrete I/O Module Digital In/$t Mod$le $sed to read
in/$ts s$c as> /$s#$ttonsselector s%itces li&it s%itces/roi&it' s%itces
Digital )$t/$t Mod$le $sed toactivate> indicator ligts signalingcol$&ns rela's &otor coils
Availa#le in vario$s AC and DCvoltage ratings
Mod$les receive /o%er !roac8/lane
Devices receive /o%er !ro& 4eld,s$//lied voltage so$rce
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Analog I/O Module T'/ical analog in/$ts and o$t/$ts
var' !ro& 0 to 20 &A B to 20 &Aor 0 to 10 .
T%o #asic t'/es o! analog in/$ts> C$rrent sensing
oltage sensing
T'/ical 9$antities &eas$red>
te&/erat$re s/eed
level
6o%
%eigt
/ress$re
/osition
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Special Modules High-speed counter:co$nts inde/endentl' !ro& te /rocessor rates $/ to 1008J*
Thumbwheel module:reads t$%eel s%itces
TTL module:co&&$nicate %it TTL,level signals
Encoder-counter module> Reads encoder stores data to #e read later #' /rocessor
BASIC or ASCII module:r$ns $ser,%ritten +AIC and C /rogra&s inde/endentl'!ro& PLCE inter!ace #et%een re&ote devices and PLC /rocessor
Stepper-Motor module: Provides /$lse trains to drive a ste//er &otor
BCD output module:Gsed to control +CD o$t/$ts li8e ,seg&ent dis/la's
ID module: allo%s co&/le PID control algorit& to #e co&/$ted o$tside te PLCCPG !reeing te PLC !ro& tese c$erso&e calc$lations
Motion !nd osition Control module:control ste//er and servo &otors %it ig/recision !or ig,s/eed &acining and /ac8aging o/erations
Communic!tions module: Gsed to esta#lis /oint,to,/oint co&&$nications !orecange o! data a&ong &od$les co&/$ters PLCs o/erator stations /rocesscontrol s'ste&s etc.
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Ladder Logic
Fundamental Circuits
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AND gate
A B Q
0 0 0
0 1 0
1 0 0
1 1 1
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OR gateA B Q
0 0 0
0 1 1
1 0 1
1 1 1
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NOT gateA B
0 1
1 0
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NAND gateA B Q
0 0 1
0 1 1
1 0 1
1 1 0
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NOR gateA B Q
0 0 1
0 1 0
1 0 0
1 1 0
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XOR gateA B Q
0 0 0
0 1 1
1 0 1
1 1 0
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Inverting Inputs and Outputs
A rela' &$st #e $sed to invert teo$t/$t o! a logic o/eration.
A si&/le
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Memory and Project
Organization
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Programmable Automation Controller More advanced &at and logic &ani/$lation !$nctions
PACs loo8 and act li8e PLCs #$t %it e/anded ca/a#ilities> advanced control o! co&&$nications
data logging
signal /rocessing
&otion control
/rocess control
&acine vision
For Allen,+radle' PLCs tese PACs incl$de>
ControlLogi Co&/actLogi
FleLogi
o!tLogi 500
DriveLogi
o!t%are &a8es te diHerence. tandard Ladder Logic doesn:t cange #$taddressing o! instr$ctions does.
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Memory Layout ControlLogi -CL /rocessors ave a 6ei#le &e&or' str$ct$re no
4ed areas o! &e&or' allocated !or s/eci4c t'/es o! data or !or I)
Me&or' organi*ation is con4g$red #' te $ser in RLogi 5000
A CL s'ste& can #e co&/osed o! onl' a controller and standard I)&od$les in a single cassis or it can #e as co&/le as a igl',distri#$ted s'ste& containing several cassis and net%or8s %or8ingtogeter.
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Configuration Con4g$ration o! a &od$lar CL s'ste&
involves esta#lising a co&&$nications lin8#et%een te controller and te /rocess.
Te so!t%are needs to 8no% %at ard%areis #eing $sed in ordered to #e a#le to sendor receive data.
Con4g$ration incl$des %at /rocessor-sI) &od$les s/ecial &od$les and
net%or8ing are #eing $sed.
RLogi 5000 is $sed to con4g$re te&e&or' o! te controller
RLin is $sed to create a connection#et%een RLogi 5000 and te ard%are.
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Configuration (contd) To esta#lis co&&$nications %it a controller a driver &$st #e created
RLin.
R"o allo%s 'o$ to vie% all con4g$red net%or8 drivers.
A!ter drivers are con4g$red te &od$les are con4g$red in RLogi 500&$st #e con4g$red correctl' or te' %ill not %or8 /ro/erl' -or at all.
RLin can also #e $sed to 4nd data a#o$t &od$les li8e 4r&%are and rversion.
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Project RLogi 5000 -and 500 stores a
controller:s /rogra&&ing andcon4g$ration in!or&ation in a 4lecalled aproject.
Te /ro(ect 4le contains allin!or&ation relating to te /ro(ect> tas8s
/rogra&s
ro$tines
A controller can onl' old andeec$te one /ro(ect at a ti&e.
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Project (contd) RLogi 5000 /ro(ect organi*ation tree so%s
Tas8s Progra&s
Ro$tines
Data t'/es
Trends
I) con4g$ration
Tags
Folders gro$/ co&&on !$nctions togeter
Rigt,clic8ing on diHerent o#(ects #rings $/relevant contet,sensitive /o/$/ &en$s
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Tasks Tas8s are te 4rst level o! sced$ling %itin a
/ro(ect A tas8 is a collection o! sced$led /rogra&s
"en a tas8 is eec$ted te associated/rogra&s are eec$ted in te order listed -te/rogra& sced$le.
Tas8s /rovide sced$ling contain no eec$ta#lecode.
)nl' one tas8 &a' eec$te at a ti&e Main t'/es o! tas8s>
Contin$o$s eec$te non,sto/ #$t are al%a'sinterr$/ted #' /eriodic tas8sE lo%est /riorit'.
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Programs Progra&s are te second leve
sced$ling %itin a /ro(ect
Te !olders $nder Tas8 ?Maindeter&ine %ic /rogra&s eand in %at order.
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Routines
Ro$tines are te tird level or sc%itin a /ro(ect.
Ro$tines contain te eec$ta#le /ro(ect.
7ac ro$tine contains a set o! lo
!or a s/eci4c /rogra&&ing lang$ "en a ro$tine is created it is s/e
Ladder Logic e9$ential F$nction +loc8 Diagra& or tr$ct$red Tet.
An' one ro$tine &$st #e in onl' on#$t diHerent ro$tines &a' containlang$ages %itin te sa&e /ro(ect
Li#raries o! standard ro$tines caand re$sed on &$lti/le &acine
a//lications.
A ro$tine can #e assigned as> Main ro$tine eec$tes 4rst in te
$#ro$tine called #' anoter ro$co&/le tas8s or tose tat re9$ione /rogra&&ing lang$age.
Fa$lt ro$tine eec$tes i! controlle/rogra& !a$lt. 7ac /rogra& can
ro$tine -i! desired.
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Tags Tag,#ased addressing str$ct$re
Tags are &eaning!$l na&es li8e?varia#les@
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Tags (contd) ?co/e@ re!ers to %ic /rogra&s ave
access to a tag co/e &$st #e declared %en 'o$
create te tag
T%o sco/es> Progra& sco/e -local data visi#le %itin
ro$tines %itin te /rogra&
Controller sco/e -glo#al data accessi#le#' all ro$tines %itin a controller
Te sa&e tag na&e &a' a//ear %itindiHerent /rogra&s as local varia#les#eca$se oter /rogra&s cannot see tetag.
Te sco/e o! a tag &$st #e declared%en 'o$ create te tag.
I) t t ti ll d 4
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Tags (contd)
I) tags are a$to&aticall' de4ncontroller sco/ed tags.
Tere are !o$r diHerent t'/es o!tags> #ase
alias
/rod$ced cons$&ed
+ase stores vario$s t'/es o! d!or $se #' logic in te /ro(ect 7. Local>2>).Data.B
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Tags (contd) Alias $sed to create an alternate na&e !or a
tag or anoter na&e !or an alread',na&edaddress in &e&or'
An' action to te #ase also a//ens to tealias and vice versa.
Prod$cedcons$&ed tags are $sed tosare tag in!or&ation over a net%or8#et%een 2 or &ore devices.
A /rod$ced tag sends data Prod$ced tags are al%a's control,sco/ed
A cons$&ed tag receives data M$lti/le controllers can connect to an'
data #eing /rod$ced %ic /revents teneed to send &$lti/le &essagescontaining te sa&e data.
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Data Types Logi controllers are #ased on 32,#it o/erations
T'/es o! data tat can #e a #ase ta are> +))L
I
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Data Types (contd) +))L one #it o! data stored in #it
0 o! a B #'te &e&or' location I
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Structures tr$ct$res are anoter data,t'
A str$ct$re,t'/e tag is a gro$/diHerent data t'/es tat !$ncta single $nit and serve a s/eci/$r/ose.
7ac ele&ent o! a str$ct$re is a &eer and eac &eer ca diHerent data t'/e
Tere are tree diHerent t'/esstr$ct$res in a ControlLogicontroller> Prede4ned
Mod$le,de4ned
Gser,de4ned
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Predefined Structures Te controller creates /rede4ned
str$ct$res !or 'o$ tat incl$de> ti&ers
co$nters
&essages
PID
In te 4g$re te Co$nter str$ct$recontains te /reset val$e te
acc$&$lation val$e and teco$nter instr$ction:s stat$s #its.
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Module-defined Structures Mod$le,de4ned str$ct$res are
a$to&aticall' created %en te &od$les are con4g$red !or te s
"en 'o$ add in/$t or o$t/$t &a n$er o! de4ned tags area$to&aticall' added to te contrtags
Te 4g$re so%s t%o str$ct$res added %en an in/$t &od$le is a
)ne stores in/$t data and te otstores con4g$ration data.
?Local@ indicates tat tese tagste sa&e rac8 as te /rocessor. Te ?1@ indicates tat te &od$le
1 o! te cassis.
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User-defined Structures Gser,de4ned str$ct$res /rovide te a#ilit'
to store and andle data as a gro$/.
7a&/le> Te str$ct$re in te 4g$recontains data !or a storage tan8 so tatall data relative to te tan8 are storedtogeter.
"en designing te /rogra&&er createste str$ct$re tat contains all te diHerentas/ects o! te storage tan8
7ac &eer as a &eaning!$l na&e andan a//ro/riate data t'/e.
It is eas' !or installation and &aintenance/ersonnel to locate all data associated%it te o/eration o! te tan8 as it isstored togeter.
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Creating Tags Man' %a's to create tags>
create tags !ro& te tag editor #/rogra&&ing
enter tag na&es as 'o$ /rogra&
$se O as /laceolders and enter na&es later
"en de4ning tags te !ollo%in!or&ation &$st #e s/eci4ed> Tag na&e
Tag descri/tion -o/tional Tag t'/e
Data t'/e
Dis/la' st'le
"eter te tag is cons$&a#le n$er o! controllers tat can cit
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Monitoring and Editing Tags A!ter tags ave #een created te'
can #e &onitored in te ?MonitorTags@ %indo%
Te ?Force Mas8@ is $sed to !orcein/$ts and o$t/$ts %entro$#lesooting.
In te ?7dit Tags@ %indo% 'o$ canedit eisting tags or create ne%
tags.
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Array Man' control /rogra&s re9$i
a#ilit' to store #loc8s o!in!or&ation as ta#les tat caaccessed at r$nti&e.
An arrayis a tag t'/e tat coa #loc8 o! &$lti/le /ieces o!
7ac ele&ent o! an arra' &$te sa&e data t'/e -e. all +
all I
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Bit-Level Programming
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Program Scan "en a ControlLogi controller
eec$tes a /rogra& it &$st 8no%in real ti&e%en eternal devicescontrolling a /rocess are canging.
D$ring eac o/erating c'cle te/rocessor>1. Reads all te in/$ts
2. tores tese val$es
3. 7val$ates te $ser /rogra&B. 7nergi*es and deenergi*es teo$t/$ts in accordance %it te $ser/rogra&.
Tis is teprogram scan.
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Program Scan (contd) D$ring te /rogra& scan te controller reads te r$ngs
and #rances !ro& rigt,to,le!t and to/,to,#otto& as!ollo%s> Te stat$s o! in/$ts at te input moduleare cec8ed !or tr$e
-1 or )
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Creating Ladder Logic )! te 4ve availa#le /rogra&&ing
lang$ages !or PLCs Ladder Logic iste &ost /revalent.
In general Ladder Logic isco&/osed o! I
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Creating Ladder Logic (contd) )! te 4ve availa#le /rogra&&ing lang$ages !or PLCs Ladder Logic is te
&ost /revalent.
In general Ladder Logic is co&/osed o! I
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Creating Ladder Logic (contd) All in/$t instr$ctions &$st #e to te le!t o! an o$t/$t instr$ction.
Te last instr$ction on a r$ng &$st #e an o$t/$t instr$ction.
Te IC -7a&ine I! Closed ret$rns TRG7 i! te in/$t val$e is 1.
Te I) -7a&/le i! )/en ret$rns TRG7 i! te in/$t val$e is 0.
Te )T7 -)$t/$t 7nergi*e coil instr$ction sets te tag associated %it it toTRG7 -1 %en te r$ng as logic contin$it'. "en tr$e it can #e $sed toenergi*e an o$t/$t device or to set te val$e o! a &e&or' #it to 1.
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Creating Ladder Logic (contd) ControlLogi PLCs -RLogi 5
s$//ort &$lti/le o$t/$ts on or$ng.
It also s$//orts series o$t/$tcon4g$rations tat would noi! connected tis %a' in an aelectrical circ$it. Tis is not te case !or RLogi
tis series o$t/$t con4g$ratio
not #e valid.
RLogi 5000 also /er&its o$instr$ctions to #e /laced #etin/$t instr$ctions as long aslast ite& on te r$ng is an o$
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Tag-Based Addressing RLogi 5000 s$//orts tag,#ased addressing str$ct$re.
A tag is li8e a ?varia#le@ na&e !or a section o! &e&or' %ena /iece o! data is stored.
Tags are &eant to give &eaning!$l na&es to oter%ise diKc$lt,to,re&eer addresses.
In te ea&/le te tag Li&its%itc as addressLocal>1>I.Data.2-C. Local indicates tat te &od$le is in te sa&e rac8 as te /rocessor
1 indicates tat te in/$t &od$le is in slot 1 o! te rac8
I indicates tat te &od$le is te in/$t t'/e
Data indicates tat it is a digital in/$t
2 indicates tat te li&it s%itc is attaced to ter&inal 2 on te&od$le
C indicates tat it is a ?controller@ tag %ic as glo#al access
In te ea&/le te tag Jigli&itligt as addressLocal>2>).Data.B-C. Local indicates tat te &od$le is in te sa&e rac8 as te /rocessor
2 indicates tat te in/$t &od$le is in slot 2 o! te rac8
) indicates tat te &od$le is te o$t/$t t'/e
Data indicates tat it is a digital o$t/$t
B indicates tat te ig li&it ligt is attaced to ter&inal B on te&od$le
C indicates tat it is a ?controller@ tag %ic as glo#al access
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Tag-Based Addressing (contd) )ne advantage o! te $se i! tag,#ased addressing is tat all te
allocation o! varia#le na&es !or /rogra& val$es is not tied to s/eci4c&e&or' locations in te &e&or' str$ct$re.
Initiall' all /rogra& develo/&ent can /roceed %it ($st te tagna&es and te data t'/es assigned.
Gsing tag aliases /rogra&&ers can %rite code inde/endent o!electrical connection assign&ents.
At a later ti&e in/$t and o$t/$t 4eld devices are easil' &atced to
te /in n$ers on te res/ective &od$le te are connected to.
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Adding Ladder Logic to the Main Rou In te 4g$re o! te ard%ired
&otor startsto/ circ$it tenor&all',o/en start #$tton is&o&entaril' closed to energte contactor coil ad close itscontacts to start te &otor.
Te seal,in a$iliar' contact connected in /arallel %it t#$tton to 8ee/ te &otor coienergi*ed %en te start #$treleased.
Te nor&all' closed sto/ #$t&o&entaril' o/ened to de,energi*e te contactor coil asto/ te &otor.
AddingLadderLogictotheMainRou
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Adding Ladder Logic to the Main Rou(contd) Te 4g$re so%s te PLCLadder
Logic set$/ !or te &otor startsto/circ$it.
Te ?O@ are $sed in /lace o! tagna&es to so% tat %e do not aveto tie an instr$ction to a &e&or'addresstag #e!ore %e create tenet instr$ction.
Te %iring is as so%n> Te sto/ #$tton is %ired to in/$tter&inal 3.
Te start #$tton is %ired to in/$tter&inal B.
Te contactor coil is %ired to ter&inalB o! te o$t/$t &od$le.
Adding Ladder Logic to the Main Routine( d)
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(contd) Tags el/ doc$&ent or ?co&&
'o$r ladder code.
For tis si&/le circ$it 3 tags
created> Motortart
Motorto/
MotorR$n
Loo8ing at Motortart a lin8tro$g te &od$le to te 4edevice &$st #e s/eci4ed to liin/$t ter&inal 3 to te /ro/erna&e.
Tag na&es are do%nloaded anstored in te controller #$t tdescri/tion is not. It is conside#e /art o! te doc$&entation
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g g(contd)
Te sa&e data can #e re!erenced&$lti/le ti&es $nder diHerentna&es $sing ?aliases@.
"en te &otor is o/erating> Te IC Motortart instr$ction is
!alse.
Te IC Motorto/ is tr$e.
Te )T7 instr$ction is tr$e #eca$sete r$ng as logic contin$it'.
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Internal Relay Instructions Internal rela' instr$ctions are $sed
%en oter tan real,%orld 4elddevices are needed as in/$t oro$t/$t re!erence instr$ctions.
Co&&onl' an internal rela' #it is$sed as an o$t/$t %en te RL) o!te r$ng is $sed to control oterinternal logic.
In RLogi 5000 %e do tis #'creating a tag -eiter /rogra& orcontroller t'/e and assigning a+ool data t'/e to it.
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Latch and Unlatch Instructions Te o$t/$t latc -)TL instr$ctio
retentive o$t/$t instr$ction tat
$sed to &aintain or latc an o$
I! tis o$t/$t is t$rned on -energit %ill sta' energi*ed on !$t$re sc'cles even i! te r$ng tat eneit is no longer tr$e.
Te onl' %a' to t$rn te energi*o$t/$t #ac8 oH is to energi*e an
$nlatc -)TG instr$ction %it tsa&e tag as te /revio$sl' activ-)TL.
Te latced state %ill even #e&aintained i! te PLC is /o%ereand #ac8 $/ again.
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One-Shot Instruction Te one,sot -)
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References1. Fran8 D. Petr$*ella ?Ca/ter 1 , Progra&&a#le Logic Controllers
-PLCs> An )vervie%@ Progra&&a#le Logic Controllers BteditionMcQra%,Jill 2011.
2. Fran8 D. Petr$*ella ?Ca/ter 2 PLC Jard%are Co&/onents@Progra&&a#le Logic Controllers Btedition McQra%,Jill 2011.
3. Fran8 D. Petr$*ella ?Ca/ter B F$nda&entals o! Logic@Progra&&a#le Logic Controllers Btedition McQra%,Jill 2011.
B. Fran8 D. Petr$*ella ?Ca/ter 15 ControlLogi Controllers@ Part 1 Me&or' and Pro(ect )rgani*ation Progra&&a#le Logic ControllersBtedition McQra%,Jill 2011.
5. Fran8 D. Petr$*ella ?Ca/ter 15 ControlLogi Controllers@ Part 2 +it,Level Progra&&ing Progra&&a#le Logic Controllers BteditionMcQra%,Jill 2011.