Professional Documents
Culture Documents
Local partner of
PLC Design,
Troubleshooting and
Maintenance
04 October 2020
PLC Introduction
• Programmable Logic Controller (PLC)
• A PLC is an industrial rugged digital computer that monitors inputs, makes decisions based on its program, and
controls outputs to automate a process or machine.
• https://library.automationdirect.com/history-of-the-plc/
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PLC Brands
• Siemens – Simatic Controllers
• S5
• S7
PLC Brands
• Rockwell Automation – Allen-Bradley Controllers
• SLC500 / PLC5
• Compactlogix / Controllogix
PLC Brands
• Mitsubishi Melsec / Schneider Modicon / Omron Sysmac
Types of PLC
• Fixed vs Modular
• Fixed Input/Output or Compact PLCs
• Cheaper
• Normally used for small machines that will not need expansion in the future
• Modular PLCs
• Scalable number of I/Os
• Medium PLCs
• Upto 4MB memory
• Hundreds of I/Os
• Large PLCs
• Larger than 4MB memory
• Thousands of I/Os
Types of PLC
• Safety PLC (https://www.controleng.com/articles/safety-plcs/)
• A programmable logic controller designed for use in mission-critical or safety-related applications.
Programming HMI/SCADA/Other
Communication
Terminal Systems
Power Supply
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Parts of PLC
• Rack / Chassis
• Acts as backbone of the PLC system
• Converts AC to DC
• Built-in communication
• LED Indication
• Stop/Run Switch
• Battery
Parts of PLC
• Input Modules
• Digital Inputs
• Number of inputs – 8, 16 or 32 points
• Fast input
• Hardware interrupt
• Grouping
• Sinking or Sourcing
Parts of PLC
• Input Modules
Parts of PLC
• Input Modules
• Analog Inputs
• Number of inputs – 2, 4, 8, 16 points
• Output current
• Hardware interrupt
• Grouping
• Sinking or Sourcing
• Relay type
Parts of PLC
• Output Modules
Parts of PLC
• Output Modules
Parts of PLC
• Output Modules
• Analog Outputs
• Number of outputs – 2, 4, 8 points
• Modbus
• Profibus
• Asi Gateways
Parts of PLC
• Function Modules
• Counter or Encoder Modules
• Weigher Modules
Parts of PLC
• Programming Terminal
• PC or Laptop
• Programming Software
• Simatic Step 5, Simatic Step 7 for Simatic PLCs
• RSLogix 5, RSlogix 500, RSLogix 5000, Studio 5000 for Allen-Bradley PLCs
• Programming Cable
• Ethernet Cable
• Serial Cable
• USB Cable
How PLC Works
• Cyclic Scan
• Input Scan – reads status of input modules and updates the input data
• Program Scan – execute user program
• Other Tasks – e.g. internal diagnostic, communication
• Output Scan – writes the output data to the output modules
• Periodic Scan
• Interrupts cyclic program execution to perform a specific program
• e.g. Execute specific user program every 100ms
• Hardware Interrupts
• Interrupts cyclic program execution to perform a specific program
• e.g. Hardware interrupts from a digital input module
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How PLC Works
• Scan Time
• Amount of time to perform one scan cycle of the plc (from getting the inputs, then program execution, to
updating the outputs)
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PLC Programming Software
• Hardware Configuration
• Communication Configuration
• Program Blocks
• Compare Tools
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PLC Programming Languages
• Ladder Diagram (LD)
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PLC Programming Languages
• Ladder Diagram (LD)
• Also known as relay logic
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PLC Programming Languages
• Function Block Diagram (FBD)
• A simple graphical method to program a relation between inputs to an output
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PLC Programming Languages
• Sequential Function Charts (SFC)
• Step Based Programming
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PLC Programming Languages
• Structured Text (ST)
• Text Based Programming
• Difficult to troubleshoot
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PLC Programming Languages
• Instruction List (IL)
• Text Based Programming
• Compact programming
• Difficult to troubleshoot
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Troubleshooting
• LED Indication
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Troubleshooting
• Status Display
• Newer PLCs have displays for faster diagnostic
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Troubleshooting
• Software Diagnostic
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Troubleshooting
• Getting Online Support
• https://support.industry.siemens.com/cs/start?lc=en-US
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Troubleshooting
• Getting Online Support
• https://www.rockwellautomation.com/en-us/support.html
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Maintenance
• Backup program
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