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Chapter 8
PLC Installations and Startup
PLC Installations ‡ Receiving a PLC ‡ PLC Enclosures ‡ Electrical Noise ‡ PLC Power Supplies ‡ PLC Installation Safety ‡ PLC Wiring ‡ PLC Startup ‡ Initial PLC Checks ‡ Input Section Checks ‡ Output Section Checks ‡ Program Checks ‡ Final Checks

Chapter 8 ² PLC Installations and Startup

Installation issues that a technician must address include receiving a PLC, PLC enclosures, electrical noise, power supplies, safety, and wiring.

Chapter 8 ² PLC Installations and Startup When receiving a PLC and any associated hardware. there are several procedures that must be followed. .

Chapter 8 ² PLC Installations and Startup An enclosure protects a PLC from the surrounding environment and protects technicians from contact with energized parts. .

.Chapter 8 ² PLC Installations and Startup PLCs can be mounted to a backpanel or to a DIN rail.

Chapter 8 ² PLC Installations and Startup Fans. and/or solar shields are used to prevent excessive heat buildup inside PLC enclosures. . cooling units.

.Chapter 8 ² PLC Installations and Startup Proper installation of a PLC in an enclosure should prevent most electromagnetic interference problems.

Chapter 8 ² PLC Installations and Startup PLCs have separate metal raceways (conduits) for voltage supply wires and signal wires. .

.Chapter 8 ² PLC Installations and Startup Ground lug connections must be tight and mechanically sound to guarantee a good electrical connection.

.Chapter 8 ² PLC Installations and Startup The twisting of conductors and the shield/drain wire provide enhanced noise reduction. The shield/drain wire is only grounded at one end (the PLC end) when connected to analog input devices.

and related items use a common power source to avoid ground loops and mismatched hot and neutral phases and to ensure all items are powered up and powered down together. . output components.Chapter 8 ² PLC Installations and Startup PLC power supplies. input devices.

Chapter 8 ² PLC Installations and Startup Emergency stop buttons are wired to master control relays (MCRs) and are located on machinery and process equipment to protect equipment and personnel. .

Chapter 8 ² PLC Installations and Startup Hold-up time is the length of time a PLC can tolerate a power loss without affecting operation. .

Chapter 8 ² PLC Installations and Startup In order to prevent noise-related problems. . conductors of different voltage levels and signal types must be separated as much as possible and must not be tywrapped together.

terminal strip.Chapter 8 ² PLC Installations and Startup The three methods for terminating PLC wiring in an enclosure are direct. and interface module. .

. a prefabricated cable must be used to connect the interface module to the PLC.Chapter 8 ² PLC Installations and Startup When input devices and output components are connected to an interface module.

.Chapter 8 ² PLC Installations and Startup Input and output modules are chosen according to the type of module and voltage level required for an application.

Chapter 8 ² PLC Installations and Startup PLC input and output modules are placed in a PLC chassis to ensure optimum performance and prevent noise-related problems. .

.Chapter 8 ² PLC Installations and Startup A sourcing PLC input or output has the negative (±) polarity connected to the field device. while a sinking PLC input or output has the positive (+) polarity connected to the field device.

.Chapter 8 ² PLC Installations and Startup Technicians performing a PLC startup require specific startup items.

Chapter 8 ² PLC Installations and Startup Initial checks are visual tests performed by a technician before any power is applied to a PLC. .

Chapter 8 ² PLC Installations and Startup Input section (or module) checks verify that input devices function properly and are wired to the correct PLC input terminal. .

.Chapter 8 ² PLC Installations and Startup Output section (or module) checks verify that all output devices function properly and are wired to the correct PLC output terminal.

.Chapter 8 ² PLC Installations and Startup Program checks verify that a PLC program functions properly without the application or process that the PLC controls actually being run.

.Chapter 8 ² PLC Installations and Startup A final check verifies that an application or process controlled by a PLC functions properly in RUN mode under actual conditions.