Sarmiento Cabico Sibal Industrial Automation, Inc.

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.

• Invented by Dick Morley in 1964 to replace hard-wired relay logic systems

• 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

• Normally used for process systems and more complex machines

• More function and communication available

• Less downtime and easier to replace defective parts

Types of PLC
• According to Size
• Small PLCs (Micro/Nano)
• Less than 1MB memory
• Less than 64 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.

• If a safety PLC fails, it does so without endangering people or processes.

• Certified to the EIC 61508 standard

Parts of PLC
• Basic PLC Block

Programming HMI/SCADA/Other
Communication
Terminal Systems

Input Devices Input Modules CPU Output Modules Output Devices

Power Supply

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Parts of PLC
• Rack / Chassis
• Acts as backbone of the PLC system

• Holds the different PLC modules

• Power Supply Module

• Supplies power to the plc system

• Converts AC to DC

• PLC normally works on 24V DC

Parts of PLC
• CPU Module
• Central Processing Unit

• Stores and executes the program

• Includes memory cards

• Built-in communication

• LED Indication

• Stop/Run Switch

• Battery
Parts of PLC
• Input Modules
• Digital Inputs
• Number of inputs – 8, 16 or 32 points

• Rated input voltage – 110/220VAC, 24VDC

• 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

• Type of input – voltage, current, resistor, thermocouple

• Rated input – 0-5V or 0-10V, 0-20mA, 4-20mA

• Current inputs: 2-wire/4-wire, self or loop powered

• Resistors – 2/3/4 wire, check for supported types

• Thermocouple – check for supported types

Parts of PLC
• Input Modules
Parts of PLC
• Input Modules
Parts of PLC
• Input Modules
Parts of PLC
• Input Modules
Parts of PLC
• Output Modules
• Digital Outputs
• Number of outputs – 8, 16 or 32 points

• Rated output voltage – 110/220VAC, 24VDC

• 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

• Type of output – current, voltage

• Rated input – 0-5V or 0-10V, 0-20mA, 4-20mA

Parts of PLC
• Output Modules
Parts of PLC
• Output Modules
Parts of PLC
• Communication Modules and Gateways
• Ethernet

• 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

• GX Developer for Melsec PLCs

• Unity Pro for Schneider 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)

• Typically less than 100ms

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PLC Programming Software
• Hardware Configuration

• Communication Configuration

• Data Blocks and Data Types

• Program Blocks

• Cross Reference Tools

• Compare Tools

• Data Monitoring Tools

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PLC Programming Languages
• Ladder Diagram (LD)

• Sequential Function Charts (SFC)

• Function Block Diagram (FBD)

• Structured Text (ST)

• Instruction List (IL)

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PLC Programming Languages
• Ladder Diagram (LD)
• Also known as relay logic

• Current flows from left to right

• Best suited for electrical practitioners

• Difficult to use for complex functions

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PLC Programming Languages
• Function Block Diagram (FBD)
• A simple graphical method to program a relation between inputs to an output

• Good for creating usable functions

• Can be difficult to troubleshoot

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PLC Programming Languages
• Sequential Function Charts (SFC)
• Step Based Programming

• Use of steps and transitions

• Easy to troubleshoot for processes

• Not applicable to some application

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PLC Programming Languages
• Structured Text (ST)
• Text Based Programming

• High level language similar to Basic, C

• Good for complex functions and loops

• Difficult to troubleshoot

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PLC Programming Languages
• Instruction List (IL)
• Text Based Programming

• Resembles assembly language

• 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

• Check operating conditions like temperature and humidity

• Clear dust buildup

• Clean or replace filters of plc panel/enclosure for proper ventilation

• Check connections for a tight fit

• Check battery indicators, replace if blinking

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YOUR ATTENTION
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