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FUNDAMENTOS DEL CONTROLADOR PROGRAMABLE

FUNDAMENTOS DEL CONTROLADOR PROGRAMABLE. CR. ¿QUE ES UN CONTROLADOR PROGRAMABLE?. OUTPUTS. ENTRADAS. PROGRAMMABLE CONTROLLER. A solid state device that controls output devices based on the status of the inputs, and a user developed program.

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FUNDAMENTOS DEL CONTROLADOR PROGRAMABLE

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  1. FUNDAMENTOS DEL CONTROLADOR PROGRAMABLE

  2. CR ¿QUE ES UN CONTROLADOR PROGRAMABLE? OUTPUTS ENTRADAS PROGRAMMABLE CONTROLLER • A solid state device that controls output devices based on the status of the inputs, and a user developed program. • Originally developed to directly replace relays used for discrete control.

  3. INPUT DEVICES • Pushbuttons • Selector Switches • Limit Switches • Level Switches • Photoelectric Sensors • Proximity Sensors • Motor Starter Contacts • Relay Contacts • Thumbwheel Switches • 120 VAC • 240 VAC • 12 VDC • 24 VAC/VDC • TTL

  4. OUTPUT DEVICES • Relays • 120 VAC/VDC • 240 VAC/VDC • 24 VAC/VDC • Triac • 120 VAC • MOSFET • 24 VDC • Valves • Motor Starters • Solenoids • Control Relays • Alarms • Lights • Fans • Horns

  5. Inside a PLC Communications Circuits Circuits Central Processor O u t p u t Input CR High Voltage High Voltage Isolation Barrier MEMORY Isolation Barrier data program Low Voltage DC Power Supply or AC Power Supply 85-264 VAC, 50/60Hz

  6. Micro Typically less than 32 I/O Small Typically less than 128 I/O Medium Typically less than 1024 I/O Large Typically greater than 1024 I/O PLC’s Come in a Variety of Sizes...

  7. Packaged Packaged with expansion Modular (rack less) Modular (rack based) Distributed And a variety of shapes/configurations

  8. Motor M1 OOOO OOOO OOOO Stop Packaged PLC Power supply, Inputs, Outputs and Communication port are enclosed in a single package. INPUT and OUTPUT devices are wired individually to the packaged controller. OUTPUT O/3 I/1 I/Ø INPUTS Start

  9. Packaged PLC with Expansion OOOO OOOO OOOO Base is identical to the standard Packaged PLC, but it also has the ability to drive additional I/O. The most common form of expansion is a block of I/O that uses the same base, or makes use of different types of expansion “modules”. Connections between the base and the expansion device is either direct (mating connector), or by using a wired approach (ribbon connector is very common). 2 Slot Expansion Chassis

  10. Mix N Match Components Processors, Power Supplies and I/O are plugged into a rack or chassis Available in Small, Medium, and Large platforms Flexibility results in higher costs when compared to packaged Modular PLC’s are either rack based or are rack-less Allen-Bradley SLC-500 and PLC 5 are modular PLC’s Force I/O SLC 5/03 CPU Processor RUN indicator RUN FORCE indicator FLT DH485 Processor FLT DH-485 Port BATT RS232 indicator status indicator RUN REM PROG OUT 0 RS-232 Port Battery status status indicator indicator DH-485 Port connection for Keyswitch programming RUN, REM, terminal PROG IN 0 RS-232 Port for programming terminal Power Supply Output Modules Input Modules Modular PLC’s(The Ultimate in Flexibility)

  11. Identical in functionality to rack based PLC’s Typically not as robust (packaging) Typically found on “smaller” (small and medium) sized PLC’s. Will likely become the prevalent form of packaging in the future. Modular Rack-Less PLC’s(The Ultimate in Flexibility)

  12. Rely on communications for EVERYTHING All I/O is connected to the processor through a “High Speed” data link. Typically found on “larger” (medium and large) PLC’s. For certain applications this type of form factor is very advantageous. Usually higher cost for hardware, but much lower cost for system integration. Distributed

  13. Typical PLC Application Motor Solenoid 2 Solenoid 1 Ingredient A Ingredient B Sensor 1 Sensor 2 Solenoid 3

  14. Operation of Mixer(Defining the Outputs) Solenoid 1 On = Sol 3 is off, and Motor is off, and Sensor 2 is off, and Auto Switch is on Off = Sol 3 is on, or Motor is on, or Sensor 2 is on Solenoid 2 On = Sol 3 is off, and Motor is off, and Sensor 2 is on Off = Sol 3 is on, or Motor is on, or Sensor 1 is on Motor On = Sensor 1 is on, and Solenoid 2 is off, and Solenoid 1 is off Off = Solenoid 3 on Solenoid 3 On = Sol 1 is off, and Sol 2 is off, and Motor has run for 30 sec. Off = Solenoid 3 has been on for 60 sec. Motor Solenoid 2 Solenoid 1 Ingredient A Ingredient B Sensor 1 Sensor 2 Solenoid 3

  15. Input Wiring Isolation Barrier Terminal Block Input Devices 1 2 3 L1 4 PLC 5 L1 6 7 8 9 10 L2 COM

  16. CR Output Wiring Isolation Barrier Terminal Block Output Devices L1 OUT 1 L2 OUT 1 OUT 2 OUT 2 PLC L1 OUT 3 L2 OUT 3 OUT 4 OUT 4 OUT 5 OUT 5 OUT 6 OUT 6

  17. PLC Operating Cycle START Input Scan Housekeeping Program Scan Communications Output Scan

  18. Ladder Logic Concepts Read / Conditional Instructions Write / Control Instruction | | ( ) Start (Rung #1) | | |/| ( ) | | |/| ( ) | | | | |/| ( ) | | | | |/| ( ) End (Rung #5)

  19. | | |/| ( ) T T T Logical Continuity Ladder Logic Concepts Input Instructions Output Instruction | | |/| ( ) F T F No Logical Continuity

  20. I/4 I/5 O/0 | | | | ( ) Logical AND Construction IF input 004 AND input 005 have power THEN energize output 0 Off

  21. I/4 I/5 O/0 | | | | ( ) Logical AND Construction IF input 4AND input 5 have power THEN energize output 0 On T T T Logical Continuity

  22. O/0 ( ) I/5 | | Logical OR Construction IF input 4OR input 5 have power THEN energize output 0 Off I/4 | |

  23. T On I/4 O/0 | | ( ) Logical Continuity I/5 F | | Logical OR Construction IF input 4OR input 5 have power THEN energize output 0

  24. I/4 O/0 | | ( ) I/5 | | I/4 O/0 | | ( ) I/5 | | Logical OR Construction IF input 4OR input 5 have power THEN energize output 0 T On Logical Continuity F F Off Logical Continuity T

  25. I/4 I/0 I/1 I/9 O/0 |/| | | | | | | ( ) I/5 I/1 I/7 I/8 | | |/| |/| |/| I/2 I/3 | | | | I/1 | | Complex Construction I/10 | | I/11 |/|

  26. INPUT Input Instructions - XIC, XIO Input Push Button The status of the instruction is If the data file bit is XIC Examine if Closed -| |- XIO Examine if Open -|/|- True False Logic 0 True False Logic 1

  27. | | |/| ( ) T T T OUTPUT Output Instruction - OTE Rung State Output Terminal Status Bit TRUE ON ENERGIZED OTE Output Energize -( )- FALSE De-energized OFF Output Pilot Light

  28. INPUT INPUT OUTPUT SLC 5/03 CPU RUN FORCE FLT DH485 BATT RS232 RUN REM PROG IN 0 Putting it all Together OUT 0 OUT 0 IN 0 | | ( )

  29. SOL6 LS1 FS2 Addressing Example L1 L2 L1 L2 PB1 I:1/2 O:3/1 I:1/1 I:1/3 | | | | | | ( ) DEVICE PB1 LS1 FS2 SOL6 ADDRESS I:1/1 I:1/2 I:1/3 O:3/1

  30. SOL2 PB1 LS1 PB2 LS2 CR3 LS3 M1 LS4 CR3 B3/0 |/| |/| Relay Logic to Ladder Logic I:1/1 I:1/2 O:3/0 | | | | ( ) I:1/3 I:1/4 B3/0 | | | | ( ) I:1/5 | | O:3/1 I:1/6 ( ) | | INPUT Address Assignment: PB1- I:1/1 PB2- I:1/4 LS1- I:1/2 LS2- I:1/3 LS3- I:1/5 LS4- I:1/6 OUTPUT Address Assignment: SOL2- O:3/0 M1- O:3/1

  31. SOURCING vs. SINKINGThe Mystery...

  32. SOURCING vs. SINKINGDC I/O (General) +VDC + DC Power Supply - DC COM

  33. SOURCING vs. SINKINGDC I/O (General) SINKING Pushbutton SOURCING Pushbutton +VDC + + DC Power Supply DC Power Supply - - DC COM

  34. SOURCING vs. SINKINGDC Inputs +VDC Field Device + IN1 DC Power Supply DC Input Module + DC Input Module DC Power Supply - Field Device - DC COM IN1

  35. SOURCING vs. SINKINGDC Outputs +VDC +VDC + Field Device OUT1 DC Power Supply DC Output Module DC Output Module + - DC Power Supply Field Device OUT1 - DC COM DC COM

  36. RULES F F F F Field devices on the positive side (+VDC) of the field power supply are sourcing field devices. Field devices on the negative side (DC COM) of the field power supply are sinking field devices. Sourcing field devices must be connected to sinking I/O cards and vice versa. Sinking field devices must be connected to sourcing I/O cards and vice versa.

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