Copyright 2011 Rockwell Automation, Inc. All rights reserved. Basic PLC
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1 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Basic PLC Programming
2 PLC Basics Agenda 1. Introduction to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2010 Rockwell Automation, Inc. All rights reserved. 2
3 How did the PLC get started? > GM (Hydramatic Division) approached suppliers to help with a problem: Relay walls covered the plant floor. Changes and Troubleshooting took weeks/months. High costs Everyy change g (model ( year) y ) was major j destruction and re-wiring. g GM needed d d the th flexibility fl ibilit off solid lid state ; t t a controller t ll th thatt could ld bbe programmed and maintained by plant engineers; and was rugged enough to withstand the factory environment and provided easy troubleshooting... troubleshooting Allen Allen--Bradley PLC Copyright 2010 Rockwell Automation, Inc. All rights reserved. 3
4 What is a PLC? A solid state (electronic) device that controls output devices based on programming and input signals. Inputs Control Program Outputs Copyright 2010 Rockwell Automation, Inc. All rights reserved. 4
5 Two types of I/O (Inputs & Outputs) Digital Analog Also called Discrete Has many possible states between two Has two possible states values. Represented by 1 or 0 Example: Temperature sensor. Electrically: Range of values between two limits. For 0 is usually 0 Volts (AC or DC) example: 1 is a fixed voltage value such as 0 F represented by 0 5VDC, 24VDC, 120VAC, etc. 100 F represented by 4095 (example) Technology: Relays, Triac, Transistor, Electrically: 4-20mA, 0-5VDC, -10 to 10VDC MOSFET, TTL Copyright 2010 Rockwell Automation, Inc. All rights reserved. 5
6 PLC Control Program Program Instructions used to process inputs and set outputs Primarily written as (Relay) Ladder Diagram: Start_Button Light Programs can also be written in other languages Function Block or Structured Text Data (Variables) Examples Start_Button is assigned to a digital input Light is assigned to a digital output Copyright 2010 Rockwell Automation, Inc. All rights reserved. 6
7 PLC Basics Agenda 1. Introduction to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2010 Rockwell Automation, Inc. All rights reserved. 7
8 Today's applications require a high level of control capability and advanced features Arithmetic (Addition, Subtraction, Multiplication, Division, etc) Data Comparison (Equal, Greater Than or Equal, Less Than or Equal) Word Manipulation (Copy, Move, etc) Communications or Messaging data between PLC s Sequencing Data Manipulation Motion and Process Control (Used for Temperature, Pressure, Speed, Flow regulation) Copyright 2010 Rockwell Automation, Inc. All rights reserved. 8
9 Simple PLC Instructions (IEC 1131) Contacts Direct Reverse Coils Direct Reverse Set Reset S R Instruction Blocks Arithmetic (+ - * / COS SIN TAN) Binary (Mask, Shift) Boolean (AND,OR,NOT,XOR) Comparator (< > = CMP) Counter (CTD, CTU, CTUD) Data Conversion (ANY_TO_**) Process (PID, SCALER, more ) String (FIND, REPLACE, more ) Time (TON,TOF,TONOFF) Copyright 2010 Rockwell Automation, Inc. All rights reserved. 9
10 Ladder Logic Example This is a very simple rung of logic, from a PLC program: Start t_ Button Light The rung is read as: If the Start Button is on, turn the Light. If the Start Button is off, then turn the Light off. Copyright 2006 Rockwell
11 I/O Addressing Often, a descriptive name of the device connected to the I/O point is used in addition to, or in place of the I/O variable which describes the physical location on the controller. Example of user-defined name Start Button Light _IO_Embedded_Digital_Input_0 _IO_Embedded_Digital_Output_0 Example of system-defined I/O variable Copyright 2006 Rockwell
12 Software Introduction 12
13 RAS1 Connected Components Workbench Software Easy to Acquire/Install Free Internet download Easy to Configure Single software for component class products Graphical ldevice Configuration Easy to Program Extensive use of Microsoft and IEC standards Symbolic Programming Rockwell Automation and user-defined function blocks Easy to Update Sft Software updates dt available ilbl via Internet
14 Slide 13 RAS1 updated screenshot. Rick Sykora, 9/1/2010
15 RAS2 Connected Components Workbench Controller Software Graphical Micro800 controller configuration IEC editors Ladder Diagram, Function Block, Structured Text User-defined function blocks Run-time program download Extensive Standard Instruction Set IEC base instructions with Rockwell Automation extensions
16 Slide 14 RAS2 updated screenshot Rick Sykora, 9/1/2010
17 Using Programming Software (CCW) Brief walk-through on developing program Copyright 2010 Rockwell Automation, Inc. All rights reserved. 15
18 PLC Basics Agenda 1. Introduction to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2010 Rockwell Automation, Inc. All rights reserved. 16
19 So where could you use a PLC? Conveyor control Printed circuit board handling equipment SCADA(Supervisory Control And Data Acquisition) Remote pump/lift station (water/wastewater) Flow monitoring for leak detection (Oil & Gas) Strapping pp g machineryy / trash compactors p Palletizers Compressor control Amusement park rides and attractions Hard-wired relay panels or Single Board Computers Many, many more Copyright 2010 Rockwell Automation, Inc. All rights reserved. 17
20 PLC Basics Agenda 1. Introduction to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2010 Rockwell Automation, Inc. All rights reserved. 18
21 Programming a PLC Traffic Light example Now let s take a look at a modern traffic light application. With sensors to determine the presence of a car at the various parts of the intersection, the traffic light controller must determine the lighting sequencing and timing to allow traffic to flow in a orderly fashion. In your lab, you will learn to program a Micro800 to control a traffic light and use it and our PanelView Component operator interface to test the program. Copyright 2006 Rockwell
22 Your Lab box Copyright 2010 Rockwell Automation, Inc. All rights reserved. 20
23 For more information on the Micro800 and Connected Components Workbench, please visit the Essential Components Booth Copyright 2010 Rockwell Automation, Inc. All rights reserved. 21
24 Copyright 2011 Rockwell Automation, Inc. All rights reserved.
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