1. 1 FUNDAMENTOS DEL CONTROLADOR PROGRAMABLE

2. 2 ¿QUE ES UN CONTROLADOR PROGRAMABLE? PROGRAMMABLE CONTROLLER ENTRADAS 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. OUTPUTS CR

3. 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. 4 OUTPUT DEVICES Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns Relays 120 VAC/VDC 240 VAC/VDC 24 VAC/VDC Triac 120 VAC MOSFET 24 VDC

5. 5 CR Isolation Barrier Isolation Barrier Inside a PLC Central Processor MEMORY program data High Voltage High Voltage Low Voltage AC Power Supply 85-264 VAC, 50/60Hz CircuitsCircuits DC Power Supply or Communications InputInput CircuitsCircuits OutputOutput

6. 6 PLC’ s Come in a Variety of Sizes...  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

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

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

9. 9 Packaged PLC with Expansion 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). OOOO 2 Slot Expansion Chassis

10. 10 Modular PLC’s (The Ultimate in Flexibility) OUT 0 IN 0 PROG SLC 5/03 CPU RUN FLT BATT FORCE RS232 DH485 RUNREM DH-485 Port status indicator RS-232 Port status indicator Processor RUN indicator Processor FLT indicator Battery status indicator Force I/O indicator Keyswitch RUN, REM, PROG DH-485 Port connection for programming terminal RS-232 Port for programming terminal Power Supply Input Modules Output Modules  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

11. 11 Modular Rack-Less PLC’s (The Ultimate in Flexibility)  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.

12. 12 Distributed  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.

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

14. 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 1 Solenoid 2 Solenoid 3 Sensor 1 Sensor 2 Ingredient A Ingredient B

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

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

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

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

19. 19 Ladder Logic Concepts Input InstructionsOutput Instruction | |/|( ) Logical Continuity TT T | |/|( ) No Logical Continuity TF F

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

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

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

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

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

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

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

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

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

29. 29 Addressing Example L1 L2 PB1 LS1FS2 SOL6 DEVICE PB1 LS1 FS2 SOL6 | ( )| I:1/1 I:1/2 O:3/1 I:1/3 ADDRESS L1 L2 I:1/1 I:1/2 I:1/3 O:3/1

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

31. 31 SOURCING vs. SINKING The Mystery...

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

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

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

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

36. 36 RULES 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. 