DAY 1

SESSION 1

OVERVIEW OF AB PLC’S SYSTEM

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Overview of AB PLC’s System 6 – 10 December 2010
 WHAT IS PLC?
• Programmable Logic Controller (PLC) or programmable
controller is a computer-based device that used to control
industrial equipment.
• Used to replace relay functions.
• PLC controlling an equipment based on input/output status of
the equipment and logical program.

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Overview of AB PLC’s System 6 – 10 December 2010
 RELAY
• Relay was used for control logic.
• Relay is a simple device that use magnetic field to control the
switch.
• Contact that will be closed when the coil energized is called
normally open.
• Contact that will be closed when the coil wasn’t energized is
called normally closed.

Coil

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Arus Listrik
Overview of AB PLC’s System 6 – 10 December 2010
 HOW DOES RELAY CONTROL?

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Overview of AB PLC’s System 6 – 10 December 2010
 EQUIVALENCY BETWEEN RELAY
AND PLC PROGRAM

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Overview of AB PLC’s System 6 – 10 December 2010
 PLC SYSTEM ARCHITECTURE

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Overview of AB PLC’s System 6 – 10 December 2010
 BASIC COMPONENTS OF PLC
• Power Supply

outputs
inputs
• Processor
• Memory
I/O System Power Supply
• I/O Interface
• Programming Device & Languages
PROCESSOR

Programming Memory
Device Unit

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Overview of AB PLC’s System 6 – 10 December 2010
 HOW DOES A PLC WORK ?
• Examine the status of inputs and outputs
• Controls some process or machine through outputs using
some control logic
• This control logic is executed periodically by the processor in
a predetermined sequential order
• User can change the control logic using a programming
language and it is stored in the program memory

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Overview of AB PLC’s System 6 – 10 December 2010
 PLC WORK
POWER ON
Sanity Check

Yes
STOP
Indikator On Error
No

Save to Scanning
Memori All Inputs

Ladder Logic Solved

Scanning
All Outputs

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Outputs Change
Overview of AB PLC’s System 6 – 10 December 2010
 PLC WORK (2)

POWER ON

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Overview of AB PLC’s System 6 – 10 December 2010
 PROCESS CONTROL USING PLC
When a process being
controlled, PLC:

Output

Input
• Use input from the
sensor to make logical
decision, and;
• Update the output to
drive the actuator

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Overview of AB PLC’s System 6 – 10 December 2010
 TYPICAL CONFIGURATIONS FOR
PLC Large

• Small Size: Medium

• Up to 128 I/O
• Memory up to 2 KB
• Medium Size:
• Up to 2048 I/O
• Memory up to 32 KB
• Large Size:
• Up to 16000 I/O
• Memory up to 2 MB
Micro

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Small

Overview of AB PLC’s System 6 – 10 December 2010

 PROCESSOR & MEMORY
System input bus
Clock

output
bus
CPU Data
Memory
Program
Memory

I/O
Port address bus

• 80386/80486 microprocessor based

• Random Access Memory (RAM) Instruction Cycle :
• Electrically Erasable Programmer • Fetch the next instruction from program
Read Only Memory (EEPROM) memory
• Place it in the instruction register in the
CPU

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• Increment the program counter by one
• Execute the instruction
Overview of AB PLC’s System 6 – 10 December 2010
 ALLEN-BRADLEY PLC
PROCESSORS
Built-in Total I/O
Networks Through Local
Controller Communication (Local and
Additional Modules I/O
Ports Distributed)
SLC 5/03 • RS-232 • DeviceNet 32 local only
• 1747-L53x • 1 DH-485 (1747-L53x) • EtherNet/IP
• 1 DH+ (1747-L54x) Each interface uses an
SLC 5/04 • 1 EtherNet/IP (1747- RS-232 port. 136 local only
• 1747-L54x L55x)
SLC 5/03 540 additional I/O capacity
• 1747-L55x with DeviceNet I/O

EtherNet/IP PLC-5 • RS-232 • DeviceNet 512 3,072 additional I/O

• 1785-LxxE • 1 EtherNet/IP • EtherNet/IP capacity with
• up to 2 DH+/Universal DeviceNet, ControlNet
Remote I/O and Universal Remote
I/O
ControlNet PLC-5 • RS-232
• 1785-LxxC15 • 1 ControlNet
• up to 2 DH+/Universal
Remote I/O
DH+ PLC-5 • RS-232
• 1785-LxxB • up to 4 DH+/Universal

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Remote I/O

Overview of AB PLC’s System 6 – 10 December 2010

 ALLEN-BRADLEY PLC
PROCESSORS (2)
Built-in Total I/O
Networks through Local
Controller communication (local and
additional modules I/O
ports distributed)
CompactLogix: • RS-232 • DeviceNet 960 9000 digital
• 1769-L31 • 1 EtherNet/IP digital or
• 1769-L32C, 1769- • 1 ControlNet 256 analog
L32E • DH-485 (via RS-232) additional I/O capacity
• 1769-L35CR, 1769- • Modbus via ladder with DeviceNet I/O
L35E routine (via RS-232)

ControlLogix: • RS-232 • DeviceNet 512 128,000 digital

• 1756-L55 • DH-485 (via RS-232) • ControlNet or
• 1756-L61, 1756-L62, • Modbus via ladder • EtherNet/IP 4,000 analog
1756-L63 routine (via RS-232) • DH+ additional I/O capacity
• 1756-L60M03SE • Universal Remote I/O with DeviceNet I/O

FlexLogix: • RS-232 • DeviceNet 512 distributed I/O via

• 1794-L34 • DH-485 (via RS-232) • ControlNet digital DeviceNet, ControlNet,
• Modbus via ladder • EtherNet/IP and EtherNet/IP
routine (via RS-232) 128
analog

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Overview of AB PLC’s System 6 – 10 December 2010
 ALLEN-BRADLEY PLC
PROCESSORS (3)

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Overview of AB PLC’s System 6 – 10 December 2010
 INPUT/OUTPUT SYSTEMS
• Discrete Inputs/Outputs
• Analog Inputs/Outputs
• Special Purpose Modules
• Intelligent Modules
• Communication Modules

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Overview of AB PLC’s System 6 – 10 December 2010
 DESIGNING I/O SYSTEMS :
ELECTRICAL
Input voltage rating Output current rating
• Lists the magnitude and type of • The maximum current that a single
signal the module will accept output circuit in a module can safely
Input current rating carry under load
• The minimum input current required Output power rating
at the module’s rated voltage that the • The maximum total power that an
field device must be capable of output module can dissipate with all
supplying to operate the input module output energized
circuit
Backplane current requirements
Input threshold voltage
• Lists the current demand that a
• The voltage at which the input signal particular I/O module internal
is recognized as being ON/true circuitry places on the rack power
Output voltage rating supply
• The magnitude and type of voltage
that can be controlled within a stated
tolerance

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Overview of AB PLC’s System 6 – 10 December 2010
 DESIGNING I/O SYSTEMS :
MECHANICAL
Number of I/O points per module
Number of wires
Wire size specification
• Number of conductors
• Largest wire gage that the I/O terminal points will accept
Ambient temperature rating
• Based on the heat dissipation characteristics of the circuit
components inside the I/O module
• 0 - 60 C typical
Humidity rating
• 5 - 95 % typical relative humidity

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Overview of AB PLC’s System 6 – 10 December 2010
 PROGRAMMING DEVICES
Used to enter, store, and monitor the PLC software
PC-based system
Connected to the PLC only during :
• programming & testing
• startup
• troubleshooting
com m unic atio n
cable
PLC
Com m unic atio n
Card
Personal Com pute r

POWER

AO
AO
PLC

DO
DO
DO

TC
TC

TC
TC
AI
AI
AI
DI

DI
DI
DI

SUPPLY

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I/O Module s

Overview of AB PLC’s System 6 – 10 December 2010

 AB PLC PROGRAMMING SOFTWARE CONFIGURATION

RSLogix Driver :
Programming Programming - RS232
Software & Communication - RS 485
Software - ENET
- Modbus

RSLinx Driver :
Communication - RS232
Software - RS 485
- ENET
- DH+

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Overview of AB PLC’s System 6 – 10 December 2010
 IEC1131-3 STANDARD LANGUAGES
Ladder Diagram (LD)
• Uses a standardized set of ladder logic symbols
Sequential Function Charts (SFC)
• Blocks connected together like a circuit diagram
Functional Block Diagram (FBD)
• A graphical language used to describe sequential operations
Instruction List (IL)
• Low level language
Structured Text (ST)
• High level structured language designed for automation processes

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Overview of AB PLC’s System 6 – 10 December 2010
 LADDER DIAGRAM (LD)
Representations of relay ladder diagrams
The most widely used
Composed of six categories of instructions
• Relay type
• Timer/counter
• Data manipulation
• Arithmetic
• Data transfer
• Program control

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Overview of AB PLC’s System 6 – 10 December 2010
 SEQUENTIAL FUNCTION CHARTS
(SFC)
• Represented as a set of well-defined steps, linked by
transitions
• Actions within the steps are detailed by using the Structured
Text language (ST)

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Overview of AB PLC’s System 6 – 10 December 2010
 FUNCTIONAL BLOCK DIAGRAM
(FBD)
• Describes a relationship or function between input and output
variables
• Well suited for many applications involving the flow of
information or data between control components
• Allows the programmer to build complex control procedures
• Extensive function blocks library is provided
ALM_01
ALM ...
0
Alarm
LV001
0
In HHAlarm
90 0
90 HHLimit HAlarm
70 0
70 HLimit LAlarm
0
LLimit LLAlarm
30 0
30 LLLimit ROCPosAlarm

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10 0
10 Deadband ROCNegAlarm

Overview of AB PLC’s System 6 – 10 December 2010

 INSTRUCTION LIST (IL)
Very effective for small simple applications or for optimizing parts
of an application
A list of low level instructions
Consists of standardized operators
• Data manipulation
• Arithmetic
• Branch instruction
Example :

Start : LD IX1 (* load input IX1, start pushbutton *)

ANDN MX5 (* AND with NOT of MX5)
ST QX2 (* store output QX2 to start motor *)

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Overview of AB PLC’s System 6 – 10 December 2010
 STRUCTURED TEXT (ST)
Used mainly to implement complex procedures
Default language for the description of the actions within steps
and conditions attached to the transitions of the SFC
Statement types :
• assignment imax:=max_ite;
• subprogram or function call cond:=X12;
• “C” function block call if not(cond(*alarm*))
then return;
• Selection (if, then, else, case, etc) end_if;
• Iteration (for, while, repeat, etc)
for i:=1 to max_ite do
• Control (return, exit, etc) if i<>2 then
• Special SPcall();
end_if;
end_for;

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Overview of AB PLC’s System 6 – 10 December 2010
 PLC SYSTEM DESIGN
1. Process Description
2. I/O Sizing
3. Memory Sizing
4. Selecting programming language
5. Peripheral requirements
6. System drawing and I/O wiring diagrams
7. System programming

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Overview of AB PLC’s System 6 – 10 December 2010
 PROCESS DESCRIPTION
States the purpose and the steps of the process/plant operation
Process Description is the most important step in the design
process
Bridge of communications between the user and the designer
• Piping and Instrument Diagram (P&ID) and Mechanical Flow
Diagrams (MFDs)
• Simplified drawing that shows only the equipment and
instrumentation controlled or measured by the PLC is required
• This drawing will be used to show the status of the process in
each step or state to aid in the programming of the system

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Overview of AB PLC’s System 6 – 10 December 2010
 PIPING & INSTRUMENT DIAGRAM
(P&ID)

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Overview of AB PLC’s System 6 – 10 December 2010
 I/O SIZING (1)
Estimate the number of input/output (I/O) required to control the
process
• Obtain the number of device from P&ID diagram
• Add the number of I/O points from each devices to obtain total I/O
points
Consider different types of I/O :
• Discrete AC/DC
• Limit switches, push buttons, selector switches, solenoid, etc.
• TTL
• solid state displays and electronic instrumentation
• Analog
• Level transmitter, pressure transmitter, etc.
• Encoders

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Overview of AB PLC’s System 6 – 10 December 2010
 I/O SIZING (2)
Select PLC size :
• Micro : up to 32 I/O points
• Small : 32 - 256 I/O points
• Medium: 256 - 1024 I/O points
• Large : > 1024 I/O points
Estimate the number of I/O module
• Classify each type of I/O points
• Discrete, analog, isolated, TTL, dry contact
• Select suitable I/O modules from PLC manual and obtain the number
of I/O points per module
• The number of each I/O module type required =
[Total I/O points] / [Number of I/O points per module]

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Add spare and future expansions (10-20% spare capacity)
Overview of AB PLC’s System 6 – 10 December 2010
 MEMORY SIZING
The amount of memory required depends on :
• control program complexity
• the number of I/O points
Precise (almost impossible) method to determine memory size :
• Write out the control program
• Count the number of instructions used
• Multiply this count by the number of words used per instructions
(obtained from PLC programming manual)
• Add the amounts of memor used by executive programs and the
processor overhead
Practical method :
• Total memory = 10 x [the number of I/O points]

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Overview of AB PLC’s System 6 – 10 December 2010
 I/O AND MEMORY SIZING
EXAMPLE

I/O Points PLC size = Medium-sized (1024

• Remote Area 1 : I/O = 70 + 35 + 6 = 111 I/O points max.)
• Remote Area 2 : I/O = 95 + 50 + 10 = 155
• Main Process Area : Memory size =
I/O = 300 + 156 + 32 + 5 = 493 10 x 759 = 7590 or 8K
• Total I/O points = 759
• Spare points = 10% x 759 = 76

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Overview of AB PLC’s System 6 – 10 December 2010
 REDUNDANT CONFIGURATION
• I/O modules are not permitted in either chassis of a redundant
chassis pair
• Both chassis of a redundant chassis pair must have identical
slot-for-slot configurations

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Overview of AB PLC’s System 6 – 10 December 2010
 SELECTING PROGRAMMING
LANGUAGE
Most PLCs offer the basic ladder logic instructions plus a
combination of the other types of languages
Programming language selections is depends on :
• Complexity of the control system
• Background knowledge of the control system programmers and
operators

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Overview of AB PLC’s System 6 – 10 December 2010
 PERIPHERAL REQUIREMENTS
Peripheral = other equipment in the PLC system that is not
directly connected to field I/O devices
• Compact portable programming device from PLC manufacturer
• Portable PC with PLC software
• Magnetic tape storage unit to store control program
• PROM Programmer
• Process I/O simulators
• Communications modules
• Depends on plant network design
• Extra modules is required for integration within different brands
• Operator interfaces
• hard-wired local and main control panels
• GUI software runs on a personal computer
• Intelligent peripheral devices such as touch screen

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• Industrial PC with function keys and GUI software

Overview of AB PLC’s System 6 – 10 December 2010

 SYSTEM DRAWING
Gives an overall view of the system hardware
• I/O modules
• processor
• peripheral equipment
• system interface
• communication cabling
Useful in identifying all the interface cables by model number

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Overview of AB PLC’s System 6 – 10 December 2010
 EXAMPLE OF I/O WIRING
DIAGRAMS
• Field wiring is normally indicated by a dashed line
• PLC output addresses are given on the left-hand side
• TB = Terminal Box
• JB = Junction Box

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Overview of AB PLC’s System 6 – 10 December 2010
 SYSTEM PROGRAMMING
Person involved in system programming :
• System design engineer
• Plant operations personnel
• Maintenance personnel
• Control system integrator
Programming by system design engineer takes less time and
require less documentation (flowcharting, process description,
etc.)
Selection of programming language type should usually be left to
plant operations personnel for easier maintenance and
troubleshooting

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Overview of AB PLC’s System 6 – 10 December 2010
 INSTALLATION
Control Panel Design
• Layout
• Heating Consideration
• Enclosure Standards (NEMA)
Maintenance Features
Panel Duct and Wiring Design
Power Distribution Design
Grounding Considerations
Electrical Interference Considerations
I/O Module Installation and Wiring
Equipment Layout Design

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Overview of AB PLC’s System 6 – 10 December 2010
 NEXT
SESSION 2

AB CONTROLLOGIX PLC’S HARDWARE

CONCEPT

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Overview of AB PLC’s System 6 – 10 December 2010