Introduction

Introduction
This report is a study to find out what the following PLC requirements mean in laymens terms. The document will contain information that will be broken down in the form of explanations and drawings of each of the following.

Capacity
Program Memory (words) Ladder Memory (words) CMOS RAM UVPROM EEPROM Total I/O Local / Local Expansion Remote Interrupt Input Remote I/O channels I/O module point density I/O module slots per base 1152 640 512 8pt 2 8 / 16 / 32 4/6/8 6.5 k 3.5 k

Performance
Scan time / K (Boolean) 3.0 ms

Functionality
Run Time edit RLL Built-in Communications 1x 15 Pin RS232C, 9600 baud Port 1x 25 Pin Networking Port, RS232C or RS422, baud Rate selectable via CPU dipswitch. Instructions Control Relays Timers Counters Real-Time Clock / Calendar 113 440 128 128

Speciality modules

Telephone / radio modem Modbus slave Modbus Master High Speed PID Thermocouple 12 bit Analogue Input/ Output Magnetic Pulse Input 100kHz high-speed Counter

Report And Analysis

Example of a rack or rail mounted PLC.

Capacity
Program Memory (Words) 6.5k
The program memory is all the information that is stored in the PLC unit; this may take the form of Ladder Memory, CMOS RAM (CMOS Random Access Memory, UVPROM, EEPROM (UVP, EEP Read Only Memory). The PLC unit uses the Read Only Memory information for start-up before programming. After programming in day-to-day running both Read Only Memory and Random Access Memory are utilised within the system. There are several different types of memory in a PLC unit and the amount of memory is measured in words. Smaller memory is measured in bits, nibbles and bytes, 1 bit, 4 bits = nibble, 8 bits = byte, 16 bits = 1 word, 32 bits (double word). There are 16 bits of information to one word therefore 6.5k x 1024 = 6656 words 6656 x 16 = 106496 bits of information.

Ladder Memory (Words)

3.5k

The Ladder Memory contains a list of instructions called upon in order to write ladder programs and is where the ladder programs that have been written for special purposes are stored and saved. The PLC unit then utilises the Ladder program to run the system that is connected to it. Again this will be 3.5k x 1024 = 3584 words 3584 x16 = 57344 bits of information.

Below is an example of a typical ladder program utilised for programming PLCs.

CMOS RAM
CMOS RAM stands for Complimentary Metal Oxide Semiconductor random access memory. This is a battery powered form of memory that will only span the life of the battery, then the information will be lost until the battery is replaced. This memory is very small and contains information that changes from day-to-day such as real time clocks, dates and months. The CMOS RAM also contains system start-up information therefore the system will not run without this memory. Changes can be made to the parameters of this memory (date and time), but the initial base program remains the same and cannot be erased in day-to-day use.

UVPROM
UVPROM stands for Ultraviolet Programmable Read Only Memory. The ultraviolet form of memory programming is an outdated form of reusable chip for the Read Only Memory. This memory is permanent and can only be erased by UV, so when programming is done and a mistake is made in the program the only way to erase the mistake is to place the processor in an ultraviolet light compartment whereby the complete memory will be erased, only then can programming be started from the beginning again. EEPROM EEPROM stands for Electrically Erasable Programmable Read Only Memory. In laymans terms this means the memory of the PLC unit can be programmed or the program erased by using electrical voltage (5 volts to program approx 6 volts to erase) instead of a UV light source, this makes the unit reusable and without having to remove the chip makes this method cost effective. Although the EEPROM memory

does need a special programming device in order to program the Read Only Memory this will have been done by the manufacturer prior to purchasing.

Total I/O

1152

The I/O is an abbreviation and in laymans terms stands for Input / Output. The Inputs and Outputs are the points where cables of devices on a system run by PLC are connected to the CPU (Central Processing Unit) and the units slaves (Remotes). The Inputs and Outputs are normally referenced to on a ladder program with the letter P and a number following (e.g. P1, P55, P134); this is called addressing the devices. An Input (or information provider) may take the form of a thermostat, external clock or even a pulse sensor that pulses every time an object passes in front of it. This then would be linked to the Input terminal and programmed to a counter within the CPU to be shown on the ladder program as a counter. An Output (or controllable device) is used in the same way as an Input, but on an Output the CPU controls the devices actions (on / off, move etc). The 1152 is the number of Inputs / Outputs on the complete system. The Inputs are normally the lower numbers and the connection points are found at the top of the PLC and visa versa for the Outputs.

Local / Local Expansion

640

Local / Local Expansion refers to the combined number of Input and Output connections on the Master CPU unit 640 in total, the CPU unit may have an even number of Inputs and Outputs (320 Inputs, 320 Outputs) or odd number of Inputs and Outputs (440 Inputs, 200 Outputs) as the split of these connections is not known the information will have to be obtained before the PLC is obtained.

Remote

512

The remotes or slaves (2 off) on the PLC system have a combined number of Inputs / Outputs 512 in total. Once again the split of the Inputs / Outputs has not been documented on the specification sheet and therefore more information must be obtained.

Interrupt Input

8pt

The Interrupt Input module is able to interrupt a CPUs scan at any point and stop the program in hand to operate a high speed counter or to move to another part within the

same program, or move to another program altogether which might be stored in the memory but with different commands relating to specific events that may have happened or are in the process of happening within the system, (i.e. interrupts the sequential execution of the ladder program A. J Crispin). The specification states that this is an 8-point Interrupt Input therefore the program can be interrupted in 8 different places. The Interrupt Input comes as a separate module that connects to the base unit.

Remote I/O channels

The Remote I/O channels as is understood are the slave units by the Master CPU. As the specification states there are 2 Remote (slave) units on this system. The Remote (slave) can be installed with a the master unit to increase the number of Inputs / Outputs on the system, or if one PLC is utilised in different areas some distance from the master unit the Remote (slave) can be placed closer to the points were the unit is needed therefore cutting down on the number of cables that the system will be utilising, therefore making this method more economical or cost effective.

I/O module point density

8/16/32

The modules on a rail type PLC unit contain Input / Output connection points. Therefore the point density is the amount or number of Input / Output connection points on a single module that fits into the base unit. As seen on the specification the point density of the modules are 8 connections per module, 16 connections per module, 32 connections per module.

I/O module slots per base

4/6/8

As is now known rack or rail type PLCs come in a module form, module slots per base means how many modules can clip into a base as unit to form the master PLC unit. The PLC unit does not need to have all the slots filled with modules in order for the unit to work, blank fillers may be obtained to fill the spaces in the base, therefore a larger unit may be obtained if later updates are planed for the system. The specification states that three types can be obtained; a 4 slot per base, a 6 slot per base, and an 8 slot per base.

Performance
Scan time / K (Boolean) 3.0ms
The scan time on a PLC system is the amount of time the PLC takes to loop scan the complete program 3.5k rung by rung, and therefore making periodic checks on the states of the Inputs within the program, and in so doing the CPU will be able to make changes to the states of the Outputs in the program and therefore execute the changes on the running equipment in the field. On this particular system the specification states the scan time to be 3ms. Boolean is a form of algebra that is useful when analysing switching circuits like ladder diagrams.

Functionality
Run Time edit
Run Time edit means that the PLC ladder program can be modified or updated while the program is in use. This allows the programmer to find the faults that may be in the program and make modifications without having to shut the system down. RLL Relay Ladder Logic is the form of language or form of writing that is utilised when designing a ladder program. Ladder logic initiated in the electrical industry when relays were used to control equipment; therefore the relays in Relay Ladder Logic do much the same thing within the PLC. The PLCs internal relays are not physical relays but simulated relays on a ladder rung in the ladder program. These internal relays can be used to activate or de-activate devices within a system it is operating. The input relays or contacts and the output relays or coils on the ladder rung are physical relays as they send a signal to the devices on the system that is being controlled by the PLC, and therefore the devices relay contacts are made and / or broken on external devices

Built-in Communications 1x 15-pin RS232C, 9600-baud port 1x 25-pin Networking port, RS232 or RS422,

The 1x 15-pin RS232C, baud port and the 1x 25-pin Networking port, RS232 or RS422 are connection points that allows interface between two systems or pieces of equipment (male & female plug and socket). The male is normally on the cable end and the female on the equipment side, but not always as all systems do differ. Not all the pins are used in every application as this all depends on the systems requirements in the action being performed. These connectors or plugs and sockets are also known as D connectors. The D connector is not only found on PLCs, they can also be found on personal computers (PC) and most equipment that is used with a PC (printers, scanners etc). Therefore connectors can be associated as part of the network highway. The RS232C is limited to shorter distances (approx 15 meters) as noise begins to limit the numbers of bits per second transferred through the cable, the RS422 is utilised for longer distances as this method utilises a balanced form of transmitting with two lines, the noise affects both lines equally thus having no affect on the transmitted signal. The make up of these cables are governed by standards. This standard says that each pin on the port should have a special purpose and this purpose will be the same on all PLCS, PCS and equipment utilised by them. Hewlett Packard developed the Ethernet or IEEE-488 standard; this was done to link computers and instruments and was known as the General Purpose Instrument Bus. The list of pin numbers is as follows. Pins Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin 1-4 5 6 7 8 9 10 11 12 13-16 17 18-24 Data lines. End of message or identify Device. Data Valid (device identified). Not ready for Data. (Devices ready to accept Data). Not Data Accepted. (Device informs Data being accepted). Interface Clear. Service Request. Attention. SHIELD. Data. Remote Enabled. Ground / Common.

As can be seen by the above, the standard set-up should remain the same on all the GPI Buss that are produced within the IEEE (Institute of Electronic and Electrical Networking Port 25 Pin Engineers). Telephone connection 25 Pin Network Port

Baud Rate selectable via CPU dipswitch

Baud rate stands for the number of bits per second exchanged in data transfer or the speed in which data is transmitted, so 1 baud = 1 bit per second. The specifications state the PLC does 9600 baud; therefore 9600 bits per second are transmitted. The DIP switch allows the baud rate to be adjusted to suit the devices and the PLC as the PLC will only work on a digital signal (sequence of pulses at normally 0-5 Volts) and not Analogue (signal size related to the amount of info being sent) and not Discrete switching (just on / off signal) therefore the DIP switch is essential to the running of the PLC. Common Baud Rates used with RS232C 50 75 110 150 300 600 1200 2400 4800

Baud rates continued

9600

19200 38400 76800

Instructions

113

The instruction is found in the ladder program and this is normally done in order to tell the machine or device what to do next (e.g. move / compare / end). Due to there not being a standard for abbreviations all PLCs do not utilise the same instruction abbreviations, therefore IMO will not be the same as Allan Bradley. The instruction is always found on a ladder program after an open or closed contact on the right hand side of the ladder or rung in a small box. In this PLC unit 113 different instructions are found (e.g. move / compare / end / timer on / timer off). As is known different PLC companies utilise different instruction abbreviations, therefore a list of instructions within the PLC manuals would generally accompany the unit.

Control Relays

480

The Control Relays do have a few different names that companies utilise e.g. flag, auxiliary relay, coil or as it is addressed within a ladder rung M but not all, once again companies use different addresses. The relay or coil is able to switch devices on and off, themselves being switched on and off within a running program. A device on an output can be addressed to the internal relay, which is symbolised in the ladder rung with ( ) and can addressed to for example M111. As can be seen in the specifications this particular PLC contains 480 relays and in theory this would mean 480 devices can be addressed to a coil / relay I / Os permitting.

Timers

128

The timers within the PLC come standard and can be either delay on timers, which is the most commonly used timer or delay off timers. The timers in a PLC can vary from 1millisecond to 1 second and the use of these timers depends on the operation being performed within a system. In the specifications it is stated that this particular type of PLC contains 128 timers, therefore 128 different devices can contain timers, or a device can be timed out 128 times.

Counters

128

The PLC comes standard with Counters installed, and as with timers this system has 128 Counters. The specifications do not specify how many up counters, down counters and up/down counters the PLC contains; these counters can also be standard or high-speed counters. They can be programmed to work off light pulses to count up and down. The specification also does not state how many of these counters are volatile and how many are not, this means when the system is powered down some of the counters will reset and some will not, (these are non-volatile counters) this may cause problems if a counter resets when it is not meant to, so the correct counter must be selected by the programmer.

Real Time Clock / Calendar

The specification states that this particular PLC unit contains a real time clock and calendar. The real in this statement means that the clock and calendar within the PLC is working on the same day-to-day time as a normal clock and calendar (time and date are always changing). The clock and calendar are very useful if the system is to shut down at certain times and start up again at certain times. The real time clock and calendar as mentioned earlier in this report are located in the CMOS RAM and are kept working (even if the system is shut down) with a battery based micro chip, therefore the clock and calendar will remain accurate for as long as the battery lasts, then the battery can be replaced and the clock and calendar reset.

Speciality Modules
Telephone / radio modem
The telephone and radio modem may be the best way of running a system, as a programmer will be able to monitor and work on a system without having to actually physically be by the system, all modifications to the running of a system may be done via telephone therefore costs will be cut time wise. Below is found a simple diagram of how a radio and telephone system can make the running of a plant a lot simpler. In this diagram it is seen that a master modem has been used to drive slave or remote units via radio and telephone. The radio modem is ideal for remote areas where there are no telephone cables and no mobile telephone towers to receive a signal. Below is found a prime example of radio / telephone communications.

Telephone Link up

Telephon e

Radio link up

Modbus Master, Modbus slave

The Modbus is a type of standard or Protocol messaging structure of a PLC that is made for Master-Slave communication communication between intelligent devices. The Modbus protocol states that when the Master sends a signal to the Slave the Slave will contain an address within the master therefore the signal will be sent to this address. As is known companies who develop PLCs all have different PLC standards or protocols to which they follow. Therefore the equipment or devices that link or work off the PLC Master and Slave must follow the same standard in order for the equipment or devices to work. If the standard is not followed and the equipment or devices are not compatible problems may arise within the system or the system may not work at all. Therefore the Master and Slave must be of the same standard or protocol. Below is a list of a few different standards from other companies. Alan Bradley Mitsubishi Siemens Telemacanique Toshiba Micrologix Medoc Profibus Interbus Toshibaline

High Speed PID

PID stands for Proportional Integral Derivative. PID is a combination of controls and is used in various fields, to control airflow, water flow, pressures, temperatures and

many other fields. PID controls the output frequency of an inverter according to a PID calculation. PID works by reducing the error and bringing a motor as close to a set value as possible without actually going passed that set value and not to far below the set value. This is done by adjusting the output signal to the correct deviation. Below is diagram that will help in the explanation of PID.

Thermocouple
The thermocouple is a temperature sensor that consists of two dissimilar wires forming a junction. When this junction is heated the thermocouple converts the temperature into voltage thus registering at the PLC as a voltage. The thermocouple is not a very accurate system as this device is only reliable within 1 degree Celsius though it is the most widely used temperature-sensing device as the output voltages are very predictable and they can be utilised at most temperatures. But not all thermocouples register the same voltage at the same temperature so each thermocouple will have a list of calibrations of voltage to temperatures.

Fused joint on thermocouple Cold junctions

Hot junction

Hot junction Cold junctions x 2

12 bit Analogue Input / Output

A typical analogue Input / Output will accept either voltage or current signals. The voltage works on 0 5, and the system is configured to accept 4 20 milliamps.

When the analogue signal reaches the PLC input it is converted into a digital signal (binary) by an analogue-to-digital converter, therefore an analogue-digital converter card can be fitted to the PLC module allowing this conversion to take place on the inputs and on the outputs.

Magnetic Pulse Input

The magnetic pulse input is a module that directly receives magnetic pulse pickups from equipment like turbine meters and tachometer signal generators. This information can then be configured within the module to read rate of flow or volume of flow. The module can also be configured to provide a direct indication of speeds like the RPM (Revolutions Per Minute) of the turbine blades, the information can then be stored in a non-volatile memory in the PLC for easy access at any given time for updates ect.

100kHz high-speed counter

The high-speed counter is normally fitted to a section of machinery where there are fast moving parts e.g. a spinning shaft on a motor or fan blades. This counter normally works off digital pulses through a cable. These counters can be linked to an interrupt device on the PLC allowing the count to take place in the ladder program by interrupting the scan, although most PLCs do not need an interrupt device to allow the count to take place and the count will not be slowed down while the program is running, due to the counter circuit being separate, provided the buffer memory is accessible to the ladder program so that it can be read at a point when the CPU needs the count value in order to perform the next operation.

Inputs & outputs

Inputs & Outputs

High-speed counter module

Installation diagram of a typical PLC module

Below are 3 types of rack or rail type PLC bases

Summary

Summary
This report contains information about a PLC unit specification. This document will be helpful in ascertaining the different abbreviations and meanings on the PLC specification form that was received from the PLC supplier. All aspects of the specification document have been broken down into easily readable laymans terms and have therefore been made understandable. The document will be helpful for use in explaining the terms and conditions that go with the rack mounted modular PLC unit. There are drawings included in this report to help with the understanding of a PLC unit as the drawings show the inputs / outputs, the type of ladder program utilised in programming, also shown is a similar type of module used in rack mounted PLCs and how to install the module.

Discussion

Discussion
In this document we have discussed the rack or rail mounted modular PLC. The pros of the rack or rail mounted PLC will be the main topic as not enough information was provided in order to look at the cons, (e.g. the PLC make and / or supplier) therefore no other PLC of a better make, design or quality could be taken into account. The rack mounted PLC contains modules that can be added and removed depending on the needs of the system that the PLC will be installed on. The modules that can be added or removed from the PLC come with a variety of functions, for example high-speed counters (counting fast moving objects), magnetic pulse input modules (rates RPM), telephone / radio modems (for linking up modems and PLCs over long distances), thermocouples (calibrating voltage to temperature) etc. The rack or rail mounted PLC can also operate a number of remote or slave units in this scenario the master only operates two slaves, therefore adding to the amount of Inputs / Outputs on the PLC system. The slave units can as we know also be placed at a distance from the Master control unit therefore reducing the number of cables that need to be laid and therefore reducing the cost of a particular system.

Conclusion

Conclusion
In conclusion it is known that the PLC can be utilised for numerous functions in the day-to-day running of a plant, as the PLC can be programmed to perform repetitive and / or detailed work with limited or no supervision. The PLC can also do the work with little or no mistakes and has an ability to respond almost instantaneously and without thought or hesitation, therefore removing the human error factor arising from boredom, distractions and or thought behind the actions. The PLC is also able to perform a number of functions at the same time, therefore removing the need for manual labour and over staffing of a plant or factory, in turn cutting the costs of running said factory / plant. The rack or rail mounted PLC is prime example as this PLC can be programmed to fulfil the needs of a particular job description and the work will be accurately repeated.

References

References
References Programmable logic controllers An introduction Second edition Printed 2001 Programmable logic controllers And their Engineering applications Second edition Printed 1997 Alan J Crispin W. Bolton

HTI News Article Programmable logic controllers Application programs (Oct 1997) By Eugene Kowch PID consultant PID Controls PID Explained Automation Direct Technical support PLC Direct Quick designer Modbus technical overview Triconex

Internet

Internet

Internet

Internet

Internet Internet

References continued
Y.K Malaysia Programmable Logic Controllers Explained Internet

RACO Remote alarms and controls Telephone/radio modems Explained on water treatment Plants Transtronics EEPROM, EPROM, UVPROM Explained

Internet

Internet

Telebyte ROM / RAM CMOS RAM Explained

Internet

Contents

Contents
Report and Analysis Summary Introduction Conclusion Discussion References

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