DJM3072 - PROGRAMMABLE LOGIC

CONTROLLER (PLC)
 PLC has a variety of input and output capacity
value.
 Capacity means the number of terminal
connections available in the Input Unit and
Output Unit.
 A user must select the input and output
capacity in line with the work to be done by
the PLC to ensure the terminal input and
output connections is enough.
 Table 10.1 shows some of the input and
output capacity.
 INPUT UNIT

TYPE NO. MODEL CAPASITY

CQM1-ID211 8 points
DC Input
CQM1-ID212 16 points

CQM1-ID213 32 points

AC Input CQM1- IA121 8 points

CQM1-IA221 8 points

OUTPUT UNIT

TYPE NO.MODEL CAPASITY

Relay Output Units CQM1-OC211 8 points

CQM1-OC222 16 points

Transistor Output CQM1-OD211 8 points

Units
CQM1-OD212 16 points

CQM1-OD213 32 points

CQM1-OD214 16 points

CQM1-OD215 8 points

AC Output Unit CQM1-OD221 8 points

 
 As you have learned to 10.1, the PLC also has a
variety of input and output.
Before you use a PLC to control a job, you must ensure
that supplies will be connected to the unit either AC or
DC input.
You never allowed to connect the AC supply to DC
input unit and vice versa.
As for controlling the output device in the normal
switching, you need to use the output of RELAY and to
get a fast switching then you need to use the output of
the TRANSISTOR, while for high-voltage switching the
output of the AC is need.
The types of input and output have been described
above are as indicated in Table 10.1.
 A PLC memory size refers to the space
ability to save the program in the PLC
memory system.
 Table 10.2 shows some of the memory size
according to the type of CPU.
No. Model Memory Size

CQM1-CPU11-E 3.2 K-word Program Memory

1K-word Data Memory
CQM1-CPU21-E

CQM1-CPU41-E
7.2 K-word Program Memory
CQM1-CPU42-E 6K-word Data Memory

CQM1-CPU43-E

CQM1-CPU44-E
 4. DESCRIBE TYPES OF SOFTWARE
LANGUAGE

 Each PLC has its own language code.

 So you should be careful before you develop
a PLC program.
 The types of programming languages has
been learned in Unit 4.
 For your information, ladder diagram is a
most popular programming language ​used
today.
 5. DESCRIBE FUTURE SYSTEM EXPANSION
 Control system in the industry today is undergoing
a change from traditional control to automation
control whereas PLC is the main agents of this
automation system.
 You need to be sensitive to the current phenomena
which is many industries have implemented
automation control systems such as Flexible
Manufacturing based System (FMS) and Computer
Integrated Manufacturing (CIM).
 Selection of the use of PLC should also look to the
future needs of industry to ensure that the use of
PLC are not costing to the industry.
 6. DESCRIBE SUPPORT AND BACKUP
 
 Industrialautomation control system requires
the support and backup unit for carrying out the
existing control system in a fault condition.

Thisis where the role of PLC as a support and

backup unit for fast and easy connection.

Delays in replacing the control system will

cause the industry have suffered losses.
6.2 INSTALLATION TECHNIQUE
 1. DEFINE SITE INSTALLATION CONDITION
CONSIDERATION

Avoid the installation of a PLC in a place with the

characteristics below.
 Exposure to the sun.
 The ambient temperature exceeds the range of 0 
C to 55  C.
 Relative humidity exceeds the range of 10% to 90%
RH.
 Condensation occurs due to temperature changes
that occur suddenly.
 Contains flammable gases and toxic.
 Contains water, oil, dirt and chemicals.
 Easy to place vibration.
 2. DEFINE PANEL/CABINET INSTALLATION
CONSIDERATION
 Installing the PLC in the panel / cabinet has the
following characteristics:
 Sufficient space for air circulation.
 Cooling fan.
 The position of devices that generate heat is
locate under the PLC.
 Contains no high-voltage equipment.
 Power line is approximately 200 mm from the
PLC.
 According to the wiring guide below.
Use as short cable as possible.
Use a single line between the equipment and
do not connect the cable to make it long.
Avoid making a sharp curve in the cable.
Keep the area of system and control wiring
from High Voltage wiring.
Separate the input wiring, output wiring and
other wiring types.
Separate AC and DC wiring.
Establish a good grounding for all components.
 4. DEFINE TECHNIQUES TO SOLVE INSTABLE
VOLTAGE AND VOLTAGE SPIKE PROBLEMS

PLC contains many active components

(transistors, IC), where it will burn if the surge
voltage resulting from lightning occur. Thus it
is necessary to overcome this problem by using
the following guidelines:

 Ensure that protective earth terminal and the

PLC on functional earth ground with a
maximum value of 100 .
 Make sure the cable is used for grounding at
least 2 mm­2.
­
 Site grounding and green cable must be
terminated at the cable lug. This cable must
tighten the lug and solder.
 Coating and corrosion of paint must be removed
at the grounding connection.
 1. DETERMINE PLC EXTERNAL FAULTS
A. Input And Output Equipment Faults (Sensor
And Actuator)
 From a study, 60% - 80% of faults in the
automation control system usually is caused by
input and output devices. The possibility of
this damage is caused by the following:
 Sensor on the cylinder changes from the
original position.
 Sensor burn caused by over current.
 Internal contact sensor failure.
 Loop motor or solenoid valve burns caused by
over current.
B. Wiring Fault.

 Wiring faults that occurred in the PLC control

system may be caused by following matters:
 Conductor in the cable disconnected.
 Flexibility in equipment screws, terminal input
and output.
 Conductor undergoing oxidation.
C. Communication Connection faults

 Communication Connection faults that occur in

PLC control system may be caused by the
following matters:
 Conductors in communications cables severed.
 Pin connections on the terminal bend.
 Loose pin connection.
 Disruption (interference) in the communication
cable connection due to the motor, coils, high
voltage, soldering is not neat and so on.
 Short circuit occurs between conductors in the
cable communications.
D. Disturbance on Power Supply

 Disturbance on Power Supply occurred in the

automation control system when the supply
voltage drops below 85% of the rated values​​.
 This condition will cause the PLC to stop
immediately.
 2. DETERMINE PLC INTERNAL FAULTS

Internal faults in a PLC system may be caused by

the following matters:
 Relay or transistor in the unit / Output Module in
the PLC burn.
 Optocoupler on the unit / module inputs do not
work.
 Fuse burned.
 Storage battery is weak.
 Micro-electronic components (microprocessors,
RAM, ROM) burned.
 3. EXECUTE PREVENTIVE MAINTENANCE
METHODS
Although the PLC in the design of a high level of
reliability, however it may still have faults. To
avoid these problems, then preventive
maintenance is needed. Preventive
maintenance measures can be made as follows:
 
 Make periodic inspection of tightness screw
(Screw Tightness) on input and output
terminals.
Ensure that all components are free from
dust. Cooling system on the PLC cannot be
done if there is dust in layers.