plc2

Industrial Electronics Course Prof. Dr. Mohamed Ibrahim MAHMOUD

AL SHOROUK ACADEMY 1

1 Mohamed I. MAHMOUDMohamed I. MAHMOUD AL SHOROUK ACADEMYAL SHOROUK ACADEMY

IIndustrial ndustrial EElectronics lectronics CCourseourseBy Prof. Dr.By Prof. Dr.

Mohamed Ibrahim MAHMOUDMohamed Ibrahim MAHMOUD

AL SHOROUK ACADEMY

THE HIGHER INSTITUTE OFENGINEERING

DEPARTEMENT OF COMMUNICATIONS,

ELECTRONICS AND COMPUTERS

AL SHOROUK ACADEMY

THE HIGHER INSTITUTE OFENGINEERING

DEPARTEMENT OF COMMUNICATIONS,

ELECTRONICS AND COMPUTERS




”وقل رب زدنى علماً “اهللا العظيم قصد

””وقل رب زدنى علماً وقل رب زدنى علماً ““اهللا العظيم اهللا العظيم ققصدصد

””يحيطون بشئ من علمه إال بما شاء يحيطون بشئ من علمه إال بما شاء الالوو“ “ صدق اهللا العظيمصدق اهللا العظيم

بسم اهللا الرحمن الرحيم بسم اهللا الرحمن الرحيم ””وما أوتيتم من العلم إال قليال وما أوتيتم من العلم إال قليال “ “

صدق اهللا العظيمصدق اهللا العظيم







AAutomation utomation AAnd nd CControlontrolA A CA A C

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PLC In An AutomationPLC In An Automation

Supply

Feedback

On/Off

Position return

PLC Controlling a Motor Starter

Contactor

ThermalOverload

Isolating switch fuse

carrier

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Control PanelControl Panel

Why Using RelayWhy Using Relay

On/OffSwitchOn/OffSwitch

Supply

3 Ф Cable3 Ф Cable

Control PanelControl Panel3 Ф Cable

Supply

SS

SupplySupply

The circuit has three advantages1 – Provides safety for the operator2 – Reduce coast by reducing high power cable length3 – Reducing power losses

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PLC: Right Alternative to Relay ControlPLC: Right Alternative to Relay Control

Improved installation timeImproved installation timeeliminate the need for extensive wiring of eliminate the need for extensive wiring of timers, relays and other components.timers, relays and other components.

Improved flexibilityImproved flexibilityenable control system changes simply by enable control system changes simply by reprogramming.reprogramming.

Much more compact than relay control panels, Much more compact than relay control panels, yet enables complex, highyet enables complex, high--level control.level control.

Improved reliabilityImproved reliability

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PLC HistoryPLC History

The PLCs were first introduced at 1968/1969 by Dick Morely. The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay basedmachine control systems in General Motors Factories.

The first PLC was called a Modular Digital Controller (MODICON). Other companies at the time proposed computer based schemes, one of which was based upon the PDP-8. The MODICON 084brought the world's first PLC into commercial production.

A Microprocessor based PLC was introduced in 1977 by Allan-Bradley Corporation. It was based on an 8080 microprocessor but used an extra processor to handle bit logic instructions at high speed.

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DefinitionDefinition

A A PLCPLC is useris user--friendly, microprocessorfriendly, microprocessor--based, specialized based, specialized computer that carries out control schemes of many types and computer that carries out control schemes of many types and levels of complexity. It can be programmed, controlled and levels of complexity. It can be programmed, controlled and operated by person unskilled in computers operated by person unskilled in computers

AdvantagesAdvantages

Rugged: noise immune equipmentRugged: noise immune equipment

Modular: easy installation/replacementModular: easy installation/replacement

Standard I/O connections & signal levelsStandard I/O connections & signal levels

Simple programming.Simple programming.

Compact sizes.Compact sizes.

Cost competitiveCost competitive

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Computer SystemComputer System

Data ProcessingComputer System

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PLC a Process Control SystemPLC a Process Control System

Limit switch

Proximitysensor

Pushbutton

Light ContactorSolenoidvalve

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IIndustrial ndustrial PProcess rocess CControlontrolI P CI P C

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Types of Industrial ProcessesTypes of Industrial ProcessesThe three types of industrial Processes are:1. Continuous production2. Batch production3. Discrete item production

1. Continuous ProcessesIt takes in raw materials at the input and runs continuously, producing finished materials at the output. The process may run for long period of time typically: minutes hours or even weeks . (e.g steel sheet Production)

Thick Steel Block Input

Slow Speed

Sheet Steel Output

High Speed

Controlled Pressure

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Types of Industrial ProcessesTypes of Industrial Processes2. Batch ProcessesIt uses a set quantity of sources material and performs process operations on this material producing a specific quantity of finished product, that will undergo further stages of processing (e.g food & beverage production ). The process may run for long period of time typically: minutes hours or even weeks.

Fill

P1

Fill

P1

Tank 1

Tank 3

Tank 2

Alkali

P4P3

P5

Filter

Polymer

Reaction vessel

Product silo

Heater

P6

Tank 4

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Types of Industrial ProcessesTypes of Industrial Processes3. Discrete ProcessesIn this type of process an individual item under goes various operations before being produced in a final form. Alternatively, several components may be combined within the process to emerge as one unit

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Control StrategiesControl Strategies

Disturbance

Controlplan

Plantsystem

Control plan

Plant system

Disturbance

Measurements of disturbances

RequirementsRequirementsAction

OutcomeOutcome

Open Loop

FeedforwardRequirementsRequirements

ActionOutcomeOutcome

Modification to plan taking into account the disturbance.

Closed Loop

Plant system

Control plan Compare RequirementRequirement

(set point)(set point)Deviation

(Error Signal)Action

FeedbackMeasured value

MeasuredMeasuredoutcomeoutcome

Disturbance

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PID Controller StructurePID Controller Structure

Proportional Term

Integral Term

DerivativeTerm

Summing Junction

PID Output

Measured Value

Set Point

Comparator

Error

MV

Disturbance Causes Changes in MV

MV=SP

SP

MV=SP

Time

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TThree hree SSections of ections of CControlontrolSSystems ( ystems ( TT SS CC SS ))




Three Sections of Control SystemsThree Sections of Control Systems

Input SectionInput SectionProcessing SectionProcessing Section

Input SectionInput Section




InputsInputs

Input signals are normally provided by transducers / detectors

that convert physical quantities into electrical signals. They all

transmit information about the quantity that is being measured.

Depending on transducer used, the information detected may be

discontinues on/off (binary) or continuous (analog) representation

of the input quantity

There are many types of inputs such as:Pushbuttons

Proximity Sensors

Limit Switches

Temperature Sensors

Pressure Sensors…….. etc

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Types of Input TransducersTypes of Input Transducers

Transducers Measured Quantity Output Quantity

Switch

Limit Switch

Thermostat

Thermistor

Strain Gauge

Photo Cell

Proximity Cell

Thermocouple

Movement / Position

Temperature

Pressure / Movement

Light

Presence of Objects

Movement / Position

Temperature

Temperature

Binary Voltage

Binary Voltage

Binary Voltage

Varying Voltage

Varying Voltage

Varying Resistance

Varying Resistance

Varying Resistance

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PushbuttonsPushbuttons

The NO Pushbutton consists of Normally Open contacts and When pressing it, the two contacts will be connected together to permitting electrical signal pass through them.

The NC Pushbutton consists of Normally Closed contacts witch are passed electrical signal through them and by pressing it the two contacts will be disconnected and no current passing through them.

Normally Closed Pushbutton (NC)Normally Closed Pushbutton (NC)Normally Closed Pushbutton (NC)Normally Open Pushbutton (NO)Normally Open Pushbutton (NO)Normally Open Pushbutton (NO)

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Limit SwitchesLimit Switches

This type of switches is used to detect or limits the movement of mechanical systems such as gates

It could have two or three points (COM, NO, NC)

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Inductive Proximity SensorInductive Proximity Sensor

The sensor incorporates an electromagnetic coil which is used to detect the presence of a magnetic metal object.

When a metal target enters the field, eddy currents circulate within the target. This causes a load on the sensor, decreasing the amplitude of the electromagnetic field.

As the target approaches the sensor the eddy currents increase, increasing the load on the oscillator and further decreasing the amplitude of the field. The trigger circuit monitors the oscillator’s amplitude and at a predetermined level, it switches the output state of the sensor from its normal condition (ON or OFFf).

As the target moves away from the sensor, the oscillator’s amplitude increases. At a predetermined level, the trigger switches at the output state of the sensor, return back to its normal condition (ON or OFF).

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Capacitive Proximity SensorCapacitive Proximity Sensor

OutputOutput TriggerTrigger OscillatorOscillator Dielectric Plate

Dielectric Plate

Capacitive proximity sensors are similar to inductive proximity sensors. The

main difference between these two types is that capacitive proximity sensors

produce an electrostatic field instead of an electromagnetic field.

Capacitive proximity switches will sense metallic as well as nonmetallic

materials such as paper, glass, liquids, and clothes.

Three-wire, DC proximity sensor can either be PNP (Sourcing) or NPN

(Sinking). This refers to the type of transistor used in the output switching of

the sensor.

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Sourcing / SinkingSourcing / SinkingThis refers to the type of transistor used in the output switching of the sensor.

If the sensor is inactive then the transistor is off. That means the PNP output will have no current in/out. When the sensor is active this will turn on the transistor, and will allow current to flow from V+ through the sensor to the output (hence sourcing). The voltage on the PNP output will be pulled up to V+. Note: the output voltage will always be 1-2V lower than the supply voltage, because of the transistor voltage drop. When the sensor is in the off state, the PNP output will float, if it used with digital circuitry a pull-down resistor will be needed.

Sourcing / PNP SensorIf the sensor is inactive then transistor is off, that means the NPN output will have no current in/out. When the sensor is active, this will turn on the transistor, and This will allow current to flow into the sensor to ground (hence sinking). The voltage on the NPN output will be pulled down to V-. Note: the output voltage will always be 1-2V higher than the negative voltage because of the transistor voltage drop. When the sensor is in the off state, the NPN output will float, if it used with digital circuitry a pull-up resistor will be needed .

Sinking / NPN Sensor

Sensor Sensor and and

DetectorDetector

V+V+

VV--

V+V+

VV--

Sensor Sensor OutputOutput

Current flows Current flows out when out when

switched onswitched on

Physical Physical phenomenonphenomenon

Current flows Current flows in when in when

switched onswitched on

Physical Physical phenomenonphenomenon

Sensor Sensor and and

DetectorDetector

V+V+

VV--

V+V+

VV--

Sensor Sensor OutputOutput

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OutputsOutputs

Output Device Quantity ProducedInput

Motor

Pump

Solenoid

Heater

Valve

Relay

Piston

Rotational motion

Heat

Orifice variation

Elec. Switching / limited physical movement

Rotational motion + product displacement

Linear motion / pressure

Linear motion / pressure

Electrical

Electrical

Electrical / Hydraulic / pneumatic

Hydraulic / pneumatic

Electrical

Electrical

Electrical

Output devices (like relays, pumps, motors..) are tools used by a control system to alter certain key elements or quantities within the process. They are convert signals from the control system into other necessary quantities. They are also transducers but contrary signals from the control system into other necessary. There are also discontinuous (binary) or continuous (analog) devices.

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Processing SectionProcessing SectionThis corresponds to the operations required to keep process This corresponds to the operations required to keep process

““in controlin control”” in conjunction obtained from input readings, producing in conjunction obtained from input readings, producing resultant output actions. Input causes output action due to a coresultant output actions. Input causes output action due to a control ntrol plan which can either hardwired or programmableplan which can either hardwired or programmable

SystemSystem TypeType HardwireHardwire ProgramProgram

Relay Digital √ ×Electronic Logic Digital √ ×Pneumatic Logic Digital √ ×

Analog electronics Analog √ ×Computers Digital / Analog × √

Microcomputer Digital / Analog × √

PLCs Digital / Analog × √

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Concept of Relay ControlConcept of Relay Control

Concept : Controlling very high power at the output using a very low power of control signal at the input.

InputInput :: Very Low [ Voltage and Current, then Power ]

OutputOutput :: Very High [ Voltage and Current, then Power ]

~

MM

24VDC 0.1A

S

380VAC 50A

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Relay OperationRelay Operation

Relay Relay DeenergizedDeenergized Relay EnergizedRelay Energized

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RRelay elay LLogic ogic CControllerontrollerR L CR L C

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Graphic Symbols Graphic Symbols

U V W

M3 ~

Q1

2 4 6

1 3 5

I> I> I>

U1 V1 W1

U2 V2 W2

M3 ~

S1

13

14

21

22

S2

12

34

56

A1

A2

K1

21

22

13

14

67

68

K1T

55

56

S1

13

14

21

22

S2

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Motor StartingMotor StartingPower CircuitPower Circuit

L2

NPE

L1

L3

U V W

M3 ~

K1

12

34

56

Q1

2 4 6

1 3 5

I> I> I>

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Motor StartingMotor Starting

Control CircuitControl Circuit L

N

F1

A1

A2

K12

12

2

S2

S1

13

14

13

14

K1

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Ladder DiagramLadder Diagram

%Q0.0%I0.0 %I0.1

%Q0.0

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Ladder Diagram Versus Relay ControlLadder Diagram Versus Relay Control

L

N

F1A

1A

2

K1

21

22

S2

S1

13

14

13

14

K1

%Q0.0%I0.0 %I0.1

%Q0.0

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Reverse RotationReverse Rotation

L2

NPE

L1

L3

Q1

I> I> I>

1

2

3

4

5

6

U V W

M3 ~

1

2

K1

3

4

5

6

1

2

K2

3

4

5

6

Power Circuit

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Reverse RotationReverse Rotation

L

N

F1

A1

A2

K1

21

22

K2

21

22

S2

S1

13

14

13

14

K1

A1

A2

K2

21

22

K1

13

14

K2

13

14

S3

23

24

S3

Control CircuitControl Circuit

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StarStar--Delta StartingDelta Starting

L2

NPE

L1

L3

Q1

I> I> I>

1

2

3

4

5

6

1

2

K2

3

4

5

6

1

2

K3

3

4

5

6

U1 V1 W1

U2 V2 W2

M3 ~

1

2

K1

3

4

5

6

Power Circuit

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StarStar--Delta StartingDelta StartingL

N

F1

A1

A2

K3

2122

K2

2122

S2

S1

1314

6768

K1T

5556

K1T

1314

K1

13 14K3

A1

A2

K2

2122

K3A

1A

2

K1

Control CircuitControl Circuit

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PProgrammable rogrammable LLogic ogic CControllerontrollerP L CP L C

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Comparison with Other Control SystemsComparison with Other Control Systems

C/Cs Relay systemsRelay systems ComputersComputers PLC systemsPLC systems

Price Per Function

Physical Size

Operating Speed

Noise Immunity

Installation

Complex Operation

Ease of Changes

Easy of Maintenance

Fairly Low

Bulky

Slow

Excellent

Time Consuming in All Phases

None

Very Difficult

Poor - large No. of Contacts

High

Fairly Compact

Fairly Fast

Fairly Good

Time Consuming in Programming

Yes

Quite Simple

Poor-several Custom Boards

Low

Very Compact

Fast

Good

Easy in All Phases

Yes

Very Simple

Good-few Standard Cards

Type Digital / analog Digital / analogDigital

Design Hardwire ProgrammableProgrammable

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StructureStructure

Programming panel

Output devices

Input devices

Input circuits

Output circuits

Program memory

Work memory

Power supply

Control unit

Programmable controller Process

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Power SupplyPower Supply

•PLCs internal circuitry operates at +/-5V DC.

•Whether the available supply is AC or DC, a power supply is required to condition, regulate, ... this supply to the adequate need of the circuitry.

~ Filter Regulator ProtectionRectifier

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Central Processing Unit Central Processing Unit ““CPUCPU”” (1)(1)

The CPU controls and supervises all operation within PLC,

carrying out programmed instructions stored in the

memory.

An internal communications highway or bus system carries

information to and from CPU, memory and I/O units, under

CPU control.

The CPU is supplied with a clock frequency by a quartz

crystal or RC oscillator with speed depending on the

microprocessor type.

The clock determines the operating speed of a PLC and

provides timing / synchronization of all system elements.

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O/P ModulesI/P Modules

Analysis

ROM with fixed operating system program

Control SectionRegistersALUControl unit

Interface with other CPUs

Peripherals I/P scan

blockO/P scan

blockLogic scan program

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SystemROM

I/OUnit

DataRAM

μPCPU

User Program

RAM

OptionalProgramStorage

Address Bus

Control Bus

Data Bus

Buffer

Clock

Battery

Buffer

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I/O ModulesI/O Modules

PLCs operate at 5V DC to 15V DC, whilst process signals can be much greater or of different levels.

The I/O units form the interface between the microelectronics of PLC and the real world outside.

These units provide all necessary signal conditioning and isolation functions.

I/O modules are available (Digital, Analog) with all different process signals which allow PLC to be directly connected to process.

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Discrete Input ModuleDiscrete Input Module

Indicator ElectricalIsolation

Input Filter

Logic Circuits

Input terminals

Logic output to processor

Input

Common

Block Diagram

Wiring of Input Module

Input Module

Plant Neutral

10C 2 3 4 5 6 7

Plant Supply

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DC Discrete InputDC Discrete Input

To CPU

Opto-isolator

Input Terminals

common

R2

R1

R3

R4 Buffer

C

+ve Internal Supply

D1 is input signal indicator

R2 limits input current

R4 and C are provides filtering effect

D1

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DC Discrete Input with Reversed PolarityDC Discrete Input with Reversed Polarity

To CPU

Opto-isolator

Input Terminals

-/+

R2

R3

R4 Buffer

C

+ve Supply

D1 is input signal indicator



+/-

R1

D1

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AC Discrete InputAC Discrete Input

To CPU

Opto-isolator

Input Terminals

common

R2R1

R3

R4 Buffer

C

+ve Supply

NE

NE is input signal indicator



VAC

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Discrete Output ModuleDiscrete Output Module

OutputLogic

Circuits

Trigger Control

Solid State switch or

relay

Output from processor

Output terminals

Block Diagram

Wiring of Output Module

Output Module

Plant Supply

10C 2 3 4 5 6 7

Plant Neutral

ElectricalIsolation

Indicator

L1 L2 L3 L4 L7 L8L6L5

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Discrete Transistor Output ModuleDiscrete Transistor Output Module

Opto-isolator+veInternalSupply

R1

R2

FromCPU R4

+vePlant

Supply

-vePlant

Supply

R3

OutputLoad

-vePlant

Supply

PLC Plant

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Analog I/OAnalog I/O

I/P Signal

Signal Conditioning

I/PModule

A/DConverter

CPU

0 → 10V

Analog Input

0 → 10V 0 → 255

O/PSignal

AmplifierO/P

ModuleD/A

ConverterCPU

4 → 20mA

Analog Output

0 → 255

8 Bit

8 Bit

Process PLC

ProcessPLC

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HousingHousingSmall PLCs are build of individual printed circuit cards within single compact unitSmall PLCs are constructed modular basis with function modules slotted into the back plane connectors of the mounting rackModular systems housing or mounting racks are equipped with buses to exchange all information required to run the system: data, control, address,…etc.

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I/O ScanningI/O Scanning

Input Scan

Input

Status

table

User

Program

Execution

INPUTTERMINALS

OUTPUTTERMINALS

Output

Status

table

Input Scan Output ScanProgram Scan

Input terminals are read and input status table is updated accordingly.

During program scan data in I/P table is applied to user program, program is executed and O/P table is updated accordingly.

Data associated with O/P status table is transferred to O/P terminal.

Program Scan

Output Scan

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CommunicationCommunication

Point to Point

Links:

•PLC w/ programming terminal.

•PLC w/ Man Machine Interface.

Links:

•PLC w/ other PLC.

•PLC w/ any intelligent device.

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CommunicationCommunication

Networking

Remote I/O Master/slave Peer to Peer

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Programming EquipmentProgramming Equipment

Allowing writing, editing and monitoring a program as well as performing various diagnostic procedures.

Three types of programming tools are in common use:1. Hand held programmer2. Portable programming terminal3. Software to run on PC

The third type is commonly used and have larger capabilities.

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Program Design StepsProgram Design Steps

1. Description of system objectives.

2. Detailed description of system function.

3. Circuit diagram or block diagram of the system.

4. Separation of function steps.

5. Choice of PLC Function.

6. PLC input/output connection.

7. Input/output addresses.

8. Program list or diagram

9. Program test and verification.

10. System verification.

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Programming LanguagesProgramming LanguagesIEC 1131 IEC 1131 –– 11

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IEC 1131IEC 1131

1979 :1979 :The International The International ElectrotechnicalElectrotechnical Commission Commission assigned the research committee 65A to define a PLC assigned the research committee 65A to define a PLC standard.standard.

Objective :to meet the increasing complexity requirements Objective :to meet the increasing complexity requirements of control and monitoring systems and the large number of of control and monitoring systems and the large number of PLCs which are incompatible with each other.PLCs which are incompatible with each other.

Its contents :Its contents :

IEC1131IEC1131--1 : General information (1992).1 : General information (1992).

IEC1131IEC1131--2 : Specifications & equipment testing (1992).2 : Specifications & equipment testing (1992).

IEC1131IEC1131--3 : Programming languages (1993)3 : Programming languages (1993)

IEC1131IEC1131--4 : Recommendation to the user.4 : Recommendation to the user.

IEC1131IEC1131--5 : Message handling functions specifications.5 : Message handling functions specifications.

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IEC 1131IEC 1131--33

This standard describes

Two textual languages

Two graphic languages

A graphic chart

•Instruction list IL•structured Text ST

•Ladder Diagram LD•Function Block FB

•Sequential Fn. Chart SFC

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Instruction List (IL)Instruction List (IL)

Series of instructions, each one must start on a new line.

One instruction = operator + one or more operations separated by commas.

Function Blocks lunched using a special operator.

Label Operation Operand Comment

Run: LD %IX1 (*pushbutton*)

ANDN %MX5

ST %QX2 (*run*)

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Structured Text (ST)Structured Text (ST)

Syntax similar to that of Pascal enabling a description of complex algorithmic structure

succession of statements for assigning variables, controlling functions and function blocks, using operators, repetition, conditional executions.

Function blocks launched using a special operator.

J:=1

WHILE J<=100 & X1<>X2 DO

J:=J+2

END_WHILE

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Ladder Diagram (LD)Ladder Diagram (LD)

Graphic elements organized in networks connected by power supply rails.

Elements used: contacts, coil, functions, function blocks control elements (jump, return, etc.)

Start Stop

Aux.

run

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Function Block Diagram (FBD)Function Block Diagram (FBD)

Representation of functions by blocks linked to each other.

Network evaluation :from the O/P of a function block to the I/P of the connected function block.

&

&

>=1 runauto start

manucmd

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Sequential Function Chart (SFC)Sequential Function Chart (SFC)

To describe sequential control function.

steps & transitions represented graphically by a block or literally.

Transition conditions in LD, FBD, IL or ST languages.

Actions associated with the steps :Boolean variables or a section of the program written in one of the four languages.

Association between action and steps in graphical or literal form.

VA1

FILL SILO_VALVE

NOT_FILL

READY

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Hardware Hardware –– Software EquivalenceSoftware Equivalence

During the scan cycle:the PLC takes the action of an input hardware device,introduces it to the corresponding software andexecutes the related instruction.

What is the equivalent of an input device and its corresponding software?

Input Hardware Device

Corresponding Software

Equivalent Used

Normally Open Normally Open Normally Open

Normally Closed Normally Open Normally Closed

Normally Open

Normally Closed

Normally Closed

Normally Closed

Normally Closed

Normally Open

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SSmart mart RRelayselaysSR2 SR2 –– ZelioZelio

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AL SHOROUK ACADEMY 72 72


TELEMECANIQUE ZELIOTELEMECANIQUE ZELIO--LOGIC LOGIC SMART RELAYS ( SR2SMART RELAYS ( SR2--B121BD )B121BD )

SMART RELAYS ARE DESIGNED TO SIMPLIFY THE ELECTRICAL WIRING FOR INTELLIGENT SOLUTIONS.

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THE MAIN PARTS OF SMART RELAYTHE MAIN PARTS OF SMART RELAY1 1 –– Retractable mounting feetRetractable mounting feet1 3 4 5

6

7

1

10

2 2 –– Power supply terminalsPower supply terminals

3 3 –– LCD, 4 lines, 18 charactersLCD, 4 lines, 18 characters

4 4 –– Screw terminal block for Screw terminal block for digital inputs digital inputs

5 5 –– Screw terminals block for Screw terminals block for analog inputsanalog inputs

10 10 –– Relay output terminal blockRelay output terminal block

6 6 –– Connector for backup memory Connector for backup memory or PC connection cableor PC connection cable

9 9 –– Arrow keys or after first Arrow keys or after first configuring them, Z pushbuttonsconfiguring them, Z pushbuttons

7 7 –– Shift keyShift key

2

98 8 –– Selection and validation keySelection and validation key

8

The description of each part that used in the operation of the smart relay are illustrated in the above slide. Study each part in the order explained. It is enough here to know the name of each part and a brief explanation about this part.




CHARACTERISTICS OF THE SR1CHARACTERISTICS OF THE SR1--B121BDB121BD

1. Weekly clock

2. Supply voltage: 24VDC(19.2VDC Min, 30VDC Max)

3. Rated input current: 100mA

4. Number of discrete inputs: 4 inputs

5. Rated voltage for each discrete input: 24VDC

6. Number of analog inputs 0-10V: 4Each analog input is also usable in discrete I/O mode, 24VDC.

7. Number of output relays: 4

8. Relay output voltage: From 5 to 150VDC 8A Max, Orfrom 24 to 250VAC, 8A Max

The characteristics of the smart relay are illustrated in the above slide. Study each one in the order explained. It is important here to know the name of each component and the minimum, typical (rated) and maximum voltage and/or current about this component.




CONNECTING DISCRETE INPUTS CONNECTING DISCRETE INPUTS

I1 to I4 are discrete inputs 24VDCIB, IC, ID, and IE represent the analog inputs used as discrete 24VDC inputs

I1 to I4 are discrete inputs 24VDCIB, IC, ID, and IE represent the analog inputs used as discrete 24VDC inputs

Fuse

The input block of the smart relay are illustrated in the above slide. This block explain the discrete terminals that connected to 24 V DC. At the left hand side the two terminals ( + and 0 V ) are used to supply the smart relay Zelio by the rated 24 V.The terminals I1 to I6 are discrete inputs that connected to the sensors of the controlled system. The terminals IB and IC may used as discrete terminals for 24 V sensors or used as inputs for analog sensor rate 0 to 10 V DC.The above connections are used for 24 V supply and 24 V discrete or digital input that provided by digital sensors. All the necessary information are written on the body of the smart relay. The ground resistances are connected internally through the 0 V terminal.




CONNECTING ANALOG INPUTSCONNECTING ANALOG INPUTS

0 -10 V ANALOG.0 -10 V ANALOG.

FuseFuse

11 22 33 44

The terminals IB and IC may also used as analog inputs that have a voltage range from 0 to 10 V. Three terminals analog sensors that operate on 24 V DC and produces 10 V DC maximum are connected to the terminals IB and IC as illustrated in the above slide. The sensor terminals must be checked to right connection to the power supply and to the input terminals. The ground resistances are connected internally to the 0 V terminal.




CONNECTING DISCRETE OUTPUTSCONNECTING DISCRETE OUTPUTS

L/+

N/-

Load 1Load 1 Load 2Load 2 Load 3Load 3 Load 4Load 4

• +/- for the terminals of a DC voltage• L/N for line and neutral of an AC voltage

Fuse

The terminals of the output block are located at the lower end of the smart relay. This block consists of four relays operate either by DC or by AC voltage. The connection is illustrated in the above slide using the rated operating range:1 – DC voltage range from 12 to 125 V DC; ( + / - ) terminals.2 – AC voltage range from 12 to 240 V AC; ( L / N ) terminals.Each relay can support 8 A at the nominal operating voltage mentioned above.The contacts of the relays are connected in series between the supply and the load for each load individually.




COMMAND KEYSCOMMAND KEYS

The smart relay Zelio has eight keys can be used for programming in the Zeliomode. Four Keys can be configured to be used in the run mode as input switches.

Del. To delete an item or a diagram line.Ins. line To insert a diagram line.Sel. / Ok Allows to make a selection (variable, fields) to be modified, enter

into an item's parameters page, enter into a visualization page, or validate a choice. The first thing you must do is press this key to access the main menu.

Esc. To exit from a menu or a selection.Z1 to Z4 Allows to move through the data input zone. The movement is

visualized on the screen. For the items of a diagram, these keys also allow you to navigate through its parameters and then modify their value.




COMMAND KEYSCOMMAND KEYS

The smart relay Zelio has eight keys can be used for programming in the Zeliomode. Four Keys can be configured to be used in the run mode as input switches.

Del. To delete an item or a diagram line.Ins. line To insert a diagram line.Sel. / Ok Allows to make a selection (variable, fields) to be modified, enter

into an item's parameters page, enter into a visualization page, or validate a choice. The first thing you must do is press this key to access the main menu.

Esc. To exit from a menu or a selection.Z1 to Z4 Allows to move through the data input zone. The movement is

visualized on the screen. For the items of a diagram, these keys also allow you to navigate through its parameters and then modify their value.




POWERING UP THE ZELIOPOWERING UP THE ZELIO

When you switch on the supply the screen displays the INPUTS-OUTPUTS Screen.

* Objective:This function allows you to choose the language used by the module.All the messages can be displayed in 6 languages: English, French, German, Italian, Spanish and Portuguese.You can only choose the language if the module is in RUN mode.* Zelio mode:1. Select the Config. menu and then the Language menu,2. Select the language using the arrow keys, 3. Validate with the Sel./OK key.A small symbol indicates the selected language <>* Free mode:1. Select the Module/Configure Module menu,2. Select the language,3. Validate.




THE ZELIO MAIN MENUTHE ZELIO MAIN MENU

The main menu permitting you to access all the functions and parameters of all the zelio operations. There are eight menus. Among these menus there are two have sub – menus. CONFIG. (configuration) have five sub- menus and TRNSFER have four sub – menus. Most elements of this menu are self explanatory but some of them need definition such as: PARAMET. MenuThis menu allows you to modify the parameters configured or the parameters of the function blocks.VISU. menuThis function allows you to select the information that will be displayed on the third line of the screen of the module being used.




THE ZELIO MAIN MENUTHE ZELIO MAIN MENU

PASSWORD FILTERZx KEYSCYCLE & WATCHDOG

The main menu permitting you to access all the functions and parameters of all the zelio operations. There are eight menus. Among these menus there are two have sub – menus. CONFIG. (configuration) have five sub- menus and TRNSFER have four sub – menus. Most elements of this menu are self explanatory but some of them need definition such as: PARAMET. MenuThis menu allows you to modify the parameters configured or the parameters of the function blocks.VISU. menuThis function allows you to select the information that will be displayed on the third line of the screen of the module being used.




ELEMENT ENTRYELEMENT ENTRY

It is only possible to position an element (contact or coil) when the blinking cursor “ ” is displayed on the screen. Contact entry is performed in the Five left hand columns, coils can only be entered into the last (sixth) column. If you use the arrow right key move the cursor from left to right positions you will have the following positions and shapes of the cursor.

Zelio mode: Contacts are entered on the three left-hand columns.Place the flashing square cursor at the desired point.Click on the Sel./ OK key. Choose the item you want by clicking the Z1 and Z3 keys.Click on the Sel./ OK or Z2 key to position yourself on the number.Choose the number using the Z1 and Z3 keys.6. Validate with the Sel./ OK or Z2 key.To modify an item: position yourself on the item you want to modify and carry out the same procedure as for entering a new item.To delete an item: position the cursor on the desired item then press the Del key.Free mode (Principle)Select the desired item (the inaccessible items are dimmed),Enter the comment if applicable,Drag the selected item to the desired contact box.To modify the properties of an item: right click on the item.To change the item's type: select the new type and position it on the contact.To delete an item: select the item and press the Del key.To enter a line comment, click on the comment zone, enter the comment and press Enter to validate.




CControllerontroller FFunction unction BBlockslocksCC F BF B

Write your notes




TIMER FUNCTION BLOCKTIMER FUNCTION BLOCK

Objective The Timer function block allows you to time actions. It has:

a reset input RT,a command input TT,an end of timing output T or t,a preselection value.




TIMER FUNCTION BLOCKTIMER FUNCTION BLOCK

86M. Shams El-Deen

Note:

If the timer function Block name contain reset we must use it, and if not it is optional

Program

Description of the parametersTT : command

Used as a coil, this item represents the Timer function block's command input. Its operation depends on the type used.

RT : resetUsed as a coil, this item represents the reset input. Exciting the coil results in:- the Timer's current value being reset,- contact T being deactivated,

the block is ready for a new timing cycle.T (Normally Open) t (Normally Closed)Used as contact it represent the timer output, and it depends on the type selected.




TIMER PARAMETERSTIMER PARAMETERS

87M. Shams El-Deen

Write your notes




Zelio Mode

TIMER FUNCTION BLOCK PARAMETERS

Zelio modeTo enter the block type and the preset value.Once you have validated the block number, the input screen is displayed. 1. Select the type function block operation using the arrow keys and validate

with Sel./OK.2. Select the time unit S

- 1/100 of seconds : 00.00 s (maximum : 99.99),- 1/10 of seconds : 000.0 s (maximum : 999.9),- minutes : seconds : 00 :00 M : S (maximum : 99 :59),- hours : minutes : 00 : 00 H : M (maximum : 99 :59),

3. Enter the preset value using the arrow keys and validate with Sel./OK,4. Lock the parameters if necessary using the arrow keys and validate with

Sel./OK.5. End the entry by pressing Esc. to return to command diagram entry.




TIMER FUNCTION BLOCK PROPERTIES

Free Mode

Free modeTo enter the block type, the preset value and/or lock this parameter.1. Double click on a timer item or switch to parameter mode and double click on

the timer,2. Select the type of function block operation 3. Select the time unit S- 1/100 of seconds : 00.00 s (maximum : 99.99) - 1/10

of seconds : 000.0 s (maximum : 999.9) - minutes : seconds : 00 :00 M : S (maximum : 99 :59) - hours : minutes : 00 : 00 H : M (maximum : 99 :59)

4. Enter the preset value.5. Tick the lock box if necessary,6. Enter the comment if applicable,7. Validate.




TYPES OF TIMER FUNCTION BLOCK (1)TYPES OF TIMER FUNCTION BLOCK (1)

1. Type A Timer Function Block (ON Delay Timer)1. Type A Timer Function Block (ON Delay Timer)

1. Type A Timer Function Block (On Delay Timer)1. Type A Timer Function Block (On Delay Timer)

Type a : Closing delay on command rising edge with Reset.





2. Type a Timer Function Block (ON Delay with Pulse and Reset Ti2. Type a Timer Function Block (ON Delay with Pulse and Reset Timer)mer)

Type a : Closing delay on command rising edge with Reset.





92M. Shams El-Deen

3. Type C Timer Function Block (OFF Delay Timer)3. Type C Timer Function Block (OFF Delay Timer)

Type B : Calibrated pulse on command input rising edge (temporary contact). Switching on a light by means of a pushbutton with a timer switch.





93M. Shams El-Deen

4. Type B Timer Function Block (Pulse with Pulse On)4. Type B Timer Function Block (Pulse with Pulse On)

Type C : Opening delay (Rest delay). Example: maintain fan operation after motor shutdown.




5. Type W Timer Function Block (Pulse with Pulse Off)5. Type W Timer Function Block (Pulse with Pulse Off)


Type W : Calibrated pulse on command input falling edge. Example: Closing a motorway toll gate




6. Type D Timer Function Block (Flashing Relay Timer)6. Type D Timer Function Block (Flashing Relay Timer)


Type D : Symmetrical flashing. Example: fault indication by indicator light flashing.




7. Type d Timer Function Block (Flash Timer On and Reset)7. Type d Timer Function Block (Flash Timer On and Reset)


Type d : Symmetrical flashing on command input rising edge with Reset. Example: pulsed brake command after power cutout.




8. Type T Timer Function Block (Time On Addition)8. Type T Timer Function Block (Time On Addition)


Type T : Totalizer with Reset. Example: request replacement of a filter when the recommended utilization time has been exceeded.





98M. Shams El-Deen

9. Type AC Timer Function Block (Timing after closing and opinin9. Type AC Timer Function Block (Timing after closing and opining control)g control)

Write your notes





99M. Shams El-Deen

10. Type L Timer Function Block (Asymmetrical Flashing)10. Type L Timer Function Block (Asymmetrical Flashing)

Write your notes





100M. Shams El-Deen

11. Type I Timer Function Block (Asymmetrical Flashing .start/St11. Type I Timer Function Block (Asymmetrical Flashing .start/Stop on pulse)op on pulse)

Write your notes




COUNTER FUNCTION BLOCKCOUNTER FUNCTION BLOCK

1. Normal Counter Function Block Contact (C)

The contact is closed when the counter reaches the preset value

2. Reverse Counter Function Block Contact (c)

The contact is closed until the counter has its preset value

The Counter function is used to upcount or downcount pulses. The Counter function can be reset to zero or to the preset value(depending on the chosen parameter) during use. It can be used as a contact to find out if:

The preset value has been reached (upcounting),The value 0 has been reached (downcounting).

Counter maximum Value: 32767Number of Counters: 16

Counter Function Block Contacts

The Counter function blocks are used to count pulses and trigger an action.C or c : Counting threshold reachedUsed as a contact, this Counter function block item indicates that the preselection value and the current value are equal.C: The contact is closed when the counter has reached the preselection value.c: The contact is closed as long as the counter has not reached its preselectionvalue.Example: Switching on an indicator light connected to the module's output 1 when the preselection value is reached, otherwise the indicator light is off.C1—————— Q1




Count input: CCxEvery time the coil is energized, the counter is incremented or decremented by 1 according to the counting direction chosen

Reset input: RCx

resets the counting function to its initial stateThe current counting value is reset to zero if the counting type is TO

(upcounting towards the preset value),The current value is reset to the preset value if the counting type is

FROM (downcounting from the preset value).

Counter direction input (up/down counting) DCxDowncounts if the coil is energized, Upcounts if the coil is not energized.

Counter Function Block Coils COUNTER FUNCTION BLOCK

C, c contacts are entered in the same way as a conventional contact. RC, CC, DC coils are entered in the same way as a conventional coil.Zelio modeTo enter the CC preset value ( 0 to 9999 ).1. Click on the Z4 and Z2 keys to position yourself on the parameter you want to modify.2. Select the parameter by pressing the Sel./ OK key.3. Modify the value of the parameter using the Z1 and Z3 keys.4. End the entry by pressing Esc. to return to command diagram entry.5. Lock the parameters if necessary using the arrow keys and validate with Sel./OK.




COUNTER FUNCTION BLOCK ICOUNTER FUNCTION BLOCK I

Program

CC : count pulse input Used as a coil in a command diagram, this item represents the block's counting input. Each time the coil is excited, the counter is incremented or decremented by 1 depending on the counting direction you have chosen.Example: counting on the input to the Counter N°1 function block.I1—————— CC1RC: counter resetUsed as a coil in a command diagram, this item represents the Counter block's reset input. Exciting the coil will result in the current counter value being reset.Example : Reset counter N°1 when key Z1 is pressed.Z1—————— RC1




Zelio Mode

COUNTER FUNCTION BLOCK II

DC : count/countdown directionUsed as a coil in a command diagram, this item represents the counter input that determines the counting direction. If this coil is excited, the function block counts down, otherwise the function block counts. By default (this input is not wired) the function block counts.Example: counting or counting down depending on the state of one of the logic module's inputs.I2—————— DC1p=0000: Preselection value (0 to 9999)Value to be reached. This value is also called the preselection value. When the counter's current value is equal to the preselected value, the counter's contact C is closed. This parameter can be modified.




COUNTER FUNCTION BLOCK III

Lock parametersThis parameter is used to lock the function block. When the block is locked, the preselection value no longer appears in the modifiable parameters.C or c : Counting threshold reachedUsed as a contact, this Counter function block item indicates that the preselection value and the current value are equal.C: The contact is closed when the counter has reached the preselection value.c: The contact is closed as long as the counter has not reached its preselectionvalue.Example: Switching on an indicator light connected to the module's output 1 when the preselection value is reached, otherwise the indicator light is off.C1—————— Q1




TSX NANO PLC




Small Form Factor Small Form Factor -- 3 Sizes3 Sizes

16 I/O (9 inputs + 7 outputs)16 I/O (9 inputs + 7 outputs)20 I/O (12 inputs + 8 outputs)20 I/O (12 inputs + 8 outputs)24 I/O (14 inputs + 10 outputs)24 I/O (14 inputs + 10 outputs)85 x 165 x 60 mm85 x 165 x 60 mm

10 10 I/O (6 Inputs, 4 Outputs)I/O (6 Inputs, 4 Outputs)85 x 105 x 60 mm85 x 105 x 60 mm

14 I/O (8 inputs + 6 outputs)14 I/O (8 inputs + 6 outputs)16 I/O (9 inputs + 7 outputs)16 I/O (9 inputs + 7 outputs)85 x 135 x 60 mm85 x 135 x 60 mm

Base PLC nonBase PLC non--extendable PLCs (14 and 20 I/O).extendable PLCs (14 and 20 I/O).

Base PLC nonBase PLC non--extendable PLCs with 1 integrated analog input (10, extendable PLCs with 1 integrated analog input (10, 16, and 24 I/O).16, and 24 I/O).

I/O extensions (16 and 24 I/O).I/O extensions (16 and 24 I/O).

Base PLC or I/O extension extendable PLCs (10, 16 and 24 I/O).Base PLC or I/O extension extendable PLCs (10, 16 and 24 I/O).




Main Function of TSX Nano PLCsMain Function of TSX Nano PLCsScanning:Scanning: Normal (cyclical) or periodic (2 to 150 ms)

Scan Time:Scan Time: Less than 1ms for 1000 instructions, Less than 0.6 ms for 100 instruction

Execution Time:Execution Time: 0.2µs to 2µs for a single Boolean elementary instruction

Memory capacity:Memory capacity: Data: 256 internal word, 64 constant word, 128 internal bits, Program: 1000 instructions

Backup:Backup: PLC RAM: by battery, 30 days

Language:Language: Reversible PL7 instruction list or ladder

Terminal port:Terminal port: RS 485 link, UNI-TE protocol 9600 bits/s, 19200bits /s.

Max. distance :FTX 117: 10m; UNI-TE: 50m

I/O Extension:I/O Extension: 1 per PLC (Max. distance 200 M)

Peer PLCs:Peer PLCs: 3 (Max. distance 200M)

Function Blocks:Function Blocks: 32 Timers, 16 Counter, 4 LIFO/FIFO Registers (16-word block), 8 Shift Registers (16bits), 4 Drum controllers.




TSX Nano PLC Front PanelTSX Nano PLC Front Panel

Extension port

Power supply connection Connection of inputs

Removable cover for protecting terminals Analog module

addressing selector

Hinged Cover

PLC status display

Connection of outputs

Selector Switch for PLC Function Code

Sensor supply

Communication Port

Front Panel Presentation




Characteristics of TSX 07 32 1028 Nano PLCCharacteristics of TSX 07 32 1028 Nano PLC

Extendable

Supply voltage: 110/240VAC

Number of discrete inputs: 6 inputs

Type of inputs 24VDC

Number of output 4

Type of outputs Relay

Relay voltage: 24VDC, Or 24/240 VAC

2A Max




PLC Inputs ConnectionPLC Inputs Connection

Connection of the Positive Logic (sinking) InputConnection of the Positive Logic (sinking) Input

100/240100/240VACVAC

33AA

2 2 wire prox. wire prox. senssens..


RUNRUN ERRERR

I / OI / OCOMCOM

00 11 55443322

00 11 3322

II

OO

55L NL N100/240VAC100/240VAC 4433221100+ + --

24VD OUT24VD OUTININ

COMCOM

PN

P





Connection of the Negative Logic (source) InputConnection of the Negative Logic (source) Input

100/240100/240VACVAC

33AA



RUNRUN ERRERR

I / OI / OCOMCOM

00 11 55443322

00 11 3322

II

OO

55L NL N100/240VAC100/240VAC 4433221100+ + --

24VD OUT24VD OUTININ

COMCOM

NPN




PLC Outputs ConnectionPLC Outputs Connection

* Fuse rated for load* Fuse rated for load

24VDC or 240VAC 2A MAXL/+L/+

**

N/N/-- L/+L/+ N/N/--

2 OUTCOM 3 INPUTS 24VDC

OUTPUTS 2A Ry NCOUTCOM 0 1 IN 0 – 10 V

+ -

RUN ERR

I / OCOM

0 1 5432

0 1 32

I

O




Characteristics of TSX 07 32 1012 Nano PLCCharacteristics of TSX 07 32 1012 Nano PLC

Extendable

Supply voltage: 24VDC

Number of discrete inputs: 6 inputs

Type of inputs 24VDC

Number of output 4

Type of outputs Transistor Positive logic (Source)

Transistor voltage: 24VDC, 0.5A Max





Connection of the Positive Logic (sinking) Input

24VDC

3A

2 wire prox. sens.

3 wire prox. sens.

RUN ERR

I / OCOM

0 1 5432

0 1 32

I

O

5+ -24VDC 43210NC Nc

INCOM

PNP




PLC Inputs ConnectionPLC Inputs ConnectionConnection of the Negative Logic (source) Input

3A

2 wire prox. sens.

3 wire prox. sens.

NPN

RUN ERR

I / OCOM

0 1 5432

0 1 32

I

O

5+ -24VDC 43210NC Nc

INCOM

24VDC




PLC Outputs ConnectionPLC Outputs Connection

* Fuse rated for load* Fuse rated for load

++ --2424VDCVDC

**

RUN ERR

I / OCOM

0 1 5432

0 1 32

I

O

2 3 -V INPUTS 24VDCOUTPUTS 0.5A Tr Sce AOUT

COM 0 1 SGB




I/O AddressingI/O Addressing

% I or Q 0 or 1 • i

Symbol

I = input

Q = output

0 = Base PLC

1 = I/O extension

Point

i=I/O number

Examples

%I0.1 : Second input on base PLC

%Q1.2 : Third input on extension PLC




A Simple ExampleA Simple Example

Load~

S1 S2

Supply

NL

AND Function

S1 S2

Load

S1 S2 M




Ladder Logic Vs Conventional ControlLadder Logic Vs Conventional Control

stop

start

4

4

3

3

L1

L1

T1 T2 T3

L2 L3

aux

%I0.1 %I0.0

%Q0.1

%Q0.1PLC

O/P#2O/P#3O/P#4

commonO/P#1 M

I/P#2I/P#3I/P#4

commonI/P#1

L2

M

M-aux.

L1

M




FUNCTIONBLOCKSFUNCTIONFUNCTIONBLOCKSBLOCKS




Timers [%Timers [%TMiTMi]]

There are three types of timer:On Delay timer.Off Delay timer.Pulse timer

⌦ Number of timers 0 to 31

⌦ Time Base 1min (by default), 1s, 100ms, 1ms(for Tm0 and Tm1).

%TMi

IN Q

TYPE TONTP 1 minADJ Y%TM0.P: 9999

%I0.0 %Q0.0




ONON--Delay Timer Delay Timer ““TONTON””%TMi

IN Q

TYPE TONTP 1 minADJ Y%TM0.P: 9999

IN

Q

PV

CV




OFFOFF--Delay Timer Delay Timer ““TOFTOF””%TMi

IN Q

TYPE TOFTP 1 minADJ Y%TM0.P: 9999

IN

Q

PV

CV




%TMiIN Q

TYPE TOFTP 1 minADJ Y%TM0.P: 9999

PULSE Timer PULSE Timer ““TPTP””

IN

Q

PV

CV




Counters [%Counters [%CiCi]]

Number of Counters 0 to 15.

current value = preset value when S=1.

current value = 0 when R=1

%Ci.D=1 when current value = preset value.

%Ci.E=1 when current value changes from 0 to 9999.

%Ci.F=1 when current value changes from 9999 to 0.

%I0.0 %Q0.0%C0

R E

ADJ Y%C0.P: 9999

S D

CU F

CD

%Q0.1

%Q0.2

%I0.1

%I0.2

%I0.3




Up/Down CountersUp/Down Counters

Up

Down

Reset

PV

O/P

CV

%C0

R E

ADJ Y%C0.P: 3

S D

CU F

CD




PLC Sequencer (Drum Controller)PLC Sequencer (Drum Controller)PLC sequencer operates on a similar principle to an

electromechanical drum controller, which changes step according to external events. On each step, the high point of a cam gives a command which is executed by the control system. In the case of a drum controller (PLC sequencer), these high points are symbolized by state 1 for each step and are assigned to output bits %Qi.j or internal bits %Mi, known as control bits.

%DR0

R F

STEPS 8U




Drum Controller CharacteristicsDrum Controller Characteristics

Number of Drum Controllers 4 (0 to 3)

Number of Steps 8 (default)

Control Bits 16 Control Bits

Input R return controller to step 0

Input U on raising edge cause controller to advance by one step

Output F indicates that the current steps equals the last steps

%I0.0 %Q0.0%DR0

R F

STEPS 8U

%I0.1




Operating DiagramOperating Diagram

Input

Input

Output

0 11 2 3 L-1 2 00 1

U:

R:

Step No. %DRi.S

%DRi.F




Drum Controller ConfigurationDrum Controller Configuration

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