Taklimat Plc July 2008
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Welcome to Politeknik Tuanku Sultanah Bahiyah.
For PLC And CX-Programmer Training Course.
Duration : 2 Days course Time : 8.30a.m - 4.30p.m Instructor : Koh Foo Hin En. Mohd Elias
Development of The Course Day 1 8.30a.m -9.00a.m
: Your understanding about PLC
9.00a.m -10.00a.m : Introduction of PLC 10.00a.m -11. 00a.m : System Configuration & Features & Function & Unit Specification & Components 11.00p.m - 12.00p.m : Basic Command with Basic Programming method. 2.30p.m - 4.30p.m : Exercise With Actual Application
Development of The Course
Day 2 8.30a.m -9.00a.m
: Overview of PLC
9.00a.m -12.00a.m : Continue with new Exercise 2.30p.m - 4.30p.m : Exercise With Actual Application and briefing about the intermediate for PLC
What kind of control system in a plant
Start & Stop Operation
What kind of control system in a plant
Contactors, relays, timers & counters in the control panel
Controlling Motor pump
Valve
Mixer
Read & Display Flow Rate
Float Level
Oxygen Level
Hardwire logic control circuit Start
Stop Relay 1
Relay 1 Relay 1 Timer
Solenoid Timer Pump
A picture of hardwire relay logic
Introduction to PLC What is PLC ?
Programmable Logic Controller A solid-state device used to control machine or process operation by means of a stored program and feedback from input and output devices
Sense See
Human
Brain
Action Hand
Listen Leg
Taste Touch Smell
Mouth
You
Power Supply
PLC Signals from Switches, Sensors, etc
I n p u t
Memory
CPU
O u t p u t
Signals to solenoids, motor, lamps, etc.
Programming Device Operate by monitoring input signals and providing output signals. When changes are detected in the input signals, the PLC reacts, through the user-programmed internal logic, to produce output signals It continuously scans the program in its memory to achieve this control
PLC
Hardwire Logic
Control Device Wired Logic
PLC
General Purpose Specific Purpose Control sequence is fixed for one design
Control sequence can be change from time to time without need to rewire
Control Scale Small & Medium
Wired Logic
Medium & Large
PLC
Modification An example for hard wire logic Start
Stop
Start
Stop
Relay 1 Relay 1
Relay 1
Relay 1 Relay 1
Solenoid Timer
Relay 1 Stop
Timer Pump
Solenoid Counter #30
Counter Pump
Hardwire logic will need to rewire everything
Modification The same example for PLC LD START OR RELAY 1 AND NOT STOP OUT RELAY1 OUT SOLENOID LD RELAY 1 TIM 000 #0020 LD TIM 000 OUT PUMP
Start
Stop Relay 1
Relay 1
Relay 1
Solenoid Timer
Timer Pump
Modification The same example for PLC LD START OR RELAY 1 AND NOT STOP OUT RELAY1 OUT SOLENOID LD RELAY 1 LD STOP CNT 000 #0030 LD CNT 000 OUT PUMP
Start
Stop Relay 1
Relay 1
Relay 1 Stop
Solenoid Counter #30
Counter
Only need to change the ladder program
Pump
Delivery Period Several days
Almost Immediate
Wired Logic
PLC
Difficult
Maintenance
Easy
LED indicator
Wired Logic
Programming Console
Input/output connector can be remove easily without using screw driver
PLC
Economic Efficiency Advantage on small, medium and large
Advantage on small scale
$$$ Wired Logic
PLC
Power Consumption High
Low
> 2 Amp
0.2 Amp
Wired Logic
PLC
What PLC can do Sequence Control Relays Start Stop Relay 1 Relay 1
Relay 1
Solenoid Timer
Timer Pump
Timers & Counters
Sophisticated Control + x / Arithmetic Operation Prod AA BB CC
Pass
Reject 33 27 43
4 3 8
Information Handling
2 1
3
4 5
Analog Control
Supervisory Control PLC Computer
Printer
FA Network
Pager Process Monitoring
Why & When to use PLC Dramatically increase in population and housing development Limited land for plant A higher capacity of plant with high efficiency required Upgrading of small plant to run higher capacity would involve complicated control system, Intermittently Decanted Extented Aeration (IDEA).
For that purpose, PLC can do the job
Nation-wide Coverage OMRON ELECTRONICS SDN.BHD SALES NETWORK IN MALAYSIA
Elcomp Trading Ommura
Autovation EM System
Robomatics
Waste Water Treatment Article
Reliable Control Solution For Waste Water Treatment And Environmental Processes In 1990, Omron controls were selected for a central Florida Water treatment plant to ease capacity, productivity,efficiency and reliability. The facility performed : • Raw Water Pumping • Softening • Filtering • Storage / Distribution
The system included a PLC based station at each major processing stages, tied together with a triple-redundant network. The PLC / Computer network improved efficiency at the Water Treatment facility for about one-third the cost of a distributed control system.
One PLC control and monitors the softener systems ; two more PLCs control the filter systems; another PLC, located in the control room, controls the main storage and distribution system
Two independent host computer link networks connect the PLCs to the Computers. A peer to peer network provides a shared memory area to all PLCs on the network so that critical data - valve position, tank levels, motor status and various plant flows are communicated automatically. This communication is transparent to the users Operator interface terminals simplify control and monitoring of the entire operation. Fiber optic cables were installed for all communications networks to protect against lightning
Data acquisition was automated by gathering all parameters from the PLCs data memories and printing daily and monthly reports. Chemical and turbidity test results were input into the computer by operators for report generation
Future Expansion & Upgrading Maintenance office(SCADA)
Modem
RS232C
Pumps House: 1 ID ID ID O C
O C
Distance : 5km ~ 8km Pumps House: 2
A D D A
ID ID ID O C
Inverter
Pressure Interlock,
C1
Power monitor
C2
Modem
O C
RS232 C
A D D A
Inverter
C1
C2
Humidity Sensors
Pump 1
Jockey Pump
Pump 2
Pump 1
Jockey Pump
Pump 2
For PLC And CX-Programmer Training Course.
Duration : 2 Days course Time : 8.30a.m - 4.30p.m Instructor : Koh Foo Hin En. Mohd Elias
Development of The Course Day 1 8.30a.m -9.00a.m
: Your understanding about PLC
9.00a.m -10.00a.m : Introduction of PLC 10.00a.m -11. 00a.m : System Configuration & Features & Function & Unit Specification & Components 11.00p.m - 12.00p.m : Basic Command with Basic Programming method. 2.30p.m - 4.30p.m : Exercise With Actual Application
Development of The Course
Day 2 8.30a.m -9.00a.m
: Overview of PLC
9.00a.m -12.00a.m : Continue with new Exercise 2.30p.m - 4.30p.m : Exercise With Actual Application and briefing about the intermediate for PLC
What kind of control system in a plant
Start & Stop Operation
What kind of control system in a plant
Contactors, relays, timers & counters in the control panel
Controlling Motor pump
Valve
Mixer
Read & Display Flow Rate
Float Level
Oxygen Level
Hardwire logic control circuit Start
Stop Relay 1
Relay 1 Relay 1 Timer
Solenoid Timer Pump
A picture of hardwire relay logic
Introduction to PLC What is PLC ?
Programmable Logic Controller A solid-state device used to control machine or process operation by means of a stored program and feedback from input and output devices
Sense See
Human
Brain
Action Hand
Listen Leg
Taste Touch Smell
Mouth
You
Power Supply
PLC Signals from Switches, Sensors, etc
I n p u t
Memory
CPU
O u t p u t
Signals to solenoids, motor, lamps, etc.
Programming Device Operate by monitoring input signals and providing output signals. When changes are detected in the input signals, the PLC reacts, through the user-programmed internal logic, to produce output signals It continuously scans the program in its memory to achieve this control
PLC
Hardwire Logic
Control Device Wired Logic
PLC
General Purpose Specific Purpose Control sequence is fixed for one design
Control sequence can be change from time to time without need to rewire
Control Scale Small & Medium
Wired Logic
Medium & Large
PLC
Modification An example for hard wire logic Start
Stop
Start
Stop
Relay 1 Relay 1
Relay 1
Relay 1 Relay 1
Solenoid Timer
Relay 1 Stop
Timer Pump
Solenoid Counter #30
Counter Pump
Hardwire logic will need to rewire everything
Modification The same example for PLC LD START OR RELAY 1 AND NOT STOP OUT RELAY1 OUT SOLENOID LD RELAY 1 TIM 000 #0020 LD TIM 000 OUT PUMP
Start
Stop Relay 1
Relay 1
Relay 1
Solenoid Timer
Timer Pump
Modification The same example for PLC LD START OR RELAY 1 AND NOT STOP OUT RELAY1 OUT SOLENOID LD RELAY 1 LD STOP CNT 000 #0030 LD CNT 000 OUT PUMP
Start
Stop Relay 1
Relay 1
Relay 1 Stop
Solenoid Counter #30
Counter
Only need to change the ladder program
Pump
Delivery Period Several days
Almost Immediate
Wired Logic
PLC
Difficult
Maintenance
Easy
LED indicator
Wired Logic
Programming Console
Input/output connector can be remove easily without using screw driver
PLC
Economic Efficiency Advantage on small, medium and large
Advantage on small scale
$$$ Wired Logic
PLC
Power Consumption High
Low
> 2 Amp
0.2 Amp
Wired Logic
PLC
What PLC can do Sequence Control Relays Start Stop Relay 1 Relay 1
Relay 1
Solenoid Timer
Timer Pump
Timers & Counters
Sophisticated Control + x / Arithmetic Operation Prod AA BB CC
Pass
Reject 33 27 43
4 3 8
Information Handling
2 1
3
4 5
Analog Control
Supervisory Control PLC Computer
Printer
FA Network
Pager Process Monitoring
Why & When to use PLC Dramatically increase in population and housing development Limited land for plant A higher capacity of plant with high efficiency required Upgrading of small plant to run higher capacity would involve complicated control system, Intermittently Decanted Extented Aeration (IDEA).
For that purpose, PLC can do the job
Nation-wide Coverage OMRON ELECTRONICS SDN.BHD SALES NETWORK IN MALAYSIA
Elcomp Trading Ommura
Autovation EM System
Robomatics
Waste Water Treatment Article
Reliable Control Solution For Waste Water Treatment And Environmental Processes In 1990, Omron controls were selected for a central Florida Water treatment plant to ease capacity, productivity,efficiency and reliability. The facility performed : • Raw Water Pumping • Softening • Filtering • Storage / Distribution
The system included a PLC based station at each major processing stages, tied together with a triple-redundant network. The PLC / Computer network improved efficiency at the Water Treatment facility for about one-third the cost of a distributed control system.
One PLC control and monitors the softener systems ; two more PLCs control the filter systems; another PLC, located in the control room, controls the main storage and distribution system
Two independent host computer link networks connect the PLCs to the Computers. A peer to peer network provides a shared memory area to all PLCs on the network so that critical data - valve position, tank levels, motor status and various plant flows are communicated automatically. This communication is transparent to the users Operator interface terminals simplify control and monitoring of the entire operation. Fiber optic cables were installed for all communications networks to protect against lightning
Data acquisition was automated by gathering all parameters from the PLCs data memories and printing daily and monthly reports. Chemical and turbidity test results were input into the computer by operators for report generation
Future Expansion & Upgrading Maintenance office(SCADA)
Modem
RS232C
Pumps House: 1 ID ID ID O C
O C
Distance : 5km ~ 8km Pumps House: 2
A D D A
ID ID ID O C
Inverter
Pressure Interlock,
C1
Power monitor
C2
Modem
O C
RS232 C
A D D A
Inverter
C1
C2
Humidity Sensors
Pump 1
Jockey Pump
Pump 2
Pump 1
Jockey Pump
Pump 2
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