1 Introduction to the PLC 1 1.1 Introduction 1 1.2 Basic Block Diagram of the PLC 2 1.3 Size of the PLC System 3 1.4 Components of the PLC Systems 3 1.5 PLC and Process Interaction 5 1.6 Number Systems and Codes 8
2 Processors, Power Supply and Programming Devices 13 2.1 Introduction To The PLC Hardware 13 2.2 Processors (CPU) 13 2.3 PLC Power Supply 17 2.4 Programming Device 17
3 Memory System and I/O Interaction 21 3.1 Memory Systems 21 3.2 Digital I/O Interaction 24 3.3 Analog I/O Interaction 26
4 Digital Input/Output Systems 29 4.1 Basics of Discrete I/O Systems 29 4.2 Types of Discrete Field Devices 30 4.3 Types of Discrete Input Modules 31 4.4 Types of Discrete Output Modules 34
5 Analog Input/ Output Systems 39 5.1 Basic of Analog I/O Systems 39 5.2 Types of Analog Field Devices 40 5.3 Types of Analog Input Modules 41 5.4 Types of Analog Output Modules 47
6 Special Function I/O and Serial Communication Interfacing 53 6.1 Introduction 53 6.2 Fast Response Input Module 54 6.3 Counter Module 55 6.4 Positioning Module 58 6.5 Stepper Motor Positioning Module 61
7 Good Installation Practices 67 7.1 Introduction 67 7.2 PLC Modules 69 7.3 PLC Rack 71 7.4 PLC Panel Internal Wiring 72 7.5 PLC Panel Power Supply 72 7.6 Cabling Between PLC And Field Devices 74 7.7 Cabling PLC And Control Room Computers 78 7.8 PLC Earthing 78 7.9 Specific PLC Installation Requirements 81 7.10 Control Room Requirements 83
8 Fundamentals of PLC Programming 87 8.1 Introduction 87 8.2 PLC Programming Steps 89 8.3 Programming Languages 91 8.4 Basic Logic Instructions 101 8.5 Timers 103 8.6 Counter 107 8.7 Program Flow Control Instructions 111 8.8 Data Load and Transfer Instructions 114 8.9 Arithmetic or Math Instructions 117
9 Data Acquisition 123 9.1 Introduction 123 9.2 A Typical Data Acquisition System 123 9.3 Aliasing and the Sampling Theorem 124 9.4 Data Coding System 127
10 Analog and Digital Control 135 10.1 Introduction 135 10.2 Analog Inputs 135 10.3 Signal Filtering 136 10.4 Analog Display 137 10.5 Analog Control 137 10.6 Application of PID Control 139 10.7 Alternative Forms of Analog Control 145
11 Fault Tolerance - Spreading the Risk 147 11.1 How Reliable Is Our Equipment? 147 11.2 Project Planning 147 11.3 Key Questions 147 11.4 Two Key Strategies 147 11.5 The People! 149 11.6 Primary Loop Control and Interlocking 149 11.7 The Field Devices 149 11.8 Communications 149 11.9 DCS Structure 150 11.10 PLC System Options 151 11.11 The Costs 151 11.12 Utilities 151 11.13 Spare PLCs 151 11.14 I/O Allocation 152 11.15 Backing up Current Plant Data 152 11.16 Power Supplies 152
17 High Security PLC Systems 247 17.1 Introduction and Terminology 247 17.2 Background to Safety Control Systems 251 17.3 Safety Systems Concepts 251 17.4 Resistance to Random Hardware Failures 260 17.5 Architectures for Safety PLCs 262 17.6 Objections to Standard PLCs Used for Safety 263 17.7 Characteristics of Safety PLCs 267 17.8 Hardware Characteristics of a Safety PLC 267 17.9 Software Characteristics of a Safety PLC 268 17.10 Design Safety PLCs 269 17.11 Redundant Architectures for PLCs- High Availability with High Integrity 271 17.12 Conclusion of Safety PLCs 276 17.13 Application Software 276 17.14 Safe Networking 277 17.15 Classifications and Certification 280 17.16 Summary of High Security PLCs 281
18 System Programming and Implementation 283 18.1 Introduction 283 18.2 Taking Process Inputs 283 18.3 Creating I/O List 284 18.4 Deciding Hardware Configuration of PLC system 286 18.5 I/O Address Assignment 288 18.6 Developing Program Structure 291 18.7 Tips for Developing a PLC Program 293 18.8 Program Verification and Simulation 295 18.9 Creating Documentation 297
19 Best Practice Documentation 299 19.1 What Is a Manual? 300 19.2 Types of Manuals 300 19.3 Planning the Manual 302 19.4 Drafting the Manual 307 19.5 Reviewing the Manual 310
20 HMI (Human Machine Interface) 315 20.1 Introduction 315 20.2 Design Consideration of HMI 317 20.3 Hardware Interface Between PLC and HMI 325 20.4 Software Interface Between PLC and HMI 326
21 Electrical Design and Construction 327 21.1 Introduction 327 21.2 PLC Enclosure 327 21.3 Panel Layout 329 21.4 Electrical Wiring of Panel 331 21.5 Gudielines for Panel Electrial Design 332
22 Functional Specification of the System 335 22.1 Introduction 335 22.2 System Requirement Specification 337 22.3 Function Specification of the System 342 22.4 Hi-tech Mining 346 22.5 Circulation of the Functional Specification 376 22.6 Checklist of Factors for Selection of an I/O Module 376 22.7 Selection of the System 378 22.8 Testing of the System 379
23 Fuzzy Logic 381 23.1 Introduction 381 23.2 Understanding Fuzzy Logic 382 23.3 The Rules of Fuzzy Logic 383 23.4 Fuzzy Logic Example Using Rules And Patches 385 23.5 The Achilles Heel of Fuzzy Logic 387
24 Configuration of the System 389 24.1 Initial Concepts 389 24.2 Training on the System 389 24.3 Input/Output Database Creation 390 24.4 General Database Design Tips 398
25 Installation and Commissioning 399 25.1 Introduction 399 25.2 Control Room MCC Requirements 399 25.3 Installation of Equipment 400 25.4 Loop Testing 400 25.5 Manual Control 400 25.6 Automatic Control 401 25.7 System Handover 401 25.8 Maintenance and Training 402
26 Working Example of PLC Programs 403 26.1 Introduction 403 26.2 Control Philosophy 403 26.3 Typical PLC Program for Drives 405 26.4 Understanding Advanced Programming Techniques 413