Eci PLC Basic

PLC
CONTROLLER
Copyright 2011 Tesco Corporation

What we are going to cover
 What is a PLC?
 What does a PLC do?
 What are the basic parts of a PLC?
 How do we troubleshoot with a PLC?
 How to read the drawings

What is a PLC..?
 A Programmable Logic Controller, or PLC

for short, is simply a special computer
device used for industrial control systems
 Uses a program to control functions in the
field.
 The signals can be on/off or a scalar input

What is a PLC..?
Turn the light on thirty seconds

after the switch has been flipped
TIMER + REWIRE Time, labor and money

What is a PLC..? DPA TDA
MPB 17/18
18/19 18/19
+24 V.D.C.
Unloader
DPB 17/18
+24 V.D.C. 12 11
DPA 10 TDA 10
Back
Spring
Return
13
14 13 DPB 19/20
R5 -24 V.D.C.
14 Coil
Latch
DPA 9 TDA 9
Forward
Float
Push Button
9 1 DPA 8 TDA 8
Float
R5
TDA
34-37
DPA 34-37
N.C. Contact
9 5 14 13 DPB 19/20
R6 -24 V.D.C.
R6
DPB 19/20
N.O. Contact -24 V.D.C.
Coil

What is a PLC..?
MPB 17/18
+24 V.D.C.
Unloader
DPB 17/18
+24 V.D.C.
Back
Spring
Return
Latch
PLC LOGIC PROGRAM
Forward
Float
Push Button
Float

Basic parts of a PLC
 Back pan provides a place to mount the
hardware
 Power supply supplies power to the CPU and
IN/OUT cards through the back pan
 CPU the control center of the PLC, where the
program is stored
 Input/Output (I/O) cards take the signal in and
translated to the signal to the desired function
out

The Back Pan
 It provide a place where to mount all cards
 10 Slot with external CPU
 Take care when removing or installing card on to the pan

Installing and Removing
a Module

Installing a Terminal Board

Removing a Terminal Board

The Power Supply
 Ensure that the voltage and the wattage

out put is correct for the application
 Indicator lights will give you the status of
the power supply
 Contains a battery that will maintain the
program during power outages if the
program is not burnt to “E” prompt

The Power Supply
Status LED’s
PWR
OK
RUN
BATT
PLC Power Supply
RS-485 Serial Port

Power Supply Status LEDs
PWR- The top green LED indicates the operating status of the power
supply.
OK- The second green LED is steady ON when the PLC is functioning
properly and OFF if a problem is detected within the PLC.
RUN- The third green LED is steady ON when the PLC is in run mode.
BATT- The bottom red LED will only be ON when the backup battery
voltage is to low to maintain the RAM (Random Access Memory) during
a loss of power. If this red LED is ON the Lithium battery must be
replaced.

The Power Supply
* 30 Watts Max Total for all Output

The CPU
CENTRAL PROCESSING UNIT
 25MHz Processor with onboard high density

ROM memory
 It has indicator light in the top section that will
show the status of the CPU
 Contains the ports that are used to upload and
download the programs
 A special cable is required to connect the PLC
CPU to the Lap top computer
The CPU
Status LED’s
PS Port
P1
P2
CPU
Serial Port for laptop
interface

CPU Status LEDs
PS Port- Indication that the CPU is powered up and the

transfer of data is taking place within the main PLC.
P1- Turns on with the transfer of data through serial port P1

(RS-232).
P2- Turns on with the transfer of data through serial port P2

(RS-485). This is the port that we use for linking the PLC with
the Laptop.

Genius Bus Controller
 The GBC handles all data transfer between the PLC

and the devices on its bus
 The GBC places inputs in the on-board RAM when they

are received from the Genius bus
 The CPU sweep, the cycle of actions that includes

communications between the CPU and the GBC.

Status LED’s
OK
COM
GBC

Genius Status LEDs
OK- Shows the status of the GBC module. This LED

turns on after power up diagnostics are completed.
COM- Shows the status of the Genius communications

bus. This LED is on steadily when the bus is operating
properly. It blinks for intermittent bus errors and is off
for a failed bus. It is also off when no configuration has
been received from the PLC CPU.


Input / Output cards
 Input card take the information from the HID

and give it to the CPU where the CPU tells the
output cards what to do
 They have indicator light in the top section that
tell what function is being asked for
 Depending on the program it may be possible
to swap out the card without having to go into
the program

Input / Output cards
Status LED’s
A
B
F
I/O Cards

I / O Status LEDs
A/B- Show when an input or an output is selected
F- It only lights if an internal fuse is blown (*)
(*) This letter F is present on all of the discrete I/O module lens caps,
but is only functional on certain Output Modules that have internal fuses

Schematics Outline
RACK 0  Indicates the location of the Card on the

SLOT 03
back pan
DIGITAL INPUT  Tells what type of card it is, the Voltage

24 VDC, 16 PT
rating of the card, and how many
terminals are on the card.
ADDRESS:  Gives the Address in the PLC program

I001-I016

Title block

Terminal
Numbers

PLC Address

Wiring
Numbers

PLC wiring
Numbers

Drillers Panel
Indicator Lights illuminate when a

switch selection is made on the
drillers panel

VERSAMAX
 The VersaMax PLC features a compact, rackless
design and DIN-rail mounting.

VERSAMAX
Power Supply I/O Carrier Connector Style DIN Rail
Genius NIU I/O Carrier Box Style

The Power Supply
 24 VDC Power Supply provides power

for NIU, and I/O modules.
 It mounts directly on the right hand

side of the NIU.
 3.3 VDC and 5 VDC with a max of 1.5

Amps output current.

The Power Supply
Power supply

The NIU
 Network Interface Unit can be used to
interface VersaMax I/O modules to a
Genius I/O bus.
 Together, the NIU and its modules

form an I/O station capable of handing
up to 128 bytes of discrete and analog
Input data and 128 of discrete and
analog Output data.
The NIU
Status LED’s
 PWR
 OK
 Faults
 I/O Enbl
 Force
 SBA Err
 BUS B/EDM
SBA and Baud Rate

The NIU
NIU Status LEDs

PWR- Indicates that the NIU is receiving power.
OK- Indicates diagnostics executed successfully.
FAULT- Is ON if there are one of more faults.
I/O ENBL- This bicolor LED is green if the I/O scan is enable and
data is being received from the bus. Otherwise, this
LED is amber.
FORCE- Is ON if one or more I/O points is forced or bus
switching is forced.
SBA ERR- Is ON if a duplicate device SBA or no valid SBA is
selected.
BUS B- Is ON if bus B is active.

The NIU
NIU CONFIGURATION
Versamax controller (NIU) Can be configured two ways:
 Writing configuration in the Cimplicity or Profecy program.
 In most cases, it can Auto-configured.

The NIU
AUTO-CONFIGURATION
Once VersaMax is connected to main PLC:
 Turn off power to VersaMax

 Separate NIU Module from I/O modules
 Disconnect Serial Communication plug from the NIU module
 Set the NIU Genius Bus address to auto configuration:
 SBA x 10= A
 Turn ON power to VersaMax

 Confirm the following LEDs are illuminated:
 Power
 OK
 I/O ENBL
 SBA ERR
The NIU
AUTO-CONFIGURATION
 Connect all I/O modules to NIU
 Power
 OK
 I/O ENBL
 SBA ERR
 Set the NIU Genius Bus address to the following:
 SBA x 10= 0
 SBA x 1= 1
 Baud Rate= 2
The NIU
AUTO-CONFIGURATION

 Connect Serial Communication plug to the NIU module
 Power
 OK
 I/O ENBL
Note the Fault and Force LEDs should not be illuminated
 This complete the VersaMax configuration process

Drillers Panel
Terminal Numbers

Drillers Panel
Input card information

Software Familiarization
Symbols and Memory reference:
%I- Discrete Input (selector switch)

%Q- Discrete Output (pilot light)
%M- Internal coil or user bit
%R- Register memory (timers, counters, and multipliers)
%AI- Analog input (set speed or torque)
%AQ- Analog output (delivered speed or torque)
%T- Temporary Internal coil or user bit
%G- Global Data Reference
%S- System discrete bit
PROFICY MACHINE
EDITION PROGRAM

RUNNING THE PROFICY PROGRAM

RUNNING THE PROFICY SOFTWARE

RUNNING THE PROFICY SOFTWARE

RESTORING THE PROGRAM








BASIC SCREENS

HARDWARE CONFIGURATION

PROGRAM BLOCKS

PROGRAM BLOCKS

GOING ONLINE

GOING ONLINE

STATUS BAR

STATUS BAR
Target Offline
Target Online, Monitor Mode, and Equal Target Online, Programmer Mode, and
Equal
Target Online, Monitor Mode, and Unequal Target Online, Programmer Mode, and
Unequal
Target Online, Monitor Mode, and Stop Target Online, Programmer Mode, and
F Faulted F Stop Faulted

STATUS BAR
Controller Status: Displays the current Controller state in the
Status Bar at the bottom of the Machine Edition

STATUS BAR
Equality Status: The Status Bar also displays the equality of the
Hardware Configuration and of the Logic

TOGGLE ONLINE MODE

TOGGLE ONLINE MODE

CLEARING FAULTS

CLEARING FAULTS

CLEARING FAULTS

DOWNLOADING TO CONTROLLER



RUNNING THE CONTROLLER

STOPPING THE CONTROLLER

BURNING THE EPROMP

BURNING THE EPROMP

SEARCHING ADDRESSES

SEARCHING ADDRESSES

SEARCHING ADDRESSES

SEARCHING ADDRESSES

QUESTIONS

Eci PLC Basic

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Eci PLC Basic

Uploaded by

Copyright:

Available Formats

PLC

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 A Programmable Logic Controller, or PLC

Copyright 2011 Tesco Corporation

Turn the light on thirty seconds

TIMER + REWIRE Time, labor and money

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Ensure that the voltage and the wattage

Copyright 2011 Tesco Corporation

PLC Power Supply

RS-485 Serial Port

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

* 30 Watts Max Total for all Output

Copyright 2011 Tesco Corporation

 25MHz Processor with onboard high density

Copyright 2011 Tesco Corporation

PS Port- Indication that the CPU is powered up and the

P1- Turns on with the transfer of data through serial port P1

P2- Turns on with the transfer of data through serial port P2

Copyright 2011 Tesco Corporation

 The GBC handles all data transfer between the PLC

 The GBC places inputs in the on-board RAM when they

 The CPU sweep, the cycle of actions that includes

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

OK- Shows the status of the GBC module. This LED

COM- Shows the status of the Genius communications

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Input card take the information from the HID

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

A/B- Show when an input or an output is selected

F- It only lights if an internal fuse is blown (*)

Copyright 2011 Tesco Corporation

RACK 0  Indicates the location of the Card on the

DIGITAL INPUT  Tells what type of card it is, the Voltage

ADDRESS:  Gives the Address in the PLC program

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Indicator Lights illuminate when a

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Genius NIU I/O Carrier Box Style

 24 VDC Power Supply provides power

 It mounts directly on the right hand

 3.3 VDC and 5 VDC with a max of 1.5

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Together, the NIU and its modules