Basic PLC Programming with Micro800 Controller
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1 Basic PLC Programming with Micro800 Controller Name Rick Sykora/Kou Vang Title Product Manager/Sr. Application Engineer Date 10/18/2012 Rev 5058-CO900C Copyright 2012 Rockwell Automation, Inc. All rights reserved.
2 PLC Basics Agenda 1. Introduction to Terms / Concepts 2. Programming a PLC 3. Software demo 4. Hands-On Lab Copyright 2012 Rockwell Automation, Inc. All rights reserved. 2
3 How did the PLC get started? > GM (Hydramatic Division) approached suppliers to help with a problem: Relay walls covered the plant floor. Changes and Troubleshooting took weeks/months. High costs Every change (model year) was major destruction and re-wiring. GM needed the flexibility of solid state ; a controller that could be programmed and maintained by plant engineers; and was rugged enough to withstand the factory environment and provided easy troubleshooting... Allen-Bradley PLC Copyright 2012 Rockwell Automation, Inc. All rights reserved. 3
4 What is a Programmable Logic Controller (PLC)? A solid state (electronic) device that controls output devices based on programming and input signals. Inputs Control Program Outputs Copyright 2012 Rockwell Automation, Inc. All rights reserved. 4
5 Two types of I/O (Inputs & Outputs) Digital Also called Discrete Has two possible states Represented by 1 or 0 Electrically: 0 is usually 0 Volts (AC or DC) 1 is a fixed voltage value such as 5VDC, 24VDC, 120VAC, etc. Technology: Relays, Triac, Transistor, MOSFET, TTL Analog Has many possible states between two values. Example: Temperature sensor. Range of values between two limits. For example: 0 F represented by F represented by 4095 (example) Electrically: 4-20mA, 0-5VDC, -10 to 10VDC Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2012 Rockwell Automation, Inc. All rights reserved.
6 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 6 PLC Control Program Program Instructions used to process inputs and set outputs Primarily written as (Relay) Ladder Diagram: Start_Button Light Programs can also be written in other languages Data (Variables) Examples Function Block or Structured Text Start_Button is assigned to a digital input Light is assigned to a digital output
7 PLC Basics Agenda 1. Intro to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2012 Rockwell Automation, Inc. All rights reserved. 7
8 Simple PLC Instructions (IEC ) Contacts Direct Reverse Coils Direct Reverse Set Reset S R Instruction Blocks Arithmetic (+ - * / COS SIN TAN) Binary (Mask, Shift) Boolean (AND,OR,NOT,XOR) Comparator (< > = CMP) Counter (CTD, CTU, CTUD) Data Conversion (ANY_TO_**) Process (PID, SCALER, more ) String (FIND, REPLACE, more ) Time (TON,TOF,TONOFF) Copyright 2010 Rockwell Automation, Inc. All rights reserved. 8
9 Copyright 2012 Rockwell Automation, Copyright Inc. All rights 2006 reserved. Rockwell Ladder Logic Example This is a very simple rung of logic, from a PLC program: Start_Button Light The rung is read as: If the Start Button is on, turn the Light. If the Start Button is off, then turn the Light off.
10 Copyright 2006 Rockwell Copyright 2012 Rockwell Automation, Inc. All rights reserved. I/O Addressing Often, a descriptive name of the device connected to the I/O point is used in addition to, or in place of the I/O variable which describes the physical location on the controller. Example of user-defined name Start Button _IO_EM_DI_00 Light _IO_EM_DO_00 Example of system-defined I/O variable
11 Software Introduction Copyright 2012 Rockwell Automation, Inc. All rights reserved.
12 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Connected Components Workbench Software Easy to Acquire/Install Free Internet download Easy to Configure Single software for component class products Graphical Device Configuration Easy to Program Extensive use of Microsoft and IEC standards Symbolic Programming Rockwell Automation and user-defined function blocks Easy to Update Software updates available via Internet
13 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 13 Demo using Connected Components Workbench Demo of project creation (if possible, show using browse) Demo of program creation (part of upload if browsed) Demo Micro800 password protection (only works if connected) Demo configuration of Micro850 Expansion I/O via drag and drop Demo new PVc software Directly address Micro800 variables via CIP connectivity (Enet/serial) PanelView Component only; other HMIs must use Modbus TCP Demo Simple motion support for Micro830 and Micro850 (if time allows)
14 PLC Basics Agenda 1. Intro to Terms / Concepts 2. Programming a PLC 3. Application Example 4. Hands-On Lab Copyright 2012 Rockwell Automation, Inc. All rights reserved. 14
15 So where could you use a PLC? Conveyor control Printed circuit board handling equipment SCADA(Supervisory Control And Data Acquisition) Remote pump/lift station (water/wastewater) Flow monitoring for leak detection (Oil & Gas) Strapping machinery / trash compactors Palletizers Compressor control Amusement park rides and attractions Many, many more Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2012 Rockwell Automation, Inc. All rights reserved.
16 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 16 Lab Notes Beginner Lab Learn basics of PLC programming Advanced Lab Choice of lab modules based on new features HMI design using PanelView Component Creating your own instruction (User-Defined Function Block) Programming in Structured Text example
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