PLC & SCADA

1.         PLC OVERVIEW................................................................................................ 1–29

            1.1       Introduction to PLC

            1.2       Limitation of Relays

            1.3       Concept of PLC

            1.4       Building Blocks of PLC and Their Functions

            1.5       Advantages of PLC

            1.6       PLC Architecture

                        1.6.1     Central Processing Unit (CPU)

                        1.6.2     PLC Memory

                        1.6.3     Input/Output Modules

                                    1.6.3.1 Specialty I/O modules

                        1.6.4     Programmer/Monitor

                        1.6.5     Power Supply

                        1.6.6     Racks and Chassis

            1.7       Module Addressing

            1.8       PLC Registers

            1.9       PLC Operation

                        1.9.1     Input Scan

                        1.9.2     Program Scan

                        1.9.3     Output Scan

            1.10     PLC Programming Languages

            1.11     Applications of PLC

            1.12     PLC Manufactures

            1.13     I/O Modules Selection Criteria

            1.14     Interfacing I/O Devices with PLC I/O Modules

            1.15     PLC Selection Criteria

            1.16     PLC Classification

            Exercise

2.         NUMERIC SYSTEM & LOGIC CONCEPTS FOR LADDER PROGRAMMING 30–70

            2.1       Number Systems

                        2.1.1     Decimal Number System

                        2.1.2     Binary Number System

                        2.1.3     Octal Number System

                        2.1.4     Hexadecimal Number System

            2.2       Number System Conversion

                        2.2.1     Decimal to Binary Conversion

                        2.2.2     Binary to Decimal Conversion

                        2.2.3     Decimal to Octal Conversion

                        2.2.4     Octal to Decimal Conversion

                        2.2.5     Decimal to Hexadecimal Conversion

                        2.2.6     Hexadecimal to Decimal Conversion

                        2.2.7     Binary to Octal Conversion

                        2.2.8     Octal to Binary Conversion

                        2.2.9     Binary to Hexadecimal Conversion

                        2.2.10   Hexadecimal to Binary Conversion

                        2.2.11   Octal to Hexadecimal Conversion

                        2.2.12   Hexadecimal to Octal Conversion

            2.3       Binary Arithmetic

                        2.3.1     Binary Addition

                        2.3.2     Binary Subtraction

                        2.3.3     Binary Multiplication

                        2.3.4     Binary Division

                        2.3.5     Binary Arithmetic with Signed Number

            2.4       Binary Codes

                        2.4.1     Binary Coded Decimal or 8421 Code

                        2.4.2     Excess-3 Code

                        2.4.3     Gray Code

            2.5       Boolean Algebra

            2.6       Logic Gates

                        2.6.1     OR Gate

                        2.6.2     AND Gate

                        2.6.3     NOT Gate

                        2.6.4     NOR Gate

                        2.6.5     NAND Gate

                        2.6.6     EX-OR Gate

                        2.6.7     EX-NOR Gate

            2.7       Introduction to Ladder Logic

            2.8       Basic Component and Their Symbols

                        2.8.1     Switches

                        2.8.2     Indication Lamps

                        2.8.3     Fuses

                        2.8.4     Relays

                        2.8.5     Solenoid Valve

                        2.8.6     Time Delay Relay

            2.9       Fundamental of Ladder Diagram

            2.10     Ladder Logic Function

                        2.10.1   Basic Functions

                        2.10.2   Timer and Counter Functions

                        2.10.3   Math and Logic Functions

                        2.10.4   Comparison and Move Functions

                        2.10.5   Subroutines and Jump Functions

                        2.10.6   Communication and Data Functions

            2.11     Boolean Logic and Relay Logic

                        2.11.1   AND Relay Logic

                        2.11.2   OR Relay Logic

                        2.11.3   NOT Relay Logic

                        2.11.4   NAND Relay Logic

                        2.11.5   NOR Relay Logic

                        2.11.6   XOR Relay Logic

            Exercise

3.         FILE STRUCTURE AND ADDRESSING FORMATS...................................... 71–80

            3.1       PLC Files

            3.2       Input and Output Data Files

            3.3       Data File Addressing Format

            3.4       Status File

            3.5       Bit Data File

            3.6       Timer Data File

            3.7       Counter Data File

            3.8       Control Data File

            3.9       Integer Data File

            3.10     Floating Point Data File

            Exercise

4.         LAddER PROGRAMMING INSTRUCTIONS............................................ 81–129

            4.1       Ladder Diagram

            4.2       Ladder Program Execution

            4.3       Basic Instructions

                        4.3.1     Bit Instructions

            4.4       Examine IF Closed (XIC)

            4.5       Examine IF Open (XIO)

            4.6       Output Energize (OTE)

            4.7       Ladder Diagram for Boolean Logic of Inputs

                        4.7.1     AND Combinations

                        4.7.2     OR Combinations

                        4.7.3     NAND Combination

                        4.7.4     NOR Combination

                        4.7.5     XOR Combination

                        4.7.6     XNOR Combination

            4.8       Tips for Writing Ladder Diagram

            4.9       Output Latch (OTL) and Output Unlatch (OTU)

            4.10     Self Holding Relays

            4.11     One Shot

            4.12     One-Shot Rising (OSR)

            4.13     Timers

                        4.13.1   On-Delay Timers

                        4.13.2   Off-delay timers

                        4.13.3   Non-Retentive Timers

                        4.13.4   Retentive Timers

                        4.13.5   Timer Instructions Parameter

            4.14     Timer Instructions

                        4.14.1   Timer On-Delay (TON) Instruction

                        4.14.2   Timer Off-Delay Instruction (TOF)

                        4.14.3   Retentive Timer (RTO) Instruction

                        4.14.4   Cascading of Timers

            4.15     Counters

                        4.15.1   UP-Counters

                        4.15.2   Down-Counters

                        4.15.3   Up-Down Counters

                        4.15.4   Counter Instruction Parameters

            4.16     Counter Instructions

                        4.16.1   Count-UP (CTU) Instruction

                        4.16.2   Count-Down (CTD) Instruction

                        4.16.3   High Speed Counter (HSC) Instruction

            4.17     Reset (RES) Instruction

            4.18     Master Control Relay (MCR) Instruction

            4.19     Zone Control Last-State Instruction (ZCL)

            4.20     Data Handling Instructions

                        4.20.1   Convert to BCD (TOD) Instruction

                        4.20.2   Convert from BCD (FRD) Instruction

                        4.20.3   Convert from Radians to Degrees (DEG) Instruction

                        4.20.4   Convert from Degrees to Radians (RAD) Instruction

                        4.20.5   Decode 4 to 1 of 16 (DCD) Instruction

                        4.20.6   Encode 1 of 16 to 4 (ENC) Instruction

                        4.20.7   Copy File (COP) Instruction

                        4.20.8   Move (MOV) Instruction

                        4.20.9   Masked Move (MVM) Instruction

            4.21     Comparison Instructions

                        4.21.1   Equal (EQU) Instruction

                        4.21.2   Not Equal (NEQ) Instruction

                        4.21.3   Less Than (LES) Instruction

                        4.21.4   Less Than or Equal (LEQ) Instruction

                        4.21.5   Greater Than (GRT) Instruction

                        4.21.6   Greater Than or Equal (GEQ) Instruction

                        4.21.7   Limit Test (LIM) Instruction

                        4.21.8   Masked Comparison for Equal (MEQ) Instruction

            4.22     Math Instructions

                        4.22.1   ADD Instruction

                        4.22.2   Subtract (SUB) Instruction

                        4.22.3   Multiply (MUL) Instruction

                        4.22.4   Divide (DIV) Instruction

                        4.22.5   Clear (CLR) Instruction

                        4.22.6   Square Root (SQR) Instruction

            4.23     Boolean Instructions

                        4.23.1   OR Instruction

                        4.23.2   AND Instruction

                        4.23.3   Exclusive Or (XOR) Instruction

                        4.23.4   Not (NOT) Instruction

            4.24     Sequencers

                        4.24.1   Time-Driven Sequencer

                        4.24.2   Event-Driven Sequencer

                        4.24.3   Sequencer Instruction Parameters

            4.25     Sequencer Instructions

                        4.25.1   Sequencer Output (SQO) Instruction

                        4.25.2   Sequencer Compare (SQC) Instruction

                        4.25.3   Sequencer Load (SQL) Instruction

            4.26     Shift Registers Instructions

                        4.26.1   Bit Shift Instructions parameters

                        4.26.2   Bit Shift Left (BSL) Instruction

                        4.26.3   Bit Shift Right (BSR) Instruction

            4.27     Real Time Clock (RTC) Function

            Exercise

5.         SCADA.......................................................................................................................             130–153

            5.1       Architecture of SCADa

            5.2       SCADA Project

                        5.2.1     SCADA Project Creation

            5.3       Tags

                        5.3.1     Tag Types

                        5.3.2     Tag Creation

            5.4       Visibility Animation

            5.5       Text Animation

            5.6       Numeric Display and Numeric Input

                        5.6.1     Numeric Display

                        5.6.2     Numeric Input

            5.7       String Display and String Input

                        5.7.1     String Display

                        5.7.2     String Input

            5.8       Label

            5.9       Arrows

            5.10     Sliders

            5.11     Animation Tools/ Functions

            5.12     Alarming

            5.13     Data Logging

            Exercise

6.         PLC APPLICATIONS................................................................................. 154–172

            6.1       Doorbell Operation Using Basic Instructions

            6.2       Switching On-Off Light

            6.3       Liquid Level Control

            6.4       Packing Process Control

            6.5       Main Door Control

            6.6       Vehicle Parking Control

            6.7       Bottling Plant

            6.8       Drink Dispenser

            6.9       Traffic Lights Control

            6.10     Oven Temperature Controller

            Exercise