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plc software - 32.3 32.2.1 Troubleshooting After a system is in operation it will eventually fail. When a failure occurs it is important to be able to identify and solve problems quickly. The following list of steps will help track down errors in a PLC system. 1. Look at the process and see if it is in a normal state. i.e. no jammed actuators, broken parts, etc. If there are visible problems, fix them and restart the process. 2. Look at the PLC to see which error lights are on. Each PLC vendor will provide documents that indicate which problems correspond to the error lights. Common error lights are given below. If any off the warning lights are on, look for electrical supply problems to the PLC. HALT - something has stopped the CPU RUN - the PLC thinks it is OK (and probably is) ERROR - a physical problem has occurred with the PLC 3. Check indicator lights on I/O cards, see if they match the system. i.e., look at sensors that are on/off, and actuators on/off, check to see that the lights on the PLC I/O cards agree. If any of the light disagree with the physical reality, then interface electronics/mechanics need inspection. 4. Consult the manuals, or use software if available. If no obvious problems exist the problem is not simple, and requires a technically skilled approach. 5. If all else fails call the vendor (or the contractor) for help. 32.2.2 Forcing Most PLCs will allow a user to force inputs and outputs. This means that they can be turned on, regardless of the physical inputs and program results. This can be convenient for debugging programs, and, it makes it easy to break and destroy things! When forces are used they can make the program perform erratically. They can also make outputs occur out of sequence. If there is a logic problem, then these don’t help a programmer identify these problems. Many companies will require extensive paperwork and permissions before forces can be used. I don’t recommend forcing inputs or outputs, except in the most extreme circumstances. 32.3 PROCESS MODELLING There are many process modeling techniques, but only a few are suited to process control. The ANSI/ISA-S5.1-1984 Piping and Instrumentation Diagram (P&ID) standard www.PAControl.com
plc software - 32.4 provides good tools for documenting processes. A simple example is shown in Figure 32.1. control valve FV 11 Figure 32.1 A Process Model The symbols used on the diagrams are shown in the figure below XXXXXXXXXXXXX. Note that the modifier used for the instruments can be applied to other discrete devices. www.PAControl.com
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ST1 B T2 A T1 C * B T3 page 0 ST3 T
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page i 1.1 TODO LIST 1.3 2. PROGRAM
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page iii 7.5 ASSIGNMENT PROBLEMS 7.
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page v 14.3 PROGRAMS 14.3 14.4 VARI
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page vii 20.4 PRACTICE PROBLEMS 20.
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page ix 25.2 CONTROL OF LOGICAL ACT
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page xi 30. HUMAN MACHINE INTERFACE
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page xiii 35.16 P 35.21 35.17 Q 35.
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plc wiring - 1.2 • Linear - Can b
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plc wiring - 1.4 - update serial IO
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plc wiring - 2.2 logic diagrams was
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plc wiring - 2.4 115VAC wall plug r
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plc wiring - 2.6 A B B Note: When A
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plc wiring - 2.8 number there. The
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plc wiring - 2.10 i := 0; REPEAT i
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plc wiring - 2.12 x Normally open,
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plc wiring - 2.14 Solution: There a
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plc wiring - 2.16 4. Less expensive
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plc wiring - 3.2 allows the PLC to
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plc wiring - 3.4 5 Vdc (TTL) 200-24
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plc wiring - 3.6 Remember - Don’t
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plc wiring - 3.8 As with input modu
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plc wiring - 3.10 accidentally conn
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plc wiring - 3.12 could have many d
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plc wiring - 3.14 ing large power l
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plc wiring - 3.16 The lines of thes
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plc wiring - 3.18 In the wiring dia
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plc wiring - 3.20 temperature norma
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plc wiring - 3.22 3.6 SUMMARY • P
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plc wiring - 3.24 show all necessar
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plc wiring - 3.26 12. 0 1 2 3 4 5 6
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plc wiring - 3.28 16. relay output
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discrete sensors - 4.1 4. LOGICAL S
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discrete sensors - 4.3 4.2.2 Transi
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discrete sensors - 4.5 value, and t
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discrete sensors - 4.7 PLC Input Ca
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discrete sensors - 4.9 PLC Input Ca
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discrete sensors - 4.11 4.3 PRESENC
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discrete sensors - 4.13 components,
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discrete sensors - 4.15 emitter obj
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discrete sensors - 4.17 emitter ref
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discrete sensors - 4.19 ure 4.22. T
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discrete sensors - 4.21 electrode m
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discrete sensors - 4.23 Material Co
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discrete sensors - 4.25 shielded un
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discrete sensors - 4.27 4.5 PRACTIC
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discrete sensors - 4.29 in:2.I.Data
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discrete sensors - 4.31 4. 24Vdc ou
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discrete sensors - 4.33 6. 00 01 02
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discrete sensors - 4.35 8. + power
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discrete sensors - 4.37 4. a) Show
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discrete actuators - 5.2 As mention
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discrete actuators - 5.4 Two way, t
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discrete actuators - 5.6 single act
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discrete actuators - 5.8 Figure 5.6
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discrete actuators - 5.10 5.8 OTHER
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discrete actuators - 5.12 3. ADD SO
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plc boolean - 6.2 Note: By conventi
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plc boolean - 6.4 Idempotent A + A
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plc boolean - 6.6 6.3 LOGIC DESIGN
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plc boolean - 6.8 Ladder Logic for
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plc boolean - 6.10 der logic there
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plc boolean - 6.12 A = B⋅ C⋅ (
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plc boolean - 6.14 A+ CA = A+ C pro
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plc boolean - 6.16 D1 D2 D3 multipl
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plc boolean - 6.18 Solution: D = A+
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plc boolean - 6.20 The inputs and o
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plc boolean - 6.22 A = ( S⋅ M⋅
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plc boolean - 6.24 • Truth tables
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plc boolean - 6.26 b) Simplify the
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plc boolean - 6.28 2. A B D C 3. B
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plc boolean - 6.30 9. a) ( A+ B)
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plc boolean - 6.32 A B C B C D C A
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plc boolean - 6.34 17. D A Y 18. CA
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plc boolean - 6.36 c) A X B A C C A
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plc boolean - 6.38 2. Simplify the
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plc karnaugh - 7.1 7. KARNAUGH MAPS
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plc karnaugh - 7.3 expression. The
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plc karnaugh - 7.5 7.3 PRACTICE PRO
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plc karnaugh - 7.7 5. Examine the t
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plc karnaugh - 7.9 Boolean equation
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plc karnaugh - 7.11 13. Consider th
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plc karnaugh - 7.13 5. 00 FG 01 11
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plc karnaugh - 7.15 9. CD AB AB A B
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plc karnaugh - 7.17 12. DA + ACD AB
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plc karnaugh - 7.19 4. Convert the
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plc operation - 8.2 inputs and outp
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plc operation - 8.4 input scan take
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plc operation - 8.6 8.3 PLC STATUS
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plc operation - 8.8 outputs are not
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plc timers - 9.1 9. LATCHES, TIMERS
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plc timers - 9.3 The operation of t
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plc timers - 9.5 I/0 O/0 I/0 O/1 L
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plc timers - 9.7 oven has been turn
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plc timers - 9.9 The timing diagram
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plc timers - 9.11 go TON t_1 delay
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plc timers - 9.13 Start Stop Auto A
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plc timers - 9.15 A CTU Counter exa
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plc timers - 9.17 The program in Fi
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plc timers - 9.19 9.6 INTERNAL BITS
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plc timers - 9.21 Solution: A TON P
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plc timers - 9.23 Solution: Motor S
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plc timers - 9.25 Solution: Go Stop
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plc timers - 9.27 Solution: TS1 LS1
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plc timers - 9.29 8. Complete the t
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plc timers - 9.31 17. Design a conv
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plc timers - 9.33 7. A RTF Timer t
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plc timers - 9.35 9. input TON RTO
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plc timers - 9.37 14. A delay.DN TO
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plc timers - 9.39 16. left_button T
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plc timers - 9.41 18. A T4:0/TT C5:
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plc timers - 9.43 22. GIVE SOLUTION
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plc timers - 9.45 3. Explain what w
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plc design - 10.2 Most control syst
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plc design - 10.4 Description: Step
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plc design - 10.6 step4 bottom LS s
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plc design - 10.8 Description: A ha
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plc design - 10.10 3. The first wra
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plc design - 10.12 3. (for both sol
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plc design - 10.14 (with latches fi
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plc design - 10.16 a) Start in an i
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plc flowchart - 11.1 11. FLOWCHART
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plc flowchart - 11.3 START Open out
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plc flowchart - 11.5 STEP 1: Add la
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plc flowchart - 11.7 STEP 2: Write
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plc flowchart - 11.9 F2 start MCR U
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plc flowchart - 11.11 F6 MCR L outl
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plc flowchart - 11.13 FS F1 F6 T1 T
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plc flowchart - 11.15 11.4 SUMMARY
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plc flowchart - 11.17 2. Start Get
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plc flowchart - 11.19 F3 gas can fu
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plc flowchart - 11.21 first scan L
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plc flowchart - 11.23 ST3 button re
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plc flowchart - 11.25 ST8 button re
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plc flowchart - 11.27 3. A welding
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plc states - 12.1 12. STATE BASED D
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plc states - 12.3 be active while c
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plc states - 12.5 Red Yellow Green
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plc states - 12.7 Step 2: Define St
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plc states - 12.9 RESET THE STATES
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plc states - 12.11 FIRST STATE WAIT
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plc states - 12.13 FOURTH STATE WAI
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plc states - 12.15 first scan L STB
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plc states - 12.17 Informally, Stat
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plc states - 12.19 Now, simplify th
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plc states - 12.21 OUTPUT LOGIC FOR
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plc states - 12.23 Each of the alte
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plc states - 12.25 A state diagram
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plc states - 12.27 CALCULATE STATE
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plc states - 12.29 STA T5 B T4 D ST
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plc states - 12.31 4. Given the fol
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plc states - 12.33 24 V AC Power Su
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plc states - 12.35 3. T1 T2 = ST1
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plc states - 12.37 5. TA TB TC TD T
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plc states - 12.39 first scan MCR L
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plc states - 12.41 state 3 MCR rese
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plc states - 12.43 FS L state_1 U s
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plc states - 12.45 state_4 MCR remo
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plc states - 12.47 ST1 remote T1 bu
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plc states - 12.49 12.5 ASSIGNMENT
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plc states - 12.51 6. Implement the
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plc states - 12.53 using an equatio
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plc states - 12.55 INPUTS I/1 - sta
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plc numbers - 13.2 decimal binary o
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plc numbers - 13.4 start with decim
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plc numbers - 13.6 There are three
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plc numbers - 13.8 decimal binary b
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plc numbers - 13.10 13.2.2 Other Ba
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plc numbers - 13.12 Figure 13.17 AS
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plc numbers - 13.14 An example of a
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plc numbers - 13.16 DATA 124 43 255
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plc numbers - 13.18 a) from base 10
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plc numbers - 13.20 17. Do the foll
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plc numbers - 13.22 14. octal binar
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plc memory - 14.1 14. PLC MEMORY To
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plc memory - 14.3 14.3 PROGRAMS The
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plc memory - 14.5 8 - an integer 8.
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plc memory - 14.7 CU - count up bit
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plc memory - 14.9 Immediately acces
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plc memory - 14.11 A selected list
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plc memory - 14.13 onds after it ha
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plc memory - 14.15 10. first scan R
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plc basic functions - 15.2 Combinat
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plc basic functions - 15.4 A MOV So
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plc basic functions - 15.6 store th
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plc basic functions - 15.8 ACS(valu
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plc basic functions - 15.10 go CPT
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plc basic functions - 15.12 15.2.4.
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plc basic functions - 15.14 copy an
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plc basic functions - 15.16 EQU A B
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plc basic functions - 15.18 CMP exp
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plc basic functions - 15.20 Figure
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plc basic functions - 15.22 after a
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plc basic functions - 15.24 As desi
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plc basic functions - 15.26 • Val
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plc basic functions - 15.28 15.7 PR
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plc basic functions - 15.30 5. addr
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plc basic functions - 15.32 S2 part
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plc basic functions - 15.34 11. AND
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plc advanced functions - 16.1 16. A
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plc advanced functions - 16.3 Arith
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plc advanced functions - 16.5 A FFL
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plc advanced functions - 16.7 A SQO
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plc advanced functions - 16.9 A B C
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plc advanced functions - 16.11 Main
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plc advanced functions - 16.13 A B
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plc advanced functions - 16.15 Main
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plc advanced functions - 16.17 A X
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plc advanced functions - 16.19 e.g.
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plc advanced functions - 16.21 S:FS
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plc advanced functions - 16.23 STA
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plc advanced functions - 16.25 16.6
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plc advanced functions - 16.27 4. W
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plc advanced functions - 16.29 b[0]
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plc advanced functions - 16.31 3. a
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plc advanced functions - 16.33 S3 S
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plc advanced functions - 16.35 10.
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plc advanced functions - 16.37 16.1
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plc iec61131 - 17.1 17. OPEN CONTRO
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plc iec61131 - 17.3 Name Type Bits
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plc iec61131 - 17.5 technique.) i)
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plc il - 18.2 I:000/00 I:000/01 O:0
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plc il - 18.4 Operator Modifiers Da
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plc il - 18.6 mally using the MPS,
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plc il - 18.8 value. I:001/0 TON Ti
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plc il - 18.10 • The Allen Bradle
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plc st - 19.2 PROGRAM main VAR i :
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plc st - 19.4 When defining variabl
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plc st - 19.6 Character strings def
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plc st - 19.8 AND(A,B) OR(A,B) XOR(
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plc st - 19.10 The example in Figur
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plc st - 19.12 Function ABS(A); ACO
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plc st - 19.14 .... D := TEST(1.3,
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plc st - 19.16 19.4 SUMMARY • Str
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plc sfc - 20.1 20. SEQUENTIAL FUNCT
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plc sfc - 20.3 selection branch - a
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plc sfc - 20.5 press will then retr
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plc sfc - 20.7 first scan INITIALIZ
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plc sfc - 20.9 transition 5 top lim
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plc sfc - 20.11 step 6 U step 6 L t
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plc sfc - 20.13 Program 3 (for step
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plc sfc - 20.15 ST2 TR8 ST2 TR13 FS
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plc sfc - 20.17 20.4 PRACTICE PROBL
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plc sfc - 20.19 2. Start EW crosswa
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plc sfc - 20.21 4. step 1 step 2 T1
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plc sfc - 20.23 T1 remote L step 3
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plc sfc - 20.25 step 1 step 2 step
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plc fb - 21.2 A FBD program is cons
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plc fb - 21.4 Figure 21.6 shows a d
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plc analog - 22.1 22. ANALOG INPUTS
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plc analog - 22.3 A more realistic
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plc analog - 22.5 R = 2 N = R max -
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plc analog - 22.7 Figure 22.6 Low S
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plc analog - 22.9 ASIDE: This devic
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plc analog - 22.11 (Note: each type
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plc analog - 22.13 important if the
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plc analog - 22.15 Given, N = 8, R
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plc analog - 22.17 tion will change
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plc analog - 22.19 A t V eff = A A
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plc analog - 22.21 flow. The resist
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plc analog - 22.23 • Analog shiel
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plc analog - 22.25 5. A card with a
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plc analog - 22.27 7. A SIN Source
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plc analog - 22.29 22.8 ASSIGNMENT
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continuous sensors - 23.2 terized w
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continuous sensors - 23.4 θ max θ
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continuous sensors - 23.6 sensors r
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continuous sensors - 23.8 Normally
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continuous sensors - 23.10 A rod dr
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continuous sensors - 23.12 on off o
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continuous sensors - 23.14 Sealant
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continuous sensors - 23.16 After th
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continuous sensors - 23.18 stress d
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continuous sensors - 23.20 23.2.5 L
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continuous sensors - 23.22 These se
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continuous sensors - 23.24 result i
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continuous sensors - 23.26 very hig
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continuous sensors - 23.28 mV 80 E
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continuous sensors - 23.30 Thermist
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continuous sensors - 23.32 23.2.9 O
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continuous sensors - 23.34 The circ
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continuous sensors - 23.36 put is p
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continuous sensors - 23.38 ratio. I
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continuous sensors - 23.40 10. enco
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continuous actuators - 24.1 24. CON
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continuous actuators - 24.3 command
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continuous actuators - 24.5 wear, w
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continuous actuators - 24.7 ASIDE:
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continuous actuators - 24.9 L2 L1 L
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continuous actuators - 24.11 torque
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continuous actuators - 24.13 • Si
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continuous actuators - 24.15 runnin
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continuous actuators - 24.21 cally
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continuous actuators - 24.23 e f =
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continuous actuators - 24.25 24.5 S
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continuous actuators - 24.27 a) (an
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plc pid - 25.2 valve a) Water Tank
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plc pid - 25.4 to a process, and tu
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plc pid - 25.6 θ neural desired +
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plc pid - 25.8 next two sections de
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plc pid - 25.10 Figure 25.10 A Comb
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plc pid - 25.12 25.3.4 PID Control
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plc pid - 25.14 PID Control Block:
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plc pid - 25.16 S2:1/15 - first sca
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plc pid - 25.18 SOLUTION Analog Inp
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plc pid - 25.20 BT9:0/DN BT9:2/EN B
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plc pid - 25.22 25.7 PRACTICE PROBL
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plc pid - 25.24 7. S2:1/15 - first
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plc pid - 25.26 25.8 ASSIGNMENT PRO
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plc fuzzy - 26.1 26. FUZZY LOGIC T
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plc fuzzy - 26.3 1. If (bucket is f
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plc fuzzy - 26.5 1. If v error is L
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plc fuzzy - 26.7 final motor contro
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plc fuzzy - 26.9 response will be s
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plc serial - 27.2 An example of a n
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plc serial - 27.4 A typical data by
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plc serial - 27.6 Modem Computer co
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plc serial - 27.8 RI - (ring indica
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plc serial - 27.10 ABL(channel, con
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plc serial - 27.12 ACI String ST9:1
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plc serial - 27.14 on many new inst
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plc serial - 27.16 5. Write a progr
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plc serial - 27.18 5. MOV Source F8
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plc network - 28.1 28. NETWORKING
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plc network - 28.3 ... R Repeater R
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plc network - 28.5 that syntax, for
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plc network - 28.7 28.1.4 Control N
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plc network - 28.9 • Data packet
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plc network - 28.11 MG9:0/EN MSG Se
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plc network - 28.13 1 bit 11 bits 1
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plc network - 28.15 46 to 1500 byte
Page 667 and 668: plc network - 28.17 1 byte 1 byte D
Page 669 and 670: plc network - 28.19 CMD 00 01 02 05
Page 671 and 672: plc network - 28.21 Table 1: Networ
Page 673 and 674: plc network - 28.23 Figure 28.17 A
Page 675 and 676: plc network - 28.25 2. MG9:0/EN MG9
Page 677 and 678: plc network - 28.27 b) MG9:0/EN MSG
Page 679 and 680: plc network - 28.29 to advance a he
Page 681 and 682: plc internet - 29.2 Aside: Open a D
Page 683 and 684: plc internet - 29.4 SMTP (Simple Ma
Page 685 and 686: plc internet - 29.6 Aside: While lo
Page 687 and 688: plc internet - 29.8 • A client do
Page 689 and 690: plc internet - 29.10 Windows machin
Page 691 and 692: plc hmi - 30.1 30. HUMAN MACHINE IN
Page 693 and 694: plc hmi - 30.3 1. Who needs what in
Page 695 and 696: plc electrical - 31.1 31. ELECTRICA
Page 697 and 698: plc electrical - 31.3 terminals pow
Page 699 and 700: plc electrical - 31.5 L1 L2 L3 star
Page 701 and 702: plc electrical - 31.7 L1 L2 L3 M M
Page 703 and 704: plc electrical - 31.9 31.2.2 Ground
Page 705 and 706: plc electrical - 31.11 Note: Always
Page 707 and 708: plc electrical - 31.13 31.2.4 Suppr
Page 709 and 710: plc electrical - 31.15 Dirt - Dust
Page 711 and 712: plc electrical - 31.17 more sensiti
Page 713 and 714: plc electrical - 31.19 • Use NO b
Page 715 and 716: plc electrical - 31.21 4. Why are n
Page 717: plc software - 32.2 Sabotage - For
Page 721 and 722: plc software - 32.6 Table 1: ANSI/I
Page 723 and 724: plc software - 32.8 orifice plate m
Page 725 and 726: plc software - 32.10 Each block in
Page 727 and 728: plc software - 32.12 2. A basic mod
Page 729 and 730: plc software - 32.14 Project Notes
Page 731 and 732: plc software - 32.16 Application No
Page 733 and 734: plc software - 32.18 Internal Locat
Page 735 and 736: plc software - 32.20 These design s
Page 737 and 738: plc software - 32.22 ures to the to
Page 739 and 740: plc software - 32.24 2. When should
Page 741 and 742: plc selection - 33.2 • Determine
Page 743 and 744: plc selection - 33.4 PLC MEMORY TIM
Page 745 and 746: plc selection - 33.6 Typical values
Page 747 and 748: plc selection - 33.8 ized programmi
Page 749 and 750: plc selection - 33.10 33.4 PRACTICE
Page 751 and 752: plc function ref - 34.2 IIN, IOT -
Page 753 and 754: plc function ref - 34.4 MCR - Maste
Page 755 and 756: plc function ref - 34.6 CTD - CounT
Page 757 and 758: plc function ref - 34.8 TOF - Timer
Page 759 and 760: plc function ref - 34.10 RTO - Rete
Page 761 and 762: plc function ref - 34.12 FBC, DDT -
Page 763 and 764: plc function ref - 34.14 34.1.5 Cal
Page 765 and 766: plc function ref - 34.16 AVE, STD -
Page 767 and 768: plc function ref - 34.18 FRD, TOD,
Page 769 and 770:
plc function ref - 34.20 34.1.6 Log
Page 771 and 772:
plc function ref - 34.22 MVM - MoVe
Page 773 and 774:
plc function ref - 34.24 FAL - File
Page 775 and 776:
plc function ref - 34.26 FSC - File
Page 777 and 778:
plc function ref - 34.28 FFL, FFU,
Page 779 and 780:
plc function ref - 34.30 SQO - SeQu
Page 781 and 782:
plc function ref - 34.32 JSR/SBR/RE
Page 783 and 784:
plc function ref - 34.34 34.1.11 Ad
Page 785 and 786:
plc function ref - 34.36 PID - Prop
Page 787 and 788:
plc function ref - 34.38 ACI, AIC -
Page 789 and 790:
plc function ref - 34.40 ARD, ARL -
Page 791 and 792:
plc function ref - 34.42 AWT, AWA -
Page 793 and 794:
plc function ref - 34.44 Table 1: I
Page 795 and 796:
Page 797 and 798:
Page 799 and 800:
plc glossary - 35.2 analysis - the
Page 801 and 802:
plc glossary - 35.4 decimal(base 10
Page 803 and 804:
plc glossary - 35.6 CAD (Computer A
Page 805 and 806:
plc glossary - 35.8 intermittent no
Page 807 and 808:
plc glossary - 35.10 geometric dime
Page 809 and 810:
plc glossary - 35.12 EPROM (Erasabl
Page 811 and 812:
plc glossary - 35.14 ground - a bur
Page 813 and 814:
plc glossary - 35.16 IOR (Inclusive
Page 815 and 816:
plc glossary - 35.18 pneumatic syst
Page 817 and 818:
plc glossary - 35.20 nonpositive di
Page 819 and 820:
plc glossary - 35.22 photon - a sin
Page 821 and 822:
plc glossary - 35.24 after a US fed
Page 823 and 824:
plc glossary - 35.26 manufacturabil
Page 825 and 826:
plc glossary - 35.28 time-proportio
Page 827 and 828:
plc glossary - 35.30 it assumes the
Page 829 and 830:
plc references - 36.2 USA. Telemech
Page 831 and 832:
plc references - 36.4 Second Editio
Page 833 and 834:
gfdl - 37.1 37. GNU Free Documentat
Page 835 and 836:
gfdl - 37.3 cially, provided that t
Page 837 and 838:
gfdl - 37.5 Sections in the Modifie
Page 839:
gfdl - 37.7 tion License from time
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