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THE
MODERN
PLC
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TABLE OF CONTENTS
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he general health of the programmable logic controller (PLC) market is a thing to behold.
According to Frost & Sullivan, the global PLC market has witnessed growth across all regions. The
market, which experienced a strong decline in the early part of the decade, has bounced back
strongly and is expected to reach $14.58 billion in 2018, up more than 40% from five years earlier. This
growth includes the mature markets of North America and Europe, where uncertainty about economic
standing had precipitated an earlier decline. Of particular interest, Frost & Sullivan note, the small and medium PLC segments will be instrumental for market development.
Those segments are the domain of traditional PLCs.
Much has been made in recent years about the looming demise of PLCs. Critics predicted that PLCs would
be rendered obsolete with the advent of process automation controllers (PACs) and more advanced computer-based controls. But the market says otherwise.
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nance personnel.
with maintenance personnel or automation technicians, that is oriented to using ladder logic, says
to switching out PLCs. Its really an issue of education, and also a generational one, notes Elston.
want to push the end of the PLC idea; but its not
nel will even put PLCs back after they are switched
out. Theyve been doing that for years because the
current situation to
understand.
APPLICATION
BREADTH
instead of industrial
I/O points)
computers. So when
things collapsed, they
pointed the finger at soft
PLCs and went back to legacy PLCs, he says. Even
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the sector.
COST CONSIDERATIONS
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EVOLUTION
pared to more complicated solutions, it was a magnitude less expensive. They do the job. Theres no
pages that can be configured for remote monitoring and control. These web pages are stored in the
Fitchett.
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new technology because there are stringent mandated regulations to meet. At that point, PACs or
such integration.
continues to offer the power, flexibility, dependability and ease of use machine builders and end
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Combining control
and operator interface
Although relatively new on the scene, combo units have seen significant
adoption by machine builders.
By Dan Hebert
A combo controller and operator interface can save big compared to separates.
As the miniaturization of electronics continues its relentless march across the personal-consumer-device
landscape, its only natural for it to proceed apace in machine and robot automation systems. One consequence is the combination of what were once separate components into a single housing, as with a machine
controller and an operator interface device.
Although relatively new on the scene, these combo units have seen significant adoption by machine builders
because they are less expensive than separates, require no wiring or integration between the controller and
the operator interface, and take up less panel space.
For many applications, these benefits more than negate disadvantages, which include a single point of
failure for both control and operator interface and a lack of the highest-end functionality, particularly
for basic units.
These combo units come in two main flavors. The first combines a PLC with an operator interface terminal (OIT) to create a unit designed for basic machines. The second marries a PC-based controller to a
full-featured HMI, creating a unit capable of providing control and operator interface for the most complex machines.
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PC+HMI units.
end applications.
monitor alone.
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5 must-have controller
programming features
Machine builders want ease-of-use, support for multiple programming languages, ability to
reuse code, global acceptance and the ability to accommodate motion and robotic control
along with traditional PLC functions.
By Dan Hebert
hat are the most important programming software features? When I posed this question to
suppliers, I received the following answers: ease-of-use, automatic connection to the controller, one programming package for an entire family of controllers, ability to reuse code, and
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tandards are important. But often only a portion of a standard is widely used. The IEC 61131 Open
Programmable Logic Controller standardis an example of that. Although the IEC 61131 standard has
four programming languages and a structural component and defines data well, just sticking with
ladder diagram, the de facto standard for PLCs and PACs in discrete manufacturing and process skid applications, will save you money and keep you efficient in the future.
Although personal preference plays a role, using just ladder diagram programming for machine sequence
control keeps things simple for an integrators controls department and the customers support and maintenance department, and thats what most machine builders want. The quicker the customer can support the
equipment, the better. Sticking with ladder diagram helps, as the majority of programmers have little need
or awareness of the IEC 61131 specification even though it has been around for more than 20 years.
Although theIEC 61131 standardis useful and has its place in more complex applications, most programmers
do not save time or money by using multiple programming languages. Ladder diagram and maybe some
function block programming is all that is needed. Mixing several different languages in a single program is
less efficient from a programming and support standpoint.
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There are too many bits and pieces. Just reset a se-
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these techniques.
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DEC Corporations MicroSmart FC6A, released in the United States in March, is a powerful PLC with up to
520 I/O. IDEC says the MicroSmart PLC provides the power of a PAC in a low-cost controller with a small
form factor, making it an ideal fit for demanding applications in industries such as oil & gas, chemical, solar,
marine, packaging, food & beverage, material handling, utility vehicles, and OEM machinery and process skids.
Within these industries, a wide variety of applications are a good fit for the MicroSmart PLCespecially
those requiring control of standalone machines, process skids, vehicles and small-scale systems.
Basic instructions can be executed in 0.042 microseconds, and program memory is 640 kB. There are
1,024 timers, and six of the 512 counters are high-speed at rates up to 100kHz. These capabilities are
combined with extensive data and bit memory, double the capacity of a typical micro PLC. These features
allow the MicroSmart PLC to handle large programs with complex control requirements such as PID, flow
totalization and recipes.
Three MicroSmart PLC models are available, each with 24 Vdc or 100-240 Vac input power. The 16 I/O
model has 9 inputs, and 7 relay or transistor outputs. The 24 I/O model has 14 inputs, and 10 relay or transistor outputs. The 40 I/O model has 24 inputs, and 16 relay or transistor outputs. Each model also includes an
integral 0-10 Vdc analog input. The 16 and 24 I/O models can accommodate one plug-in analog cartridge,
and the 40 I/O model can accommodate two plug-in analog cartridges. Each cartridge has two analog I/O
points, either two inputs or two outputs.
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Up to 12 expansion modules can be added to the 16 I/O model, and up to 15 expansion modules can be added to the
24 and 40 I/O models.
Up to 12 expansion modules can be added to the 16
an RJ45 RS232C/RS485 serial port. A plug-in cartridge adds an additional RS232C/RS485 port. An
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http://us.idec.com/CMSContent/FC6A/index.html
States, IDEC has more than 30 local sales offices to assist custom-
ers with choosing the right switches, relays, power supplies, PLCs,
www.IDEC.com/usa
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