Page 1 ISA Lunch and Learn Ken Carfagno November 6, 2013 Agenda • Theory & Practice - Basic control (e.g., regulatory control, feedback, etc) - Discrete control (e.g., relay logic, Boolean algebra) - Sequential control (e g batch) Sequential control (e.g., batch) - Typical Configuration and Programming - Input/output termination and wiring • Implementation - HMI (e.g., graphics, alarm management, trending, historical data) 2 HONEYWELL - CONFIDENTIAL File Number - Network security
Transcript
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ISALunch and Learn
Ken CarfagnoNovember 6, 2013
Agenda
• Theory & Practice- Basic control (e.g., regulatory control, feedback, etc)- Discrete control (e.g., relay logic, Boolean algebra) - Sequential control (e g batch)Sequential control (e.g., batch)- Typical Configuration and Programming- Input/output termination and wiring
Since I am using relays and pushbuttons to do my remote control, I need an electrical diagram to use as my guide for connecting all of the electrical wires so I create the following pushbutton / relay wiring schematic diagram.
R1
R1
120 VAC
H NPB-1
PB-2 (Start)(Stop)(Open Valve)
R2
ZSO-2 R1
(Run Pump)(Valve Opened)
R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
ClosedStopped
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R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
R1 seals in PB 2 so that when I remove my finger from the button R1 stays energized
OpenStopped
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- R1 seals in PB-2 so that when I remove my finger from the button, R1 stays energized.
- A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.
R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
R1 seals in PB 2 so that when I remove my finger from the button R1 stays energized
OpenStart
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- R1 seals in PB-2 so that when I remove my finger from the button, R1 stays energized.
- A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.
- Valve open contact ZSO-2 is wired from the valve (the contact is closed when the valve is fully open). A closed ZSO-2 contact along with the closed R1 contact energizes relay R2.
- A contact from R2 relay is wired to the pump. A closed R2 contact starts the pump.
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R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
OpenStart
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- Press normally closed PB-1 and relay R1 is de-energized.
R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
Press normally closed PB 1 and relay R1 is de energized
ClosedStopped
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- Press normally closed PB-1 and relay R1 is de-energized.
- When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve.
- Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.
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R1
120 VAC
H NPB-1
PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
P ll l d PB 1 d l R1 i d i d
ClosedStopped
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- Press normally closed PB-1 and relay R1 is de-energized.
- When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve.
- Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.
- We are back at the beginning of our sequence when I remove my finger from PB-1.
R1
120 VAC
H NPB-1
PB-2 R1 Contact
120 VAC
Here is how we would wire our control circuit.
Typical Connection and Wiring
R2
R1
R1
R2 Contact
120 VAC
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ZSO-2
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Control Via PLC, Ladder Logic
Here is how we would wire our devices to the PLC I/O.
DI DO
DI 1
DI 2
DI 3
DO 1
DO 2
DO 3
PB-1
PB-2
ZSO 2
Pump
Valve
PB-1 Stop
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
ZSO-2
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ZSO-2
PB-2 Start
R1
R1
120 VAC
H NPB-1
PB-2DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1
PB-2
ZSO-2
PumpValve
R2
R1DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
ZSO-2 R1
We take all of our wiring information and I/O module information create this program
This is what our PLC programming language looks like.
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( )
( )
1
DO
2
DO
1
DI
3
2
DO
1
1information create this program.
Notice the relationship between our I/O point numbers and the programming.
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R1
R1
120 VAC
H NPB-1
PB-2DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1
PB-2
ZSO-2
Pump
Valve
R2
R1DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
ZSO-2 R1
Also take note that my DI-1 logic contact is normally open. This is because it will be held close by PB-1 when the PLC power is on.
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( )
( )
1
DO
2
DO
1
DI
3
2
DO
1
1
DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1
PB-2
ZSO-2
Pump
Valve
R1
R1
120 VAC
H NPB-1
PB-2
DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
R2
R1
ZSO-2 R1
The programming is done on a laptop PC.
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( )
( )
1
DO
2
DO
1
DI
3
2
DO
1
1
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Control via DCS, Function Blocks
R1
R1
120 VACH N
PB-1PB-2
R2
ZSO-2 R1
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Sequential Control
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Sequential Control
• Time ordered control• Series of step to meet control objective
- Examples: Equipment Startup or shutdown Equipment Startup or shutdownNon-continuous (batch) process
• Sequential Control follows a common pattern- Take action which will cause a change in the process- Wait for the desired change to complete- Repeat
