Introduction

 PLCs are generally mounted within a machine or in a separate

enclosure as away of protecting them against extreme
temperatures, humidity, dust shock, vibration, and corrosive

PLC Installation environments.

 The National Electrical Manufactures Association (NEMA) has

defined enclosure types based on the degree of protection an
enclosure will provide.

 NEMA 12 enclosure is recommended for PLCs

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Introduction…
 Metal enclosures are used since they provide shielding that helps
minimize the effects of electromagnetic radiation that may be
generated by surrounding equipment
 The heat that accumulates in the enclosure must be dissipated into
the surrounding air
 The temperature inside the enclosure must not exceed the
maximum operating temperature of the controller, 60℃ maximum
Introduction…
 PLCs are always mounted horizontally with the name of the
manufacturer facing out and right side up
 Proper spacing of components in a manner that provides adequate
room within the enclosure may be sufficient for heat dissipation
 Additional cooling provisions may be required where high internal
or ambient temperatures are encountered

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 Wiring Wiring…
 How do we connect the PLC to the system being controlled?  Wiring a device to the PLC involves:

 Wiring involves connection of such devices as:  Proper provision of power to the devices

 limit switches  Sizing of wiring to ensure current carrying capacity

 proximity sensors  Routing of wiring for safety and to minimize interference

 photoelectric detectors  Ensuring that all connections are made properly and to the

 external high current contactors correct terminals

 motor starters  Providing adequate fusing to protect the system

 lights etc.

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Wiring… Wiring…
 The following are some general guidelines for PLC wire routing:  Low level signal conductors such as thermocouples and serial

 Use the shortest possible wire runs for I/O signals communication should be run as shielded twisted pair and routed

 When possible, conductors that are run from the PLC enclosure to separately

another location should be in a metal conduit as the metal can serve  A fiber optic system, which is totally immune to all kinds of

as a shield against EMI electrical interference, can also be used for signal wiring

 Never run signal wiring and power wiring in the same conduit

 Segregate I/O wiring by signal type. Route ac and dc I/O signal

wires in separate wire ways

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 PLC Power Connection PLC Power Connection…
 The power requirement for the PLC being used will vary  Power connection to the ac units is not so critical
depending on the model selected  Proper fuses must be inserted in the power line connections to
 PLCs operate on a wide range of power, 24v, 110v, 120v, 240v etc. protect both the PLC and the power wiring from overcurrent either

 Some manufacturers produce units that will operate on any voltage from accidental shorts or equipment failure causes

without any modifications to the unit  The installation manual for the PLC being used will provide fusing

 Connection of power to the dc type units require that careful information for that unit

attention be paid to ensuring that (+) and (-) power wire are
correctly connected. Failure to do so can result in serious damage
to the PLC
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Input Wiring Input Wiring…

 Inputs to modern PLCs are generally opto-isolators. An opto-
isolator is a device consisting of a light producing element such as
an LED and a light sensing element such as a phototransistor.
When a voltage is applied to the LED, light is produced which
strikes the photodetector
 Some manufaturers produce PLCs with ac/dc inputs. When using
these PLCs, the polarity of the input, if it is dc, does not matter
because one of the LEDs will light no matter which polarity
voltage is applied
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 PLC inputs are configured in one of two ways:
 All inputs are isolated from each other, that is, there is no
common connection between any two inputs
 One side of each input is connected to one common terminal
 The power supply for inputs may be either external or internal to
the PLC
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 Output Wiring
 Output units are available with a common terminal and isolated
from each other
 The type of output unit selected will depend upon the outputs being
controlled and the power available for controlling those devices
Commissioning
 Commissioning: preparing a control process for start-up
 Involves a series of tests to ensure that the PLC, ladder logic
program, the I/O devices, and all associated wiring operate
according to specifications

 Typically, power for driving output devices must be separately  Before commissioning any control system, you should have a good
provided since there can be a wide range of requirements understanding of how the control system operates and how various
depending upon the device components interact

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Commissioning… Commissioning…
 The following are general steps to be followed when c) Examine the PLC’s indicator lights. If power is properly applied,
commissioning a PLC system: the power indicator should be on and there should be no fault

a) Before applying power to the PLC or the input devices, indication. If the PLC does not power up properly, it may be

disconnect or otherwise isolate any output device that could faulty. PLCs rarely fail, but if they do fail, it usually happens

potentially cause damage or injury. Typically, this precaution will immediately upon powering up.

pertain to outputs that cause movement such as starting a motor or d) Verify that you have communication with the PLC via the
operating a valve programming device that is running the PLC programming

b) Apply power to the PLC and input devices. Measure the voltage siftware

to verify that rated voltage is being applied

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 Commissioning…
e) Place the PLC in a mode that prevents it from energizing its
output circuits. Depending on the mode of the PLC, this mode
may be called disable, continuous test, or single-scan mode. This
mode will allow you to monitor input devices, execute the
program, and update the output image file while keeping the
output circuits de-energized
Commissioning…
f) Manually activate each input device, one at a time, to verify that
the PLC’s input status lights turn on and off as expected. Monitor
the associated condition instruction to verify that the input device
corresponds to the correct program address and that the
instruction turns true or false as expected
g) Manually test each output. One way of doing this is by applying
power to the terminal where the output device is wired. This test
will check the output field device and its associated wirirng

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Commissioning…
h) After verifying all inputs, the outputs and program addresses,
verify all preset values for counters, timers etc.

i) Reconnect any output devices that may have been disconnected

and place the PLC in the run mode.
END
j) Test the operation of all emergency stop buttons and total system
operation

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