Plasser & Theurer Control Systems

Hydraulic & manually

Relays & mechanical conductors

Programmer P500, P600

P700

P-IC2.0

1959 2013

December 2016 Service 2

P-IC2.0
 Introduction
PLC System :- Programmable Logic
Controller
in German it is called SPS System.
(Speicher Progammierbare Steuerung SPS)
Plasser PLCs- P-500,P-600,P-700.
PIC2.0
Developed by- Plasser & Theurer

It is used to control- Hydraulic , Pneumatic Valves,

December 2016 Service
Hydraulic & Pneumatic Actuators. 3
 Main functions of a Programmer unit/Programmable Logic
Control(PLC) are:-
This unit controls functions of machines.
It ensure proper method of working.
It ensure precision output.
It does not permit any wrong operation to ensure safety
during working.
 It helps to detect fault in machine.
 It saves valuable time to detect & remove faults.
 Programmer Unit
This unit consists of Programmer PCB
which has Processor &
Memory(EPROM/EEPROM). Program of
machine is stored in memory This PCB
receives inputs X(yellow LED),when
inputs are same as in Program then
output commands Q(Red LED) are
generated to allow the functions.
 Parts of a Programmer Unit:-

Programmer unit

Programmer PCB Input/output PCB Time delay PCB Load relay PCB
PARTS OF PROGRAMMER PCB
Programmer
PCB

P-500 (Old Machines) P-600 (New Machines)

Processor MC14500 + Processor MC 14500 or

EPROM Xilinx PLD + EEPROM
 Hardware of Programmer unit

I/O Signal
Subroutine Board
Timer Board
Board(PCB)
Power Output Board

December 2016 Service 8

 Input output PCB EK553P/EK653P
• EK553P/EK653P PCB is input-
Otput PCB. This PCB indicates
Inputs & Outputs of Processor.
• Through this PCB we communicate
with Programmer PCB in
Hexadecimal Codes(0 to F).
• I/0 PCB has 16 yellow LEDs with
X mark which indicates input to
Processor and red 16 Red LEDs
with Q mark which indicates output
from Processor.
 I/O Board :- Input/Output PCB d b z
This PCB consists of 16 inputs (0 - F),
denoted by X indicated by Yellow
LEDs Input signals receive through opto-
couplers through “d” pins of 48 pin
connector
This PCB also
of PCBs
consists of 16 outputs (0
- F) denoted by Q indicated by Red
LEDs
output signals are latched at output-ICs
Transfer over transistor arrays to output
pins “z” of pin connector of PCB.
All connections are On the rear side on 48 pin
connector .The Pins are designated in even
nos.
December 2016 Service 10
 I/O Board
• When any input goes to Processor
X Q
from switch, pedal switch ,
relay ,sensor,limit switch, transistor O
O
O
O
0
1

through I/O PCB then concerning O

O
O
O
2
3
O O 4
yellow LED [Link] O
O
O
O
5
6
output comes from Processor then O
O
O
O
7
8
red LED glows. O
O
O
O A
9

• Syntax of Inputs & outputs:- X13, O

O
O
O
B
C

X21, or X112, X123, Q10, Q19 etc. O

O
O
O
D
E
O O F
 Syntax of Input & output

X12 X3E Q5D

 QL PCB EK554P

• The outputs of I/0 PCB EK553P are

only capable to operate small loads i.e.
transistors, LEDs. EK553P can not
operate solenoids [Link] operate
solenoid load relays(QL relay) are used
which are provided on PCBs. These
PCBs are called QL PCBs EK554P.
Output of EK553P operates QL relay
in EK554P and QL relay operates
solenoids .
Power Output Board

December 2016 Service 14

Syntax of Input & output
 Syntax of Input & output

1 X 1 1
Location Input PCB 1 st Yellow
10U6 13
Chasis 1st position LED Re6

2 X 1 9 10 U 6

Panel Input 1st position 9th Yellow Panel No PCB 6th slot in Panel No B10
No B2 PCB LED B10
Re6 ---- 6th relay in PCB
 Syntax of Input & output

Q 1 1 Q 0 1
Output PCB 1st Red
1st position LED Subroutine PCB 1st Red LED
Output 0 position

Q 1 9
output 1st position 9th Red LED
PCB
 Subroutine Board
Subroutine :-
Subroutine programs are those programs which
are shared by more than one programs or utilized
more than one time or repeatedly in main
programs.
In tamping machines tamping cycle is main
cycle(Main Program) in which other functions like
lining, lifting, squeezing, forward movement of
machine/satelite, movement of hooks occurs in
cyclic manner which are called Subroutines.

December 2016 Service 20

Syntax of Input & output
P-500 Subroutine
Regular I/O boards (EK553P) are used for subroutine
boards .
Nominated subroutine boards use the same place as a
regular I/O board i.e. in CSM position 0 , 6 , 9 etc are
utilized for subroutine PCBs .
16 Inputs , X (0 to F) combined with 16 Outputs , Q ( 0
to F ) , X & Q work In pair. ( Total 16 , Q X Ckts )
Subroutine Active  both X-LED and Q-LED are ON (Q
X)
Connecting a jumper between pin connector `z´ and
pin connector `d´
of the I/O PCB EK553P. 0
December 2016 Service 22
P-600 Subroutine
 A special developed subroutine board includes 2x16
subroutines
 Connection - jumpers Q to X are made internally
(row `d´ and row `z´ of the pin connector is not
 connected)
Both LED rows have the same colour

 Board `0/1´ 
subroutines of board `0´ (LEDs row on the left side)

subroutines of board `1 (LED row on the right side)

 A double subroutine board uses the same space as a
P500 subroutine board

December 2016 Service 23

TIME DELAY PCB (Q/Q’ PCB)
 Time Delay PCB EK552P
• In the machine in different functions
(tamping cycle) certain time delay are
required which are provided by time delay
PCB EK552P .
• time delay outputs are denoted by Q1 .
• This PCB has Eight yellow LEDs & red
LEDs.
• When time starts yellow LED glows,
and when time is over then red LED
[Link] PCB consists of
potentiometers by which time can be
adjusted .
•
 Timer Board

December 2016 Service 26

TIME DELAY PCB
Time setting
potentiometers
 X Q X Q X Q X Q 1 0
0 0 0 0 0
1 1 1 1 1
2 2 2 2 2 QL20 : Logic connection
3 3 3 3 3 = 19 Λ 53
4 4 4 4 4
5 5 5 5 5
6 6 6 6 6 1S75 v 19 Λ 52 Λ
7 7 7 7 7 A 58 Λ 0B
8 8 8 8 8
9 9 9 9 9
A A A A A
B B B B B
C C C C C
D D D D D
E E E E E
F F F F F

0 1 2 5 Solenoi
QL2
d1S
A
Directio
nal 75
Valve

Q20,Ql20
Q20,Ql20

OF OF
O
F O F
N
N

Switch …. Push button, illuminated Switch ＯＮ Inductive limit 28

December 2016
ON Service = active switch X58 28
 INTINTERFACING DIAGRAM of Programmer UnitDIAGRAM
Programmer
Switches I/O PCB X PCB

Programmer Functional PCBs

I/O PCB Q (Lining,lifting,Tamping , Solenoids
PCB Actuators
Driving) Servo/Prop/DC
Valves Cyl/Motors
QL Relay PCB
 INTERFACING DIAGRAM FOR Q & QL

Output from I/O PCB QL Relay PCB HYD./Pne Solenoids

FLOW OF SIGNAL THROUGH Q/Q’ PCB

Output from I/O

Q
Time Delay 0.2-
Q’ Functional
PCB 3.5 SEC.
PCBs/
QLrelays
•
LOGIC CHART
LOGIC CHART consists of Program of Every machine, which is saved in Memory
(EPROM/EEPROM) of programmer, in tabular form indicating inputs and outputs .
• It shows all source of inputs(X) like manual switches, Pedal switch, limit switches,
Proximity switches , Pressure switches, Relays, Transistors in machine.
• It shows all different types of outputs like main outputs(Q) , subroutine outputs(Q/S),
time delay outputs(Q’), Load outputs(QL) .
• It explains the systematic flow chart of any function.
• Without it we cannot detect failures in PLC.
• Enable to detect the electric faults easily & quickly.
• Enables us to make a correlation among Ele/hyd and pneu circuits.
• In new machines Plasser has provided computerised logic chart(Software of Logic
chart), this chart has reduced the failure time considerably it is called SPS Diagnosis.
LOGIC CHART
NOTATIONS IN A LOGIC CHART :- LOGIC Chart is based on three Logical
operations, AND(^), OR(v), NOT(-) .
S.N. Notation Pronunciation Meaning
1. X X
Input

2. Q Q
Output

3. Q’ Q dash
Delayed Output

4 S S Subroutine(P600)

5. QL QL
Load Output

6. ^ AND
Mandatory function

7. v OR
Optional function
 Logic diagram

Examples

Input signal: X4F0: Board group 4

Board F
Single address 0

Output signal: Q23A: Board group 2

Board 3
Single address A

Switch/connection description: 2X19C:

Box 2
Board group 1
Board 9
Single address C
December 2016 Service 35
 Logic Conditions (45 v 46) Λ 5F Λ 4D Λ 16 Λ
5D
V

December 2016 Service 36

 Diagnose-Input signal

December 2016 Service 37

 Diagnose-Output signal

December 2016 Service 38

 Diagnose- Power output signal

December 2016 Service 39

 Logic Conditions (45 v 46) Λ 5F Λ 4D Λ 16 Λ
5D
V

December 2016 Service 40

 Diagnostic Function description

Power output
- Board 6,
- Address 3
Solenoid

Destination
1 = external
S = Solenoid
142 = Valve number
B = Valve function
- Find in Hy-diagram

December 2016 Service 41

 Logic diagram

 45  Main switch track

 
  or
 46  Main switch Switch
 
 and
5F rh. Inside tamping unit move to
inside
 and
4D NOT move tamping unit in track
mode
 and
Work STOP
16 work ON Pneumatic ON
 and
5D Release Signal from AKA

December 2016 Service 42

COMMON FAILURES IN PROGRAMMER
UNIT
 Multicheck unit

• With the help of this unit

we can check :-
• Outputs of Transducers,
Input Potentiometers
and PCBs .
• Power supply PCBs .
• Currents of Proportional
Valve & Servo Valve .
MULTICHECK SYSTEM
MULTIPLEXING OF SIGNALS
 TWO DIGIT ADDRESS SYSTEM

Let address is F ‘XY’

‘X’ shows selection of Red ‘Y’ shows selection of Blue

switch. Value of ‘Y’ may be switch. Value of ‘Y’ may be
0/1/2. 0 to F
MULTIPLEX PCB EK-28V
DIFFERENT SECTIONS OF MULTICHECK

Parts of Multicheck System

I/O PCB Warning Circuit Locking Circuit Ammeter Voltmeter

CURRENT MEASUREMENT SYSTEM
Ammeter System

Proportional
Control

Tamping Satellite
Servo Control Unit Control

Servo Valve Servo Valve Servo Valve Driving

LHS Lift. RHS Lift. Lining Pump Ctrl.
 THREE DIGIT ADDRESS SYSTEM

Let address is F ‘XYZ’

‘Z’ shows selection of

‘X’ shows selection of PCB. ‘Y’ shows selection of Red Blue switch. Value of ‘Z’
Value of ‘X’ may be 0/1 it is switch. Value of ‘Y’ may be
selected by a toggle switch may be 0 to F
0/1/2.
 Thanks

Any Question Please