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PROGRAMMABLELOGIC
CONTROLLER
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Control Systems TypesControl S
ystems Types
Programmable Logic Controllers
Distributed Control System PC- Based Controls
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IntroductionIntroduction
The PLC is an assembly of solid state digital
logic elements design to make logicaldecisions and provide outputs.
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Programmale LogicPro
grammale Logic
ControllersControllers
Seuential logic solver
P!D Calculations. "dvanced Subroutines
B!T #perations.
Data Transfer.
Te$t %andling.
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"pplications & 'achine controls( Packaging( Palleti)ing( 'aterial handling(
similar Seuential task as *ell as Process control
"dvantages of PLC & They are fast and designed for the rugged industrial
environment.
They are attractive on Cost-Per-Point Basis.
These Devices are less Proprietary + ,.g.. sing #pen Bus
!nterface. These Systems are upgraded to add more !ntelligence and
Capabilities *ith dedicated P!D and ,thernet 'odules.
Disadvantages of PLC & PLC *ere Designed for /elay Logic Ladder and have Di0culty
*ith some Smart Devices.
Programmale LogicPro
grammale Logic
ControllersControllers
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PLC Types
2ano +Small
'icro +'edium
Large
Basic criteria for PLC Types
'emory Capacity !3# /ange
Packaging and Cost per Point
Programmale LogicPro
grammale Logic
ControllersControllers
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Central Processing nit +CP
!nput #utput 'odules
Po*er Supply
Bus system
Programming Device
P L C ComponentsP L C Components
CPU
PROGRAM
DEVICE
IN OUT
m
MODULEMODULE
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!t is a micro-controller based circuitary. The CP consists offollo*ing blocks &
"rithmatic Logic nit +"L( Program memory
Process image memory +!nternal memory of CP
!nternal timers and counters
1lags CP performs the task necessary to ful4ll the PLC funtions. These
tasks include Scanning( !3# bus tra0c control( Program e$ecution(Peripheral and ,$ternal device communication( special functionsor data handling e$ecution and self diagnistics.
P L C ! Central ProcessingP L C ! Central Processing
"nit"nit
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These modules act as interface bet*een real-time status ofprocess variable and the CP.
"nalog input module & Typical input to these modules is
5-67 m"( 7-87 9
,$ & Pressure( 1lo*( Level T$( /TD +#hm( Thermocouple +m9 Digital input module & Typical input to these modules is 65 9
DC( 88: 9 "C( 6;7 9 "C
,$. & S*itches( Pushbuttons( /elays( pump valve on o< status
PLC ! Input modulePLC ! Input module
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867 9 acL8 L6
L6
L8
8
6
;
5
PB
input4elddevice
!nput moduleterminal board
!nput status
indicator
PLC ! Input modulePLC ! Input module
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These modules act as link bet*een the CP and the outputdevices in the 4eld.
"nalog output module & Typical output from these modulesis 5-67 m"( 7-87 9
,$ & Control 9alve( Speed( 9ibration Digital output module & Typical output from these modules is
65 9 DC( 88: 9 "C( 6;7 9 "C
,$. & Solenoid 9alves( lamps( "ctuators( dampers( Pumpvalve on o< control
PLC ! Output modulePLC ! Output module
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120 V acL1 L2
L2
L1
1
2
3
4
Output statusindicator
Output field
device
Module blown
Fuse indicator
Output module
PLC ! Output modulePLC ! Output module
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I#O SPECI$ICATIONI#O SPECI$ICATION
!2PT 9#LT"=, > 'agnitude and type of voltage #2-ST"T, !2PT 9#LT"=, /"2=, > voltage at *hich signal is
recogni)ed 2ominal current per input > 'in. current to operate input circuit "'B!,2T T,'P /"T!2= > 'a$ temp of surrounding the !3#
module !2PT D,L"? > Time duration for input signal to be on before
kno*n as valid input. + @-ms to 6:ms 2#'!2"L #TPT 9#LT"=, > !t is min and ma$ o3p operating
voltage.e.g. /ated 867 v ac o3p ckt. Aorks in @6 to 8; v range.
'" #3P C//,2T /"T!2= > 'a$ current a single o3p or modulecan safely carry under load #11 >ST"T,L," C//,2T P,/ #3P > 'a$ value of leak current
Eo*s through the o3p in #11 position ,L,CT/!C"L !S#L"T!#2 > 'a$ volts bet*een !3o and logic ckt.
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The po*er supply gives the voltage reuired forelectronics module +!3# Logic signals( CP( memory unitand peripheral devices of the PLC from the line supply.
The po*er supply provides isolation necessary toprotect the solid state devices from most high voltageline spikes.
"s !3# is e$panded( some PLC may reuire additionalpo*er supplies in order to maintain proper po*erlevels.
P L C ! Po%er SupplyP L C ! Po%er Supply
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!t is path for the transmission of the signal . Bu
system is responsible for the signal e$changebet*een processor and !3# modules
The bus system comprise of several single line ie*ires 3 tracks
P L C ! Bus SystemP L C ! Bus System
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Relay ConnectionRelay Connection
L2
L1
1
2
3
4
L2
L1
1
2
3
4
C
M
M
C CL
M
M MM
T1 T2 T3
L1 L2 L3
MOTO
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Ad&antage o' PLC O&er RelayAd&antage o' PLC O&er Relay
StyleStyle
/,L"? PLC
8-%ard *iring 8-Less *iring
6-Changes di0cult 6-,asy modi4cation
;-'ore po*er ;-Lo* po*er
5-'ore maintenance 5-Solid state reliability
:-Di0cult to e$pand -,ase of e$pansion
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PLC CyclePLC Cycle
Outputs
Machine
or
Process
Programmable
controller
Inputs
Sense the !nput
Process the Logic
=ive #utput
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PLC Signal $lo%PLC Signal $lo%
Programming Terminal
O!"#$
O!"#$
O!%#&
Output De'ices
Output Mo(ulesProcessor Memor)Input Mo(ule
Input De'ices
La((er Program
O!"#$
O!%#&
I!"#*
I!%#+
O!%#&
I!"#*
I!%#+
I!"#*
I!%#+
Data Input
Image Table
Output
Image Table
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PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
'id - 8@F7s & Discrete 'achine Control
Programming
Terminal
PLC
I#O
Connection is Point to Point
ProgrammingLanguage &
- /elay ladder logic - 1le$ibility in altering
Control systemoperation
Connection is Point to Point
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,arly - to - 'id 8@7 & Discrete and ProcessControl
PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
Reasonable Computer
Running PLC
Programming ,o-t.are
PLC
I#O
Programming Language !
/ La((er Program
/ PID
/ Data ,torage
M, / DO,
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PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
Late 8@7Gs to early 8@@7Gs & Discrete andProcess Control
PC runningPLC Programming ,o-t.are
PLC
I#O
Connection in net.or0e( allo.ing
Multiple PLC
PLC became a part o- the
(e'eloping enterprise resource
s)stem
1in(o.s
PLC
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TodayToday&&Distributed !3# 'odulesDistributed !3# 'odules
Distributed !3# modules
!L
C
Distributed !3# scanner
Data Communication Bus
PLC Arc(itecturePLC Arc(itecture
E&olutionE&olution
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Remote
I/O Network
SPLITTERS
FIBER OPTIC LINK
TAPS
Remote I/O
Today &Today & %ot /edundant System%ot /edundant System
PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
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Controller Controller
Controller
Controller
1or0station 1or0station 1or0station 1or0station
,.itche( 2ub
PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
Today &Today & ,thernet Technology in PLCs,thernet Technology in PLCs
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Remote
Plat-orm
1ireless Mo(em
1ireless Mo(em
PLC
2 M IDispla) PC
PLC Arc(itecture E&olutionPLC Arc(itecture E&olution
Today &Today & Aireless communicationAireless communication
PLC
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PLC Systems o' &arious &endorsPLC Systems o' &arious &endors
Siemens S: -887( 88:( 8;:
SF - 677( ;77( 577
"llen Bradley 'icrologi$ 8777( 8677(
8:77
SLC :378( :376( :37;
PLC :387( :36: and :357
'odicon
2ano 'icro
Premium
Huantum
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8 Analog Inputs Analog Output
!p/"own FastCounter
!p Counter
Programm#ng Term#nal PC Conne$t#on
!n#telwa% Port &or $onne$t#ono& up to ' Sla(es
PC)CIA memor% e*pans#on port
PC)CIA $ommun#$at#ons port
TS+,-.
Bu#lt #n 0#spla% &or I/O1#n.ra$k2 AS.#3 an0 "#ag
I/O )o0ules
Con)guration o' PLC !Con)guration o' PLC !
ModiconModicon
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Con)guration o' PLC !Con)guration o' PLC !
SiemensSiemens
CP!
E*ternal Power
Suppl%
I/O )o0ules
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Con)guration o' PLC ! AllenCon)guration o' PLC ! Allen
BradleyBradley
CP!
Power Suppl%I/O )o0ules
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Con)guration o' PLC ! GE $AN"CCon)guration o' PLC ! GE $AN"C
CP!
I/O )o0ules Ba$k plane
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PLC Programming StandardsPLC Programming Standards
The open( manufacturer-independent programmingstandard for automation is !,C I88;8-;. ?ou can thus choose*hat con4guration interface you *ish to use *hen *riting yourapplication &
Ladder Diagram Statement List !nstruction List 1unction Block Diagram Seuential 1unction Chart Structured Te$t
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Scan RateScan Rate
The completion of one cycle of theseuence is called- SC"2
Time reuired for one cycle is calledSC"2 T!',
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Cost of hard*are( soft*are( !ntegration ,ngineering(Design( !nstallation( Start-up and Commissioning(9alidation documentation and ,$ecution( Training(Spare parts( 'aintenance( System service contract
and system life cycle. /eliability( 1le$ibility( Scalability and 9alidatability.
,ase of Database con4guration( =raphicsdevelopment( !nterlocks and Batch processing.
!ntegration of %igh-level "pplication. Control Philosophy for Centrali)ed versus /emote
#perator Console or both.
Compliance *ith an !ndustry batch standard such as
!S" SP and ne* Communication Protocol.
PLC *CS Selection CriteriaPLC *CS Selection Criteria
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Memory TypesMemory Types
/#' +/ead #nly 'emory
/"' +/andom "ccess 'emory
P/#' +Programmable /#'
,P/#' +,rasable P/#'
,"/#'- ,lectrically alterable /#'
,,P/#'-,lectrically erasable P/#'
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Binary SystemBinary System
B!T > ,ach digit of a binary number
B?T, > =roup of bit
A#/D > =roup of one or more byte
LSB > Least signi4cant bit orsmallest value
'SB > 'ost signi4cant bit or largestvalue
1 0234"#$
% &'T (O)
L*&M*&
&+T, &+T,
1% &'T (O)
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PLC ! TerminologyPLC ! Terminology
!2PT is referred by > !$$yy
#TPT is referred by > H$$yy
T!',/ is referred by > T $yy)))) 1L"=S are referred by > ' $$$$
C#2T,/S are referred by > C $$$$