1.0 Introduction To PLC
1.0 Introduction To PLC
Definition of PLC
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PLC and Computer
• A PLC and a computer both are electronic processor unit. The architecture of
a PLC’s CPU is basically same as that of a general purpose computer;
however, some important characteristics set them apart.
• Unlike computer, PLCs are specifically designed to survive the harsh
conditions of the industrial environment. A well-designed PLC can be placed
in an area with substantial amounts of electrical noise, electromagnetic
interference, mechanical vibration, and noncondensing humidity.
• Distinction of PLCs is that their hardware and software are designed for easy
use by plant electricians and technicians. The hardware interfaces for
connecting field devices are actually part of the PLC itself and are easily
connected.
• The modular and self-diagnosing interface circuits are able to pin point
malfunctions and moreover, are easily removed and replaced.
• Software programming uses conventional relay ladder symbols, or other
easily learned languages, which are familiar to plant personnel.
• A computer can execute a complex programming task and also multitasking.
An standard PLC is designed to executes a single program in an orderly
fashion. As PLCs are rapidly changing, modern PLCs have multitasking
capabilities.
• Programmable logic controller have made it possible to
precisely control large process machines and driven equipment
with less physical wiring and wiring time than it requires with
standard electro-mechanical relays, pneumatic system, timers,
drum switches, and so on.
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Historical Background
• The controller had to be designed in modular form, so that
sub-assemblies could be removed easily for replacement or
repair.
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Programmable Controller Development
1968 Programmable concept developed
1969 Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974 Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976 Remote input/output systems introduced
1977 Microprocessors - based PLC introduced
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Programmable Controller Development
1980 Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983 Low - cost small PLC’s introduced
1985 on Networking of all levels of PLC, computer
and machine using SCADA software.
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A. Flexibility
Universal Controller - can replace various independent/ standalone
controller.
B. Implementing Changes and Correcting Errors
Do not have to rewiring relay panel.
Change program using keyboard.
D. Lower Cost
Advancement in technology and open architecture of PLC will reduce
the market price.
L. Security
Software lock on a program (Password)
C. Environment Consideration
Not adapted for very high temperature, high humidity level, high vibration,
etc.
D. Fail-safe operation
Does not start automatically when power failure ( can be programmed into )
Not "Fail-safe" -Fail-shorted rather than OPEN
E. Fixed-circuit operation
Fixed control system -less costly
What is a Ladder Diagram?
A complete control scheme normally drawn as a series of
contacts and coils arranged between two vertical control
supply lines so that the horizontal lines of contacts appear
similar to rungs of a ladder. The control contacts (input
devices) are to left and coils (output devices) on the right.
Ladder diagrams are an industrial standard for representing
relay-logic control system
Leading Brands Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D
EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
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Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
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PLC Size
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- these PLC’s are capable of providing
simple to advance levels or machine
controls.
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s and
memories up to 750 Kbytes.
- can control individual production
processes or entire plant.
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Box Type Modular or Rack Type
Major Components of a Common PLC
POWER
SUPPLY
I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
From E T E To
SENSORS
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
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Major Components of a Common PLC
POWER SUPPLY
I/O MODULES
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Major Components of a Common PLC
PROCESSOR
PROGRAMMING DEVICE
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Programming Device
Also known as:
Programmer ( Square D )
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I/O Module
• The I/O interface section of a PLC connects it to
external field devices.
Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits
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I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC • Prevent voltage
INPUT TO DC AND transients from
DROPS THE VOLTAGE damaging the
TO LOGIC LEVEL processor.
•Helps reduce the
effects of electrical
noise
Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits
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I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
• Prevent voltage
transients from
damaging the
processor.
•Helps reduce the
effects of electrical
noise
Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE
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I/O Circuits
DIFFERENT TYPES OF I/O CIRCUITS
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I/O Circuits
2. General - Purpose Outputs
These are usually low- voltage and low-current and are used
to drive indicating lights and other non-inductive loads. Noise
suppression may or may not be included on this types of
modules.
3. Discrete Inputs
Circuits of this type are used to sense the status of limit
switches, push buttons, and other discrete sensors. Noise
suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.
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I/O Circuits
4. Analog I/O
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I/O Circuits
5. Special - Purpose I/O
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Discrete Input
A discrete input also referred as digital input is an input that is either
ON or OFF are connected to the PLC digital input.
In the ON condition it is referred to as logic 1 or a logic high and in the
OFF condition maybe referred to as logic o or logic low.
OFF PLC
Logic 0
Input
Module
24 V dc
IN
OFF PLC
Logic 1
Input
Module
24 V dc
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Analog Input
An analog input is an input signal that has a continuous signal.
Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
PLC
Analog
Tank Input
Module
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Digital Output
PLC
Lamp
Digital
Output
Module
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Analog Output
OUT
E Supply air
PLC 0 to 10V P
Analog
Output
Module
Pneumatic control valve
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OUTPUTS
INPUTS MOTOR
CONTACTOR
LAMP
PUSHBUTTONS
PLC
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Allen-Bradley 1746-1A16
L1 L2 I= Input
Module
I:2 slot # in rack
P. B SWITCH 0 Module
Terminal #
Address I:2.0/0
LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM
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CONTACTOR
L2 L1 N.O
MOTOR
L2
C •SOLENOID
L1
•VALVES
FIELD WIRING •LAMP
•BUZZER
OUTPUT MODULE
WIRING
L1 O:4 L2
CONTACTOR 0
LADDER PROGRAM
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Processor
The processor module contains the PLC’s microprocessor,
its supporting circuitry, and its memory system.
APPLICATION
•The application memory is divided into the data table area and
•Data Table user program area.
•The data table stores any data associated with the user’s control
•User Program program, such as system input and output status data, and any
stored constants, variables, or preset values. The data table is
where data is monitored, manipulated, and changed for control
purposes.
•The user program area is where the programmed instructions
entered by the user are stored as an application control program.
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Memory Designs
VOLATILE.
A volatile memory is one that loses its stored information
when power is removed.
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Memory Designs
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Memory Designs
Several Types of RAM Memory:
1.MOS
2.HMOS
3.CMOS
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Memory Designs
NON-VOLATILE
Has the ability to retain stored information when power is
removed, accidentally or intentionally. These memories do not
require battery back-up.
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Memory Designs
Other Types of Non-Volatile Memory
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Memory Designs
EPROM, Erasable Programmable Read Only Memory
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PLC Operation
Basic Function of a Typical PLC
Read all field input devices via the input interfaces, execute the
user program stored in application memory, then, based on
whatever control scheme has been programmed by the user, turn
the field output devices on or off, or perform whatever control is
necessary for the process application.
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While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as
individual cycles of operation:
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
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PHASE 1 – Input Status scan
• A PLC scan cycle begins with the CPU reading the status of
its inputs.
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PHASE 4 - Output Status Scan
• An output status scan is then performed, whereby the
stored output values are sent to actuators and other field
output devices. The cycle ends by updating the outputs.
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As soon as Phase 4 are completed, the entire cycle begins again
with Phase 1 input scan.
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PLC Communications
Common Uses of PLC Communications Ports
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PLC Communications
Serial Communications
Common Standards
RS 232
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PLC Communications
Local Area Network (LAN)
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PLC Communications
RS 422 / RS 485
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PLC Communications
Programmable Controllers and Networks
Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
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Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting a unit
for a particular application. These are listed below.
NUMBER OF I /O PORTS
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Specifications
OUTPUT-PORT POWER RATINGS
SCAN TIME
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Specifications
MEMORY CAPACITY
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Areas of Application
• Manufacturing / Machining
• Food / Beverage
• Metals
• Power
• Mining
• Petrochemical / Chemical
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Tank Used to Mix Two Liquids
MOTOR
A
FS FLOAT SWITCH
SOLENOIDS B
SOLENOID
C
TIMER
1 -MINUTE
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Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control circuit operates as
follows:
2. When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used to mix
the liquids together.
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Tank Used to Mix Two Liquids
4. When the tank is empty, the float switch de-energizes
solenoid C.
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Selecting a PLC
Criteria
The normally open (NO) is true when the input or output status bit
controlling the contact is 1.
The normally closed (NC) is true when the input or output status bit
controlling the contact is 0.
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Coils
That same output status bit maybe used to control normally open
or normally closed contact anywhere in the program.
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Boxes
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AND OPERATION
A B C
Rung
In the rung above, both inputs A and B must be true (1) in order
for the output C to be true (1).
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OR OPERATION
A C
Rung
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NOT OPERATION
A C
Rung
In the rung above, it can be seen that if input A is be true (1), then
the output C is true (0) or when A is (0), output C is 1.
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