PROGRAMMABLE LOGIC CONTROLLER

• Contents:
• Introduction to PLC
• Why PLC?
• Types of PLC
• How PLC works
• Architecture of PLC
• Applications of PLC
• Siemens of PLC
• PLC Protocols
• PLC Manufacturers

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 PROGRAMMABLE LOGIC CONTROLLER

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 PROGRAMMABLE LOGIC CONTROLLER
• PLC or Programmable Logic Controller is a computer control system
for the Automation Industry. It is a special-purpose computer without
a keyboard, hard drive, etc.

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 PROGRAMMABLE LOGIC CONTROLLER
• A programmable logic controller (PLC) is an industrial computer
control system that continuously monitors the state of input devices
and makes decisions based upon a custom program to control the
state of output devices.
• A programmable logic controller (PLC) controls the manufacturing
processes for integrated production lines and equipment.
• PLCs were designed to replace the need for a large bank of relays or
timers in facilities with numerous inputs and outputs.

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 Why PLC?
Panels of relays PLCs

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 Why PLC?

• PLC was initially created in the United States for the replacement of
relay systems. Richard “Dick” Morley, an electrical engineer named
the “father” of the programmable logic controller (PLC), created
Modicon, the first PLC, in 1968.
• The drawbacks of relays that make them unsuitable for the
automotive industry are listed below:
• Relays also fail quickly compared to computer components.
• It requires more run downtime.
• Relay also consumes plentiful electricity, more space, and heat.
Hence, to overcome such drawbacks, PLC was created.

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 Why PLC?

• A PLC model has a simple appearance. The essential components of

PLC are Input/output (I/O) modules, co-processor modules,
CPU, and peripheral devices.
• The CPU (Control Processing Unit) communicates with the
Input/output.
• The I/O modules may be present near or farther away from the CPU.
• Hence, PLC is not limited to one building.

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 Why PLC?

• To operate PLC , we need to program the Programmable Logic

Controller.
• Most PLCs are controlled using the applications on the
desktop/laptop.
• These applications communicate with the PLC using the
communication medium, such as Ethernet or the proprietary
communication bus.
• The selection of communication medium depends on the
manufacturer. Most manufactures also rely on the USB.

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 Types of PLC

• There are three types of PLC, which are shown below:

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 Types of PLC

• Modular PLC:
• In modular PLC, modular means adding modules.
• It allows us to expand the structure of PLC.
• It is useful when there are a large number of inputs and outputs.
• We can add more input and outputs by adding the modules in the PLC.
• It also has more memory and capability to store information.
• The example includes control processing lines in the manufacturing industry.

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 Types of PLC

Example of Modular type PLC.

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 Types of PLC

• Rack PLC:
• The modules in the rack type PLC are arranged in the rows.
• The racks are placed inside the cabinets.
• The slots in the rack PLC communicate with each other connected by the
standard network or bus.

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 Types of PLC

• Compact PLC:
• The Input / Output (I/O) modules in the compact PLC are determined by the
manufacturer of that PLC.
• It means that the I/O is fixed.
• But, the compact PLCs are used for small scale applications.

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 How PLC Works

• In simple words, PLC takes the input from the input devices,
processes it based on the logic in the CPU, and controls the output
devices based on that logic.
• PLC is lightweight and can operate without any electrical filtering or
air conditioning.

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 How PLC Works

• The devices such as pushbutton, sensors are connected as the input

devices, which can detect a change in the input signals in the PLC.
• The input signal passes through the barrier that converts the voltage into
low voltage, such as 5V.
• The CPU monitors the state of the input. Based on the specified logic, CPU
processes and produces the output signal.
• The barrier present at the output terminal prevents the PLC from external
noise and converts the low voltage to high voltage to drive output devices.
• The output signal controls the output devices, such as motor, controllers,
pilot lights, etc.

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 How PLC Works

1/30/2023 PLC Overview 16

 Architecture of PLC

1/30/2023 PLC Overview 17

 Architecture of PLC

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 Architecture of PLC

• The PLC hardware setup or architecture contains the hardware and

software that is used to perform the control functions.
The architecture of the PLC.

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 Architecture of PLC

• The components of the PLC are listed below:

• PS:
• PS stands for Power Supply.
• The power supply acts as a power source for the PLC system.
• It converts the high voltage into low voltage or DC, such as 120V AC to 24V
DC.
• The Linear power supply is less complicated than the other modes of power
supply.

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 Architecture of PLC

• SMPS:
• It stands for Switch Mode Power Supply.
• SMPS is power conversion and a high-frequency power conversion device.
• It converts the voltage level into the specifically required voltage.
• SMPS uses solid stat switches to convert the AC supply into the smooth DC
supply.
• SMPS is generally used for high power conversion from AC to DC.
• It also has high efficiency than PS.
NOTE: Solid state relays can be designed to switch both AC or DC currents by
using an SCR, TRIAC, or switching transistor output instead of the usual
mechanical normally-open (NO) contacts.

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 Architecture of PLC

Differences between PS and SMPS:

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 Architecture of PLC

• How SMPS converts voltage?

• Let's consider the AC voltage of 224V. The process will convert 224V AC to 24V
DC. It clearly explains the process of converting high voltage to low DC
voltage.
• Consider the block diagram given below:

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 Architecture of PLC

• CPU:
• CPU or Central Processing Unit is present in the Central rack of the PLC.
• The data bus is used as a medium to send data between different elements in
the PLC.
• It controls all functions, such as programmed instructions stored in the
memory of PLC.
• It also controls logic, communications, and monitoring in the PLC.
• It is the unit of the PLC that contains a microcontroller or microprocessor.
• The CPU executes the program when it is operated in the run mode.

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 Architecture of PLC

I/O separated with CPU

I/O with CPU

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 Architecture of PLC

• IM:
• IM or Interface Module is defined as an accurate, position sensing, and
absolute device.
• It is commonly used with transducers to reduce noise in harsh environments.
• Programming device:
• We need to specify the required program into the processor's memory.
• The program is initially developed in the programming device.
• After that, the program is transferred to the memory unit of the PLC.

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 Architecture of PLC

• CP:
• CP stands for Communication Process.
• The communication process in PLC includes a wiring system and a shared
protocol.
• The wiring system is used to connect different components in PLC, whereas
shared protocol allows any device to understand the bits and bytes in the
communication process.

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 Architecture of PLC

• MCB:
• MCB or Miniature Circuit Breaker acts as a safety device for the PLC.
• It automatically switches off the circuit if an overload or fault condition arises.
• MCB is commonly used instead of fuse I low voltage electrical network.
• Input Module:
• The input module of PLC detects the input devices' status, such as sensors,
switches, push-buttons, etc.
• Output Module:
• The output module of PLC controls the output devices, such as motors, relays,
lights, etc.

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 Architecture of PLC

• Rack:
• The Rack usually acts as a holding device of PLC.
• It means that it holds everything together.
• We can add racks in the PLC to hold more modules.
• The racks are also available in a different size.

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 Architecture of PLC

• Memory Unit:
• Memory Unit is the unit that stores programs, data, and information in the
PLC.
• The PLC has two types of the memory unit, which are listed below:
• Data memory: The data memory consists of the stored data from the
Input/output modules of the PLC.
• Program Memory: The program memory consists of the logic program or
ladder logic program in the PLC.

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 Applications of PLC

• We generally use a desktop or laptop for programming.

• Some of the applications of PLC are listed below:
• Controlling elevators
• Controlling traffic signals
• Washing machines
• Amusement rides
• Machinery control
• Bottle filling system
• Water tank level control
NOTE: Siemens PLC is the most common PLCs used all over the industries.

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 Siemens PLC
The Siemens PLC are divided into three generations, which are
given below:

1st Generation - Micro

2nd Generation - Mini

3rd Generation - Nano or Rack PLC

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 Siemens PLC
• The series of Siemens PLCs are listed below:

• S7200
• S7300
• S7400
• S7400H
• S7400F
• S71200
• S71500

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 Siemens PLC
• S7400F PLC also has the feature of Fault Tolerance.
• We can select the product as per the requirement.
• S7200 is the cheapest available Siemens PLC.
• It is easy to start programming with the S7-200 PLC.

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 PLC Protocols

1. PPI:
• The PPI or Point to Point Interface Protocol is a communication protocol
specially designed for S7-200 PLC. But, it is not directly opened by Siemens.
2. MPI:
• The MPI or Multi-Point Interface Protocol is an interface of the Siemens
Company.
• The MPI is used to connect the devices, such as personal computers, etc.
• The speed of MPI ranges from 187.5 kBd (Kilo Baud) to 12 Mega Baud.

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 PLC Protocols

3. Profibus:
• Process field Bus or Profibus uses a multi-drop single cable, which is used to
connect the devices.
• It is often confused with the Profinet.
• It is easy to find faults in a single cable.
• The installation cost of the Profibus cable is also low.
4. Profinet:
• The Process filed net or Profinet is also used by Siemens like Profibus.
• The response time of Profinet is faster, which provides higher data collection.

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 PLC Protocols

5. Fiber Optics cable:

• The Fiber Optics cable supports high bandwidths level and high transmission
capacity over long distances.
6. Ethernet cable:
• The Ethernet cable acts as a wired transmission intermediate between the
devices.
• Ethernet cables are considered for wiring analog input and outputs in PLC.
• The Ethernet connection provides faster security and reliability than the
wireless connection.

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 PLC Protocols

7. LAN Cable:
• The LAN cable provides the downloading and uploading capacity from the
host computer to the PLC or vice versa. The common LAN applications include
distributed control, etc.
8. Cat 5, Cat 6, and Cat 7:
• Here, Cat stands for Category. These are the common Ethernet standards that
are widely used for transmission with reduced interference.
• The speed of Cat5 is upto 100Mbps.
• The speed of Cat6 is upto 10Gbps.
• The speed of Cat7 is upto 100Gbps. It is the latest cable, which is shielded.

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 PLC Manufacturers

• The industries that make PLC are listed below:

• Siemens
It is the German multinational company that manufactures PLC. It is well
known and most used PLC all over the world.
• Rockwell Automation
It is an American company that also took over the Allen Bradley brand. It is
the largest manufacturer of PLCs and well known in the United States.
• ABB
The ABB is a Swiss multinational company that provides PLCs within vast
industries and applications.

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 PLC Manufacturers

• Omron:
It is a Japan-based electronics company.
• General Elastic:
It is an American based PLC company.
• Delta:
It deals with all types of automation machines. It is a Taiwan- based PLC
manufacturer.
• Schneider:
The Schneider is a French-based PLCs manufacturer.
• Mitsubishi:
It is a Japanese MNC group that manufactures PLC.
• Koyo Electronics Corporation Limited:
It manufactures the DirectLogic PLC brand. It is a Japanese based industry.
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 Advantages of PLCs

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 Disadvantages of PLCs

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 Thanks for Listening

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