PLC AND SCADA

Subject code: 21MT62

Module -01
Syllabus

what is A PLC, Technical Definition of PLC, What are its

advantages,
characteristics functions of A PLC, Chronological
Evolution of PLC, Types of
PLC, Unitary PLC, Modular PLC, Small PLC, Medium PLC,
Large PLC, Block
Diagram of PLC: Input/output (I/O) section, Processor
Section, Power supply,
Memory central Processing Unit: Processor Software /
Executive Software, Multi
asking, Languages, Ladder Language.
WHAT IS PLC
PLC is a solid state/ computerised industrial controller that
performs discrete or sequential logic in a factory environment.
It was originally developed to replace mechanical relays, timers
and counters.
Used to successfully execute complicated control operations
in a plant.
A sequence of instructions is programmed by the user to the
PLC memory and when the programme is executed the
controller operates the system to correct operating
specifications.
The PLC was introduced in late 1960s
Today PLC is used as a stand alone control or a part of a Complex
Computer Integrated Manufacturing System.
PLC may also provide an interface between a machine and robots
or a machine and colour graphics which are known as Human
Machine Interface (HMI).
PLC is important in the world of industrial automation.
Technical Defination Of PLC

Is currently defined by NEMA (National

Electrical Manufacturers Association) as a
“ Digital electronic Device tha t uses a
programmable memory to store instructions
and to implement the specific functions
such as logic, sequence, timing, counting and
arithmetic operations to control machine and
processes” .
History and Origin:
• • Developed to replace relays in the late
1960s
• • PLC began in the 1970s, and has
become the most
• common choice manufacturing for
controls.
• • The PLC was invented in response to the
needs of
• the American automotive manufacturing
industry
• (primarily General motors).
• • Costs dropped and became popular by
1980s
• • Now used in many industrial designs
PLC Advantages
Faster Scan time
Intelligent I/O
High speed Counters
Supervised Control capability
Reliability in operation
Flexibility in programming and reprogramming in a plant
Cost effective for controlling complex systems
Flexibility in Control techniques
Minimum Maintainance
Small physical size
Superior computational capabilities to execute complex
control techniques
ASCII message handling capablity
Ability to communicate with computer systems in a plant.
Programmable troubleshooting aids which reduces the
downtime.
PLC DISADVANTAGES
There's too much work required in connecting wires.
It is difficult to find errors.
Skillful workers are required.
There’ s difficulty with replacements.
PLC devices are proprietary, which means that parts and
software from one manufacturer can’ t easily be used in
combination with parts of another manufacturer, which
limits the design and cost
options.
PLC APPLICATIONS
• PLC’ s are generally used in industries for
controlling heavy
machinery and processes like conveyor system, CNC
machines
etc.
• PLC usage can also be observed in day to day life.
For eg : automatic washing machines, cars, video
cameras etc.
• PLC has it’ s applications in almost every
automatic machine.
COMPONENTS OF PLC
1 . Processor.
2. Memory unit .
3. Power supply.
4. I/O Modules.
5. Programming device.
Characteristics of PLC
PLC offers certain characteristic functions that make it
advantageous in an industrial environment.
It is superior in modern industrial control and
communication.
Some of the major characteristic functions of PLC are:
1. It is field programmable by the User: It allows the user to
modify the programs as per the requirements of a plant
without having it to send the unit back to the
manufacturer for this purpose.
2. It contains the programmed functions: PLCs contain at
least logic, timing, counting and memory functions that
the user can access through some kind of control
oriented programming language.
3. It scans memory, inputs and outputs (I/O) in a
predetermined manner.
4. It provides error checking and diagnostics. A PLC will
periodically carry out internal tests of its memory,
processor and I/O systems through in built program
execution to ensure what it is doing to the machine
or system, against what it was programmed to do.
5. A PLC can provide some form of monitoring capabilities
either through indicating lamps that shows the status
of inputs and outputs or by an external device that can
display the program execution status.
6. It is packaged in such a way that it can withstand the
temperature, humidity, vibration and noise found in
most factory environments.
7. A PLC can be effectively designed for a wide variety of
control tasks, although it can also be dedicated only
for a particular task.
TYPES OF PLC
PLCs are of two types: 1. Unitary PLCs
2. Modular PLCs.
1. Unitary PLC:
Unitary PLC has a power supply, a CPU and a limited
number of inputs and outputs.
It has 20 inputs- 12 outputs, 32 I/O
It is sometimes called “ shoebox type” .
It is mainly used for the control of a small system.
Unitary PLC
2. Modular PLC:
A modular PLC is one that it can be constructed using
separate modules of power supply, CPU, inputs, outputs,
timers, counters, ADC, DAC, expansion modules.
These modular PLCs are sometimes called “ rack
mounted type PLC” .
Modular PLCs can be sub-divided into the following
types
a) Small PLC
b) Medium PLC
c) Large PLC
Modular PLC
a) Small PLC:
PLC having less than 100 inputs and outputs are
designated as small PLCs.
Out of the I/Os, 20 inputs and 12 outputs are mounted
locally within the processor.
Additional I/Os can be added through remote I/O racks to
accommodate the extra inputs and outputs.
These PLCs generally have a memory from 2KB to 10KB
to store the users logic program.
b) Medium PLC:
These have extended instructions sets that include
mathematical functions, file functions, PID process control
etc.
These PLC can have between 4000 to 8000 inputs and
outputs.
They are also made to support wide variety of special
modules such as ASCII communication modules, BASIC
programming modules, 16 bit multiplexing modules, analog
input and output modules (both voltage and current),
communication modules.
c) Large PLC
The purpose of introducing large PLC was to provide enough
memory space and I/O for complete factory automation.
Major Disadvantage: Whole Factory may collapse if the PLC
starts malfunctioning.
Distributed Control: Introducing this enables to use the LAN ,
where the small or medium PLCs are connected together
through an appropriate network.
Entire factory is brought under the control of a number of
PLCs, but failure in one system will not disturb any other
system.
PLC SYSTEM
 Block Diagram of PLC
PLC has three basic sections namely 1) I/O section 2)Processor Section 3)
Programloader/monitor section
The input section converters convert the field signals to logic level signals
that the PLC’ s processor can read directly.
The processor section reads these inputs, processes the signals
executing the program and prepare the output signals.
The output section converts the logic level output signals coming from
the processor section into high level signals and releases the signals
for various field devices.
The program loader is to enter the user’ s program into the memory or
change it and to monitor the execution of the program.
I/O section
The input output section establish the interfacing between
the real world outside the PLC and the digital arena inside the
PLC.
The signals from the machines or instruments of a system
are received through the input section by a PLC.
After processing the output signals are transmitted to the
machines or the instruments for the desired control action
through the output section.
The tasks of the I/O section can be classified as:
1. Conditioning 2. Isolation 3) termination 4) Indication
The field signal is 220V or 440 V.
PLC can support a voltage of 0-10 volts, the field signal
has to be conditioned before it is applied to the PLC.
To protect the PLC from any incoming surges from the
field, isolating devices such as transformers or an
opto-isolator are used.
The I/O modules provides a proper terminal.
It indicates the status of the I/O terminal, i.e when the
voltage is off the status indicator is off.
Processor Section
This section consists of four major elements.
1.) Power supply 2.) Memory 3.) CPU 4.) I/O interface
1) Power Supply:
Basic function of the power supply is to supply conditioned power to
the components of a PLC.
The power supply is one of the most critical components of the PLC
for two reasons:
1. It is typically non redundant. Hence failure of PLC power supply can
cause entire control system to fail.
2. It contains high voltage components. Hence an insulation failure can
be a serious potential for injury or fire.
The following guidelines should be followed when
choosing the power supply of a PLC:
1) The power supply should be packed properly, so that the
heat generated by the power supply can be dissipated in
order to prevent overheating. This increases reliability.
The power supply should be tested for temperature and
electrical insulation by a proper certification agency.
The power supply should meet at least one reputable
standard for noise Immunity.
Suitable redundancy will increase reliability.
2. Memory
Two types of memory in a PLC: i) volatile memory ii) non
volatile memory.
Non volatile memories: are generally used for storing users
programs so that they are preserved during power cuts.
The non volatile memory in a PLC uses some form of
error checking to ensure that memory has not changed.
To ensure to have a safe execution of the users
programs this error checking should also be done while
PLC is controlling a machine or a process.
Different types of memory that are generally used in a
PLC are as follows.
1. Battery backed up CMOS RAM : This is the probably the
most widely used type of memory.
CMOS variety consumes such a small amount of power
that a small battery will retain memory during the power
losses.
The battery used vary from short life primary cells
(alkaline or Hg) which require periodic replacement
after 6 months to a year.
To a long life battery which may last up to 10 years to
rechargeable secondary cells.
2. EPROM Memory:
Electrically Programmable Read only Memory is
programmed using electrical pulses.
Can be erased by exposing the circuit to UV light also
called UV-EPROM.
3. EEPROM Memory:
Similar to EPROM Memory.
It can also be erased using electrical pulses.
In some PLC’ s use of EEPROM on ly alleviates the
need of an UV light source.
In other PLC’ s the EEPROM is t he only type of
memory used.
This allows the flexibility of reprogramming.
Four sections memory is subdivided: Executive
memory, internal RAM, user memory and I/O image
memory.
The executive memory holds executive software.
User memory is meant for user program storage
3. CPU
The flexibility of a PLC is dependent on : i) How
CPU is constructed ii) Overall speed of the PLC
The speed is expressed in terms of how fst the
PLC will scan a given amount of memory.
This measure is called scan rate.
It is expressed in milliseconds per thousand words
of memory.
1. Processor:
Processor is the central processing unit (CPU) of the
programmable controller, it executes the various logic
sequencing functions by operating on the PLC inputs to
determine
the appropriate output signals.
The CPU consists of one or more microprocessors similar
to that
of PCs and other data processing equipment but are
designed to
facilitate I/O transactions with different ranges with
corresponding
clock speed.
Consists of a microprocessor
for implementing the logic and
controlling the communications
among the modulus.
Designed, so the desired circuit
can be entered in relay ladder
logic form.
The processor accepts the input
data from various sensing devices,
executes the stored user program
and sends appropriate output
commands to control devices.
2. Memory:
Memory unit is connected to the CPU, which contains the
programs of logic, sequencing and I/O operations .
It also holds data files associated with these programs, Including I/O stations
bits, counter and timer constants, and other variable and parameter values.
This memory unit is referred to as the user or application memory because its
contents are entered by the user and also directs the execution of control
program and coordinates I/O operations with the aid of system memory.
3. Power Supply:
A power supply of 120v alternating current(ac) is typically
used to drive the PLC (some units operate on 240 v ac).
The power supply converts the 120v ac into direct current (dc)
voltages of ±5V.
These low voltages are used to operate equipment that many
have much higher voltage and power ratings than the PLC
itself.
The power supply often includes a battery backup that
switches in automatically in the event of an external power
source failure.
Supplies DC power to other modules
that plug into the rack.
In large PLC systems, this power
supply doe not normally supply power
to the field devices.
In small and micro PLC systems ,
the power supply is also used to power field devices.`
4. I/O Modulus:
The input/output module provides the connections to the
industrial equipment or process that is not to be
controlled.
Inputs to the controller are signals from limit-switches ,
pushbuttons,
sensors , and other on/off devices.
Outputs from the controller are on/off signals to operate
motors, valves, and other devices required to actuate the
process.
Many PLCs are capable of accepting continuous signals
from
analog sensors ad generating signals suitable for analog
actuators.
Forms the interface by which input
field devices are connected to the
controller.
The terms “ field” and “ real world”
are used to distinguish actual external
devices that exist and must be
physically wired into the system.
Forms the interface by which
output field devices are connected
to the controller.
PLCs employ an optical isolator
which uses light to electrically
isolate the internal components
from the input and output terminals.
5. Programming Device:
The PLC is programmed by means of a programming device.
The programming device is usually detachable from the PLC cabinet
so that it can be shared among different controllers.
Different PLC manufacturers provide different devices , ranging
from simple teach pendant type devices , similar to those used in
robotics, to special PLC programming keyboards and CRT displays.
PCs and laptops now widely used for programming a much faster
and a PC / laptop are also smaller now.
The software allows users to create , edit .
document, store and
trouble shoot programs .
The personal computer communicates with the
plc processor via
serial or parallel data communications link
Hand – held programming devices are sometimes used to
program small PLCs.
They are compact, inexpensive and easily to use, but are not
able
To display as much logic on screen as a computer monitor.
Hand-held units are often used on the factory floor for trouble
shooting, modifying programs and transferring programs to
multiple
machines.
Languages
Variables: These are the way in which the language allows
the user to access the I/O internal data.
On line s. OFF line: On line language is the one that can
be programmed interactively with the PLC.
OFF line: Requires that the program be generated
separately then downloaded to PLC.
Flow Control: How easy to take decisions and to control
the program execution.
Maintainability: How easy the language is to debug,
modify and teach to others.
Functions: Some language provide minimum set of logic,
timing , counting and memory functions.
Speed: Some language takes a longer time to execute than
others.
Choosing a slow but powerful language in time critical
applications can make programming much more difficult
than using a fast but simple language.
EFFECIENCY: This is the measure of how much memory is
required for a language to implement a given function.
Ladder Language

Electrical ladder diagram

Relay logic
Power flow through the ladder diagram
Program is fast
Readable program for sequence control
Multi Tasking
Some PLC can execute multiple tasks within a single processor.
Two forms of multi tasking: Time driven and Event Driven
Time Driven: The user writes programs and assigns a separate
I/O for each task.
The user may be then allowed to configure the processor to
run each task at periodic time intervals.
Event Driven: In the Event driven multitasking user defines a
particular event that causes each task to run.
Some multitasking systems allows any task to access any
variable such as an I/O point.
Configuration process typically consists of: Assigning the
I/O points to particular I/O racks.
Telling the processor how much memory I/O it has.
Assigning specific memory for tasks.
Determining the fatal and non fatal faults.
Assigning many other items interactively on a program
loader.
Not all PLC can be configured, but the processor can
enhance the efficiency of the PLC if it can be configured.