P L C
Programmable Logic Controller
Presented By
Shankar Jothyraj
Contents
What is PLC?
Basic Components of a PLC
PLC Advantages &
Definition of PLC
Central Processing Unit
What is Control?
CPU Duties
PLC Applications
History of PLC
Input Modules
PLC Size
Need for PLC
Output Modules
Leading Brands of PLC
Hardwire System and PLC
Digital and Analog Modules
Comparison
Chassis and Backplane
PLC Function
Power Supply
PLC Operating Cycle
Programming Software
Disadvantages
What is a PLC?
The Basic Block
CPU
Inputs
Outputs
A PROGRAMMABLE LOGIC CONTROLLER is a solid state
control system that continuously monitors the status of devices
connected as inputs. Based upon a user written program, stored
in memory, it controls the status of devices connected as
outputs.
Definition of PLC
A digital electronic device that uses a programmable memory
to store instructions and to implement specific functions such
as logic, sequence, timing, counting and arithmetic to control
machines and process.
It uses a programmable memory to store the instructions and
specific functions that include On/Off control, timing counting,
sequencing, arithmetic and data handling.
A PLC is a computer designed to work in an industrial
environment.
What is Control?
CONTROL is the process in a system in which
one or several input variables influence other
variables.
A Simple View of a Control System
INFORMATION
COMMANDS
C
O
N
T
R
O
L
S
Y
S
T
E
M
SENSORS
ACTUATORS
P
L
A
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T
History of PLC
During the late 1960s, General Motors (USA) was interested in
the computer application to replace the hardwire systems.
Bedford Associates (Modicon) and Allen Bradley responded to
General Motors.
The name given was Programmable Controllers or PC.
Programmable Logic Controller or PLC was a registered
trademark of the Allen Bradley.
Later, PC was used for Personal Computer and to avoid
Need for PLC
Hardwired panels were very time consuming to time, debug and
change.
The following requirements for computer controllers to replace
hardwired panels.
1.Solid-state not mechanical.
2.Easy to modify input and output devices.
3.Easily programmed and maintained by plant electricians.
4.Be able to function in an industrial environment.
Hardwire System and PLC
L
24 VDC
S1
S2
S1
K1
K1
S2
PLC
K1
0V
Hardwire
PLC
Comparison
Hardwired control systems
The functions are determined
by the physical wiring.
Changing the function means
changing the wiring.
Can be contact-making type
(relays, contactors) or
electronic type (logic circuits)
PLC Systems
The functions are determined
by a program stored in the
memory.
The control functions can be
changed simply by changing
the program.
Consist of a control device,
to which all the sensors and
actuators are connected.
PLC Function
Communications
Port
I
n
p
u
t
High
Voltage
Isolation
Barrier
C
i
r
c
u
i
t
s
Central
Processor
Unit
(CPU)
MEMORY
data
program
Low Voltage
AC Power Supply
or
O
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t
p
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t
C
i
r
c
u
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t
s
Isolation
Barrier
CR
High
Voltage
PLC Operating Cycle
Four Steps in the PLC Operations
START
Input Scan
Scan the state of the Inputs
Program Scan
Processes the program logic
Housekeeping
Input
Scan
Output
Scan
Output Scan
Energize/de-energize the outputs
Housekeeping
This step includes communications, Internal
Diagnostics, etc.
The steps are continually repeated - processed in a loop.
Program
Scan
How Does a PLC Work?
The sensors are connected to the INPUT MODULES
The processor in the CPU MODULE executes the program and scans the individual input for
presence or absence of voltage
24 VDC
Depending on the state of the inputs, the processor directs the OUTPUT MODULES to switch
Sensors
voltages
Program
Memory
Processor
Input modules
Power or ANNUNCIATORS are switched ON or OFF according to the voltage
The ACTUATORS
Supply
Output modules
states
Actuators / Annunciators
GND
PLC Signal Flow
Input Module
Processor Memory
Output Modules
Data Output
Input
Image Table
Image Table
I:0/6
I:0/6
O:0/7
O:0/7
I:1/4
O:1/5
Input Devices
Output Devices
Ladder Program
I:1/4
I:0/6
O:0/7
I:1/4
O:1/5
Programming Terminal
O:1/5
Ladder Diagram
Very similar to traditional circuit diagrams, but the
current paths are arranged horizontally instead of
LAD
- Ladder Diagram
vertically.
I 0.0
I 0.1
Q 4.0
( )
Ladder Program
O:4
L1
CONTACTOR
L2
L1
L2
CONTACTOR
N.O
L2
L1
FIELD WIRING
OUTPUT MODULE
WIRING
MOTOR
SOLENOID
VALVES
LAMP
BUZZER
Basic Components of a PLC
There are five basic components in a PLC system:
1. The PLC processor, or CPU.
2. I/O (Input /Output) modules.
3. Chassis and backplane.
4. Programming software that runs in a PC.
5. Power supply.
Central Processing Unit
What is CPU?
The Brain of a PLC.
Controlled by a program called the executive or operating system (OS).
The executive is a collection of supervisory programs permanently stored in
memory.
Four basic types of CPU operations:
CPU Duties
The CPU reads in input signal states,
processes the control program and
controls the outputs.
The CPU provides internal Memory,
timers and counters.
Stores the control program and data in
its memory.
Executes the control program.
Commands connected outputs to change
state based on program execution For
example: Turn a light on, start a fan,
adjust a speed, or temperature.
Input Modules
Input modules interface directly to devices such as switches and
temperature sensors.
Input modules convert many different types of electrical signals such
as 120VAC, 24VDC, or 4-20mA, to signals which the controller can
understand.
Output Modules
Output modules take a signal from a PLC and convert it to a signal that a field
device needs to operate. Since there are different types of output devices, there is a
wide variety of output cards available, including both digital and analog cards.
Digital/Analog Modules
Digital input modules adapt digital signals e.g. from proximity sensors.
Digital output modules convert the internal signal level of PLC into digital
process signals e.g. relays.
Analog input modules adapt analog process signals e.g. from transducers.
Analog output modules convert internal digital values of the PLC to analog
process signals e.g. temperature controller.
Digital and Analog
Digital modules use only a single bit to represent the state of the device. For
example, a switch is either open or closed. Therefore, the bit is either a 0 (switch
is open) or a 1 (switch is closed).
Analog modules use words to represent the state of a device. An analog signal
represents a value.. For example, the temperature could be 5, 9, 20, 100, etc
degrees. Analog modules use a value, such as 52, rather than a 0 or 1 to represent
the state of the device.
Inputs and Outputs
OUTPUTS
INPUTS
MOTOR
CONTACTOR
LAMP
PUSHBUTTONS
PLC
What are Inputs?
Switches and Pushbuttons
Sensing Devices
Limit Switches
Photoelectric Sensors
Proximity Sensors
Condition Sensors
Pressure Switches
Level Switches
Temperature Switches
Vacuum Switches
Float Switches
Encoders
What are Outputs?
Valves
Motor Starters
Solenoids
Actuators
Control Relays
Horns & Alarms
Stack Lights
Fans
Counter
Pumps
Printers
Chassis and Backplane
All PLCs need some method of communicating between the
controller, I/O and communications modules. Here are three ways
used to accomplish this communications between the various
components that make up the PLC system.
Power Supply
A power supply is needed to provide power to the PLC and any other
modules. Power supplies come in various forms:
Power supply modules that fit into one of the slots in a chassis
External power supplies that mount to the outside of a chassis
Stand alone power supplies that connect to the PLC or I/O
through a power cable
Embedded power supplies that come as part of the PLC block.
Programming Software
Software that runs on a PC is required to configure and program PLCs
Different products may require different programming software.
Software allows programs to be written in several different languages.
Types of Programme Memory
Program memory
Programmable
(Read-write memory)
Non-programmable
Alterable
UV erasable
EPROM / REPROM
Semiconductor RAM
Non-alterable
ROM / PROM
Electrically erasable
EEPROM / EAPROM
Semiconductor
EEPROM / EAPROM
PLC Requirements
List of items required when
working with PLCs:
1. Programming Terminal - laptop or
desktop PC.
2. PLC Software. PLC manufacturers have
their own specific software and license
key.
3. Communication cable for connection
from Laptop to PLC.
4. Backup copy of the ladder program (on
diskette, CDROM, hard disk, flash
memory). If none, upload it from the
PLC.
5. Documentation- (PLC manual, Software
manual, drawings, ladder program
printout, and Seq. of Operations manual.)
PLC Control Panel
PLC Relay
Simple PLC
network
digital inputs
analog inputs / outputs
digital outputs
PLC Advantages
Handles much more complicated
systems.
Less and simple wiring.
Increased Reliability.
More Flexibility.
Lower Cost .
Faster Response.
Easier to troubleshoot.
Remote control capability.
Communication Capability.
PLC Disadvantages
In contrast to microcontroller systems that have what is called an
open architecture, most PLCs manufacturers offer only closed
architectures for their products .
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 were Designed for Relay Logic Ladder and have Difficulty
with some Smart Devices.
To maximize PLC performance and Flexibility, a number of
Optional Modules must be added
PLC Applications
Originally hardwired arrays of
relays were used to control the
operation of heavy machines
that contain motors and other
high power devices.
PLCs were originally used to
substitute the switching relay
networks used in industrial
applications, but now they can
also be used implement other
tasks such as timing, delaying
counting, calculating,
comparing and processing of
analog signals.
PLC Size
1. SMALL - It covers units with up to128 I/Os and memories up to2 Kbytes.
- These PLCs are capable of providing simple to advance levels or
machine controls.
2. MEDIUM- Have up to 2048 I/Os and memories up to 32 Kbytes.
3. LARGE - The most sophisticated units of the PLC family. They have up to
8192 I/Os and memories up to 750 Kbytes.
- Can control individual production processes or entire plant.
Leading Brands of PLC
AMERICAN:
Allen Bradley
Gould Modicon
Texas Instruments
General Electric
Westinghouse
Cutter Hammer
Square D
EUROPEAN:
Siemens
Klockner & Mouller
Thank You!
Thank You!
