Programmable logic

controller
 Pneumatic
and Hydraulic
Power
Switchgear, electronics
Contactors
and Relays

Sensors Closed Loop

and Actors Controller
Automation

Electronic
Controls and Programmable
Microcontroller Logic Controller

Motors
 Leading Brands of PLC
AMERICAN EUROPEAN JAPANESE
1 ALLEN BRADLEY SIEMENS TOSHIBA
2 GOULD MODICON KLOCKNER & MOULLER OMRON
3 TEXAS INSTRUMENTS FESTO FANUC
4 GENERAL ELECTRIC TELEMECHANIQUE MITSUBISHI
5 WESTINGHOUSE
6 CUTTER HAMMER
7 SQUARE D
 PLC Programing Software’s
1. Velocio Software 15. Omron Software
2. Siemens Software 16. Sirea Software
3. Rockwell Automation (Allen-Bradley) So 17. VIPA Software
ftware 18. Triangle Research International Softwar
4. Schneider Software e
5. Mitsubishi Software 19. SPLAT Software
6. Modicon Software 20. Smart Software Solutions
7. Panasonic Software 21. LSIS Software
8. Keyence Software 22. Control Microsystems Software
9. Telemecanique Software 23. Teco Software
10. Beckhoff Software 24. Unitronics Software
11. GE Software 25. ABB Software
12. Automation Direct Software 26. Horner APG Software
13. IDEC Software 27. Crouzet Software
14. Opto22 Software 28. Xinje Software
 PLC Communications
Manufacturer Network
1 Allen-Bradley Data Highway
2 Gould Modicon Modbus
3 General Electric GE Net Factory LAN
4 Mitsubishi Melsec-NET
5 Square D SY/NET
6 Texas Instruments TIWAY
 PLC Acronyms
ASCII American Standard Code for Information Interchange
BCD Binary Coded Decimal
CSA Canadian Standards Association
DIO Distributed I/O
EIA Electronic Industries Association
EMI ElectroMagnetic Interference
HMI Human Machine Interface
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronic Engineers
I/O Input(s) and/or Output(s)
ISO International Standards Organization
LL Ladder Logic
LSB Least Significant Bit
MMI Man Machine Interface
MODICON MOdular DIgital CONtoller
MSB Most Significant Bit
PID Proportional Integral Derivative (feedback control)
RF Radio Frequency
RIO Remote I/O
RTU Remote Terminal Unit
Supervisory Control And Data Acquisition
SCADA
Definition of PLC
According to NEMA standard ICS3-1978
• A digitally operating electronic apparatus
which uses a programming memory for the
internal storage of instructions for
implementing specific functions such as logic,
sequencing, timing, counting and arithmetic to
control through digital or analog modules,
various types of machines or process.
 Areas of PLC Applications
• Annunciators • Casting • Digesters • Gluing
• Injection Molding • Reactors • Stitching • Weaving
• Auto Insertion • Chemical Drilling • Drilling • Grinding
• Assembly • Robots • Stack Precipitators • Web Handling
• Bagging • Color Mixing • Electronic Testing • Heat Treating
• Motor Winding • Rolling • Threading • Welding
• Baking • Compressors • Elevators • Manufacturing/
• Oil Fields • Security Systems • Tire Building Machining
• Blending • Conveyors • Engine Test Stands • Food / Beverage
• Painting • Stretch Wrap • Traffic Control • Metals
• Boring • Cranes • Extrusion • Power
• Palletizers • Slitting • Textile Machine • Mining
• Brewing • Crushing • Forging • Petrochemical/Chemical
• Pipelines • Sorting • Turbines
• Calendaring • Cutting • Generators
• Polishing • Stackers • Turning
PLC in industry
PLC in traffic light
 Relating the PLC
Traditional system PLC system

 control function is  Soft wiring

modified by physically  control function is modified
changing the wiring by just changing the control
between the devices program inside the PLC
 This is costly and time  These changes are easy and
consuming endeavor cheap
 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.
Cont.…
• 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.
Cont.…
• 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. A standard PLC is
designed to execute a single program in an
orderly fashion. As PLCs are rapidly changing,
modern PLCs have multitasking capabilities.
 Why PLCs are so popular?
• 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.
• The programmability allows for fast and easy changes in the relay
ladder logic to meet the changing needs of the process or driven
equipment without the need for expensive and time consuming
rewiring process.
• Modem PLCs are "electrician friendly", PLC can be programmed and
used by plant engineers and maintenance electricians without much
electronic and computer programming background. They can
programmed by using the existing ladder diagrams.
 Advantage and
disadvantage of
PLC
 Advantage of PLC
No Advantage Description
1 Flexibility  Universal Controller
 Can replace various independent/ standalone controller.
2 Implementing Changes and  Do not have to rewiring relay panel.
Correcting Errors  Change program using keyboard.
3 Large Quantity of Contact  Large number of' Soft Contact' available
4 Lower Cost  Advancement in technology and open architecture of PLC
will reduce the market price.
5 Pilot Running (Simulation  A program can be simulated or run without actual input
Capability) connection.
6 Visual Observation.  Can observe the opening and closing of contact switch on
CRT.
 Operator message can be programmed for each possible
malfunction.
7 Speed of Operation  Depends on scan time -millisecond.
 Asynchronous operation.
8 Ladder or Boolean Programming Method.  Easy for 'Electrician ,
9 Reliability  In general -very reliable
10 Simplicity of Ordering Control Sys.  One package with Relay, Timers, Control Block, etc.
Components
11 Documentation  Printout of ladder logic can be printed easily
12 . Security  Software lock on a program (Password)
13 Ease of Changes by Programming  Ability to program and reprogram, loading and
down loading
14 Highly versatile (universal applicability)
15 Simple troubleshooting
Simple installation
16 Quick modification of the program (highly
flexible)
17 Capable of task not possible with relays  Calculation, information exchange, text and graphic
before as indicated by the following: display, data processing, networking
18 Low space requirement
19 Low power consumption
20 High processing speed
21 No moving parts, hence no wearing parts
 Disadvantages of PLC
N Disadvantages Description
o
1 New Technology  Change from ladder and relay to PLC concept
2 Fixed program  Not cost effective for single- function application
Application
3 Environment  Not adapted for very high temperature, high
Consideration humidity level, high vibration, etc.
4 Fail-safe operation  Does not start automatically when power failure
( can be programmed into )
 Not "Fail-safe" -Fail-shorted rather than OPEN

5 Fixed-circuit operation  Fixed control system -less costly

What Is Inside A PLC?
Cont.…
• The Central Processing Unit, the CPU, contains an internal
program that tells the PLC how to perform the following
functions:
• Execute the Control Instructions contained in the User's
Programs. This program is stored in "nonvolatile" memory,
meaning that the program will not be lost if power is
removed
• Communicate with other devices, which can include I/O
Devices, Programming Devices, Networks, and even other
PLCs.
• Perform Housekeeping activities such as Communications,
Internal Diagnostics, etc.
 How Does A PLC Operate?
• There are four basic steps in the operation of all PLCs; Input Scan, Program
Scan, Output Scan, and Housekeeping. These steps continually take place in
a repeating loop.
1. Input Scan • Detects the state of all input
devices that are connected to the
PLC
2.Program Scan • Executes the user created program
logic

3. Output Scan • Energizes or de-energize all output

devices that are connected to the
PLC.

4.Housekeeping • This step includes communications

with programming terminals,
internal diagnostics, etc...
What Programming Language Is Used To Program A
PLC?
• While Ladder Logic is the most commonly used PLC programming language,
it is not the only one. The following lists of some of languages that are used
to program a PLC.
1. Ladder Diagram (LD)
• Traditional ladder logic is graphical programming language. Initially
programmed with simple contacts that simulated the opening and closing
of relays, Ladder Logic programming has been expanded to include such
functions as counters, timers, shift registers, and math operations.
2. Function Block Diagram (FBD)
A graphical language for depicting signal and data flows
through re-usable function blocks. FBD is very useful for
expressing the interconnection of control system algorithms
and logic.
3. Structured Text (ST)
A high level text language that encourages structured
programming. It has a language structure (syntax) that
strongly resembles PASCAL and supports a wide range of
standard functions and operators. For example;

If Speed1 > 100.0 then

Flow_Rate: = 50.0 + Offset_A1;
Else
Flow_Rate: = 100.0; Steam: = ON
End_If;
4. Instruction List (IL)
A low level “assembler like” language that is based on
similar instructions list languages found in a wide
range of today’s PLCs.

LD R1
MPC RESET
LD PRESS_1
ST MAX_PRESS
RESET: LD 0
ST A_X43
5. Sequential Function Chart (SFC)
A method of programming complex control systems at a more highly
structured level. A SFC program is an overview of the control system, in which
the basic building blocks are entire program files. Each program file is created
using one of the other types of programming languages. The SFC approach
coordinates large, complicated programming tasks into smaller, more
manageable tasks.
What Are Input/output
Devices of PLC?
 Input device
1. Switches and Pushbuttons
2. Sensing Devices
• Limit Switches
• Photoelectric Sensors
• Proximity Sensors
3. Condition Sensors
4. Encoders
• Pressure Switches
• Level Switches
• Temperature Switches
• Vacuum Switches
• Float Switches
 OUTPUTS
• Valves
• Motor Starters
• Solenoids
• Actuators
• Horns and Alarms
• Stack lights
• Control Relays
• Counter/Totalizer
• Pumps
• Printers
• Fans