Rayat Shikshan Sansthas

KARMAVEER
BHAURAO PATIL
POLYTECHNIC,
SATARA
PLC
Fundamentals
Department Of Electronics And
Telecommunication Engineering
 Control System and
PLC
EJ5G Subject Code: 17536
Third Year Entc

Amit Nevase
Lecturer,
Department of Electronics & Telecommunication
Engineering,
Karmaveer Bhaurao Patil Polytechnic, Satara
 Objectives
The student will be able to:

Understand classifications of control system.

Understand Steady state, time response, and

frequency response analysis.

Analyze the Stability of control system using RH

criteria.

Understand the fundamentals and diff. Hardware

parts of PLC.

Draw ladder diagrams to program PLC

3/12/17 Nevase A M 3
 Teaching & Examination Scheme

Teaching Scheme Examination Scheme

PAPER
TH TU PR TH PR OR TW TOTAL
HRS

03 -- 02 03 100 50# --- 25@ 175

Two tests each of 25 marks to be conducted as per

the schedule given by MSBTE.
Total of tests marks for all theory subjects are to be
converted out of 50 and to be entered in mark sheet
under the head Sessional Work (SW).

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 Module I Introduction to Control
System
Introduction to Control systems
(4 Marks)
Control System Definition and Practical Examples
Classification of Control System : Open Loop and Closed Loop
Systems Definitions, Block diagrams, practical examples, and
Comparison, Linear and Non-linear Control System, Time
Varying and Time In-varying Systems
Servo System : Definition, Block Diagram, Classification (AC and
DC Servo System), Block diagram of DC Servo System.
Laplace Transform and Transfer Function
(4 Marks)
Laplace Transform : Signifiance in Control System
Transfer Function : Definition, Derivation of transfer functions
for Closed loop Control System and Open Loop Control System,
Differential Equations and transfer functions of RC and RLC
Circuit
Block
3/12/17 Diagram Algebra
Nevase A M 5
 Module II Time Response
Analysis
Time Domain Analysis
(4 Marks)
Transient and Steady State Response
Standard Test Inputs : Step, Ramp, Parabolic and Impulse, Need,
Significance and corresponding Laplace Representation
Poles and Zeros : Definition, S-plane representation
First and Second order Control System
(8 Marks)
First Order Control System : Analysis for step Input, Concept of
Time Constant
Second Order Control System : Analysis for step input, Concept,
Definition and effect of damping
Time Response Specifications
(8 Marks)
Time Response Specifications ( no derivations )
Tp, Ts, Tr, Td, Mp, ess
3/12/17 NevaseA M problems on time response
6
specifications
 Module III Stability

Introduction to Stability
(4 Marks)
Definition of Stability, Analysis of stable, unstable,
critically stable and conditionally stable
Relative Stability
Root locations in S-plane for stable and unstable
system

Rouths Stability Criterion

(8 Marks)
Rouths Stability Criterion : Different cases and
conditions
Statement Method Nevase A M
3/12/17 7
 Module IV Control Actions

Process Control System

(4 Marks)
Process Control System Block diagram, explanation
of each block

Control Actions
(8 Marks)
Discontinuous Mode : On-Off Controller, Equation,
Neutral Zone
Continuous modes: Proportional Controller (offset,
proportional band), Integral Controllers, Derivative
Controllers output equations, corresponding
Laplace transforms, Response
3/12/17 Nevase A M
of P, I, D controllers8

 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
9
 Module VI PLC Hardware and
Programming
PLC Hardware
(8 Marks)
Discrete Input Modules Block diagram, typical wiring details,
Specifications of AC input modules and DC input modules.
Sinking and sourcing concept in DC input modules
Discrete Output Modules Block diagram, typical wiring details,
Specifications of AC output modules and DC output modules.
Analog Input and output modules : Block diagram, typical wiring
details and specifications
PLC Programming
(16 Marks)
I/O Addressing in PLC
PLC Instruction Set : Relay instructions, timer instructions,
counter instructions, data handling instructions, logical and
comparison instructions
PLC programming examples based on above instruction using
Ladder programming
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 Module-V
PLC Fundamentals
 Specific Objectives
Explain the basics of PLC.

Draw functional block diagram of PLC.

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Examples of PLCs

Manufacturing of Bubble Gum

Water Treatment Plant

Wood Industry

Color Mixing

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 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
14
What is a Programmable Logic
Controller?
A programmable logic controller (PLC)
is a digital computer used for
automation of electromechanical
processes, such as control of
machinery on factory assembly lines,
amusement rides, or lighting fixtures.
PLCs are used in many industries and
machines.
3/12/17 Nevase A M 15
Advantages of PLCs
Less wiring.
Wiring between devices and relay contacts
are done in the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming
easier and reduce downtime.
Reliable components make these likely to
operate for years before failure.

3/12/17 Nevase A M 16
Advantages of PLCs
Eliminates much of the hard wiring that was
associated with conventional relay control
circuits.

The program takes

the place of much of
the external wiring
that would be required
for control of a process.

3/12/17 Nevase A M 17
Advantages of PLCs
Increased Reliability: Once a program has
been written and tested it can be
downloaded to other PLCs.

Since all the

logic is contained
in the PLCs
memory, there
is no chance
of making a
logic wiring
error.
3/12/17 Nevase A M 18
Advantages of PLCs
More Flexibility: Original equipment
manufacturers (OEMs) can provide system
updates for a process by simply sending
out a new program.
It is easier to
create and change
a program in a PLC
than to wire and
rewire a circuit.
End-users can modify
the program in the
field.
3/12/17 Nevase A M 19
Advantages of PLCs
Lower Costs: Originally PLCs were designed
to replace relay control logic. The cost
savings using PLCs have been so significant
that relay control is becoming obsolete,
except for power applications.

Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.

3/12/17 Nevase A M 20
Advantages of PLCs
Communications Capability: A PLC can
communicate with other controllers or
computer equipment.

They can be networked

to perform such functions
as: supervisory control, data
gathering, monitoring
devices and process
parameters, and downloading
and uploading of programs.

3/12/17 Nevase A M 21
Advantages of PLCs
Faster Response Time: PLCs operate in real-
time which means that an event taking
place in the field will result in an operation
or output taking place.
Machines that process
thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLCs
quick response capability.

3/12/17 Nevase A M 22
Advantages of PLCs
Easier To Troubleshoot: PLCs have resident
diagnostic and override functions that
allows users to easily trace and correct
software and hardware problems.

The control program

can be watched in
real-time as it
executes to find
and fix problems

3/12/17 Nevase A M 23
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and
benefits of PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
24
Origin of PLCs

Developed to replace relays in the late 1960s

Costs dropped and became popular by 1980

Now used in many industrial designs

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Evolution of PLCs
1968 Programmable Concept Developed
1969 Hardware CPU Controller with logic
instructions, 1K of memory and 128
I/O points
1974 Use of several (multi) processors
within a PLC, timers and counters,
arithmetic operations, 12K of memory
and 1024 I/O points
1976 Remote Input/output system
introduced
1977 Microprocessor based PLC introduced

3/12/17 Nevase A M 26
Evolution of PLCs
1980 Intelligent I/O modules developed,
Enhanced communication facilities,
Enhanced software features, (e.g.
documentation), Use of personal
microcomputers as programming aids

1983 Low cost small PLCs introduced

1985 on Networking of all levels of PLC,

Computer and machine using SCADA
software

3/12/17 Nevase A M 27
Definition of PLC
(Definition 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.

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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

3/12/17 Nevase A M 29
Leading Brands of PLC

JAPANESE 1. Toshiba

2. Omron

3. Fanuc

4. Mitsubishi

3/12/17 Nevase A M 30
Areas of Applications of PLC
Manufacturing/Machining

Food/Beverage

Metals

Power

Mining

Petrochemical/Chemical

3/12/17 Nevase A M 31
Role of PLC in Automation
In an automated system, PLC is commonly
regarded as the heart of control system.
With a control application program stored within
the memory of PLC in execution, PLC constantly
monitors the state of the system.
PLC provides easy and economical solution for
many automation tasks such as logic/sequence
control, PID control & computing, co-ordination and
communication, operator control and monitoring.

3/12/17 Nevase A M 32
Role of PLC in Automation
Any manufacturing application, which involves
repetitive or discreet operation for that application
PLC, can be used.

Intelligence of an automated system is greatly

depending on the ability of a PLC to read in the signal
from various types of automatic sensing and manual
input devices.

An automatic system is also depending on the ability

of the PLC to control various output field devices like

motor, solenoid valve etc.
3/12/17 Nevase A M 33
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different
parts of PLC -
CPU Function, Scanning cycle, speed of
execution, Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
34
Block Diagram of PLC

3/12/17 Nevase A M 35
Block Diagram of PLC

3/12/17 Nevase A M 36
 Power Supply

Supplies DC power to other modules that plug

into the rack.
In large PLC systems, this power supply does
not normally supply power to the field devices.

In small and micro PLC systems, the power

supply is also used to power field devices.
3/12/17 Nevase A M 37
 Processor
Is the brain of the PLC.
Consists of a microprocessor
for implementing the logic, and
controlling the communications
among the modules.
esigned so the desired circuit can be
entered in relay ladder logic form. Processor
Module
he processor accepts input data from
various sensing devices, executes the
stored user program, and sends
appropriate output commands to
control
3/12/17
devices. Nevase A M 38
 I/O Section

Consists of input modules

and output modules.

3/12/17 Nevase A M 39
 I/O Section

Input Module

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.
3/12/17 Nevase A M 40
 I/O Section
Output Module

Forms the
interface by which
output field
devices are
connected
PLCs employ to the
an
controller.
optical isolator
which uses light
to electrically
isolate the
internal
components from
the
3/12/17 input and
Nevase A M 41
 Programming Device
PC with appropriate
software

A personal computer (PC) is the most

commonly used programming device.
The personal computer communicates with the
PLC processor via a serial or parallel data
communications link.
The computer monitor is used to display the
logic on the screen.
3/12/17 Nevase A M 42
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and
RAM
Input modules function, different input devices
used with PLC and their
3/12/17
uses
Nevase A M 43
Memory in PLC

3/12/17 Nevase A M 44
PLC Scan Cycle

3/12/17 Nevase A M 45
PLC Size
Sr. Size Description
No.
1 Small - It covers units with up to 128 I/Os and
memories
up to 2 Kbytes.
- These PLCs are capable of providing
simple to
advance levels or machine controls.
2 Medium - It 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
3/12/17
memories
Nevase A M
up to 750 Kbytes.
46
-
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
47
Types of PLC
Fixed PLC:
A Fixed PLC has all of its components-the
input section, CPU and associated memory,
power supply, and output section-built into
one self-contained unit.

All input and output terminals are built into

the PLC package and are fixed, not
removable.
3/12/17 Nevase A M 48
 Types of PLC
Fixed I/O

Is typical of small PLCs

Comes in one package, with

no separate removable units.

The processor and I/O are

packaged together.
Lower in cost
but lacks
flexibility.
3/12/17 Nevase A M 49
Types of PLC
Modular PLC:
The modular PLC comes as separate pieces.
A modular PLC is purchased piece by piece.
There may be two or three power supplies to
choose from, a handful of different
processors (CPUs), many separate input and
output cards or modules, and selection of
assemblies, called racks, chassis, or base
plates to hold the pieces together.
3/12/17 Nevase A M 50
 Types of PLC

Modular I/O

divided by compartments
nto which separate modules
an be plugged.

This feature greatly

increases
your options and the
units
flexibility. You can choose
from all the modules
available
3/12/17 Nevase A M 51
 Types of PLC

Modular I/O

When a module slides into the

rack,
it makes an electrical
connection with a series of
contacts - called the
backplane.
3/12/17 The Nevase
backplane
AM is 52
Selection Criteria of PLC
To determine the most suitable PLC to be used in
the automation task, there are several basic
considerations to be made

Necessary input/output capacity;

Types of I/O required;

Size of memory required;

Speed and power required of the CPU and

instruction set
Manufacturer's support and backup.
3/12/17 Nevase A M 53
PC Vs PLC
Sr.
Parameter PLC Systems Computer System
No.
1 Price per function LOW HIGH
2 Physical size Very Compact Fairley compact
3 Operating speed Fast Fairley fast
Electrical noise Good Quite good
4 Immunity

Installation Simple to program Programming

5 and install extremely time
consuming
Capable of YES YES
6 complicated
Operations
Ease of changing Very Simple Quite Simple
7 Functions

Ease of maintenance Good- few standard Poor- Several custom

8 cards boards
3/12/17 Nevase A M 54
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input
devices used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
55
Input Modules
Input modules serve as the link between field devices
and the PLCs CPU.
Each input module has a terminal block for attaching
input wiring from each individual field input device.
Typically input modules have either 8, 16 or 32 input
terminals.
The main function of an input module is to take the field
device input signal, convert it to a signal level that the
CPU can work with, electrically isolate it, and send the
signal, by the way of the backplane board, to the CPU.

3/12/17 Nevase A M 56
 Input Module Connections

The same input

field devices are
used.

These devices are

wired to the input
module according
to the
manufacturers
labeling scheme.

3/12/17 Nevase A M 57
Input Devices
Mechanical Switches:

A mechanical switch generates an on/off

signal or signals as a result of some
mechanical input causing the switch to open
or close.
Such a switch might be used to indicate the
presence of a work piece on a machining
table, the work piece pressing against the
switch and so closing it.
3/12/17 Nevase A M 58
Input Devices
Proximity Switches:

Proximity switches are used to detect the

presence of an item without making
contact with it.
There are a number of forms of such
switches, some being suitable only for
metallic objects.
The eddy current type of proximity switch
has a coil that is energized by a constant
alternating current and produces a
constant alternating magnetic field.
When a metallic
3/12/17 Nevase A Mobject is close
59 to it, eddy
Input Devices
Photoelectric Sensors and Switches:
(LED, Photodiode, Photo transistor):
Photoelectric switch devices can either
operate as transmissive types, in which
the object being detected breaks a beam
of light, usually infrared radiation, and
stops it reaching the detector, which
shows a U-shaped form in which the
object breaks the light beam; or reflective
3/12/17 Nevase A M 60
types, in which the object being detected
Input Devices
Encoders: (Absolute encoder, incremental
encoder):
The term encoder is used for a device that
provides a digital output as a result of
angular or linear displacement.
An incremental encoder detects changes
in angular or linear displacement from
some datum position; an absolute
encoder gives
3/12/17
the actual angular
Nevase A M 61
or linear
Input Devices
Temperature Sensors: (RTD, Thermister,

Thermocouple):

A simple form of temperature sensor that

can be used to provide an on/off signal

when a particular temperature is reached

is the bimetal element.

3/12/17 Nevase A M 62
Input Devices
Position/Displacement Sensors:
(Rotary/Linear Potentiometer)
The term position sensor is used for a sensor
that gives a measure of the distance
between a reference point and the current
location of the target, while a displacement
sensor gives a measure of the distance
between the present position of the target
and the previously recorded position.
3/12/17 Nevase A M 63
 Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules Nevase
3/12/17 function,
AM different output
64
Output Modules
Output modules serve as the link between the PLCs
microprocessor and hardware field devices.
Each output module has a terminal block for
attaching output wiring to go to each individual
field output device.
Typical output modules have either 8, 16 or 32
output terminals.
The output signal once received from the CPU, must
be stored before being sent to each output
modules output screw terminals.
3/12/17 Nevase A M 65
The storage area for output signals is called the
 Output Module Connections
Same output field
device is used and
wired to the output Triac
module.

Triac switches motor

ON and OFF in
accordance with the
control signal from the
processor.
3/12/17 Nevase A M 66
Output Devices
Relay:

For a relay connected to the output of a PLC,

when the output switches on, the solenoid
magnetic field is produced, and this pulls on
the contacts and so closes a switch or
switches.
The result is that much larger currents can
be switched on. Thus the relay might be
used to switch on the current to a motor.
3/12/17 Nevase A M 67
Output Devices
Directional Control Valves:

Another example of the use of a solenoid as an

actuator is a solenoid operated valve.
The valve may be used to control the directions
of flow of pressurized air or oil and so used to
operate other devices, such as a piston moving
in a cylinder.

3/12/17 Nevase A M 68
Output Devices
Motors

Stepper Motors

3/12/17 Nevase A M 69
References
Programmable Logic
Controllers F. D. Petruzella

Introduction to
Programmable Logic
Controllers Gary Dunning

Programmable Logic
Controllers Jhon
Hackworth, Federic
Hackworth
3/12/17 Nevase A M 70
 Thank
You
Amit Nevase
3/12/17 Nevase A M 71