Programmable Logic Controllers (PLC)

PLC Presentation Contents

Introduction What is a PLC PLC Types Choosing PLC Hardware PLC Applications Programming PLCs Advantages of PLCs Questions

What is a PLC?

Nema Definition circa 1978

. The PLC, also known as programmable controller is defined by the National Electrical Manufacturers Association (NEMA) in 1978 as: "a digitally operating electronic apparatus which uses a programmable 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 input/output, various types of machines or process".

Traditional PLC Concept

PLC performs relay equivalent functions PLC performs ON/OFF control Ladder diagram programming Designed for industrial environment

Relay Logic vs. PLC & Ladder Logic

PB1 LS1

SOL2

Inputs

Outputs

LS1

PB2

CR3

Programmable Logic Controller

C R

LS3 I/4 I/6 O/0

||
CR3 |/| LS4

||
I/5

()
B/0

M1

I/7

||
I/8

|| ||

()

B/0

|/|

I/9

O/1

||

()

Input Wiring: PLC input is the load in the circuit, sensing if voltage is present
Terminal Block Isolation Barrier

Input Devices

1 2 3 4 5 6

L1 L1

7
8 9 10 COM

P L C

L2

Input Devices
Pushbuttons Selector Switches

120/230 VAC 24 VDC

Sourcing
Sinking

Limit Switches
Level Switches Photoelectric Sensors

Proximity Sensors
Motor Starter Contacts Relay Contacts Thumbwheel Switches

Output Wiring: PLC output is the switch, controlling current flow to load
Isolation Barrier Terminal Block

Output Devices L1 L2

CR

OUT 1 OUT 1 OUT 2 OUT 2

P L C

OUT 3 OUT 3 OUT 4

OUT 4 OUT 5 OUT 5 OUT 6 OUT 6

L1 L2

Output Devices
Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns Relays
120 VAC/VDC 240 VAC 24 VAC/VDC

Triac
120/230 VAC

Transistor MOSFET
24 VDC

Inside a PLC
Communications

I n p u t

C i r c u i t s

Central Processor

O u t p u t

C i r c u i t s

CR

High Voltage
Isolation Barrier

MEMORY
program
Low Voltage AC Power Supply 85-264 VAC, 50/60Hz

Isolation Barrier

High Voltage

data

or

External DC Power Supply

PLC Operating Cycle

START

Housekeeping
Internal checks on memory, speed and operation. Service any communication requests, etc.

Input Scan
The status of external inputs (terminal block voltage) is written to the Input image (Input file).

Output Scan
The Output Image data is transferred to the external output circuits, turning the output devices ON or OFF.

Program Scan
Each ladder rung is scanned using the data in the Input file. The resulting status (Logic being solved) is written to the Output file (Output Image).

PLC Hardware Types

Most Basic of PLC Systems

In the most basic of PLC systems, a self contained (shoe box) PLC has 2 terminal blocks, one for Inputs and one for Outputs Today, most PLCs in this category are know as Micros. Typically they provide front panel LED status indication of I/O and Processor states
Inputs
Outputs

Programmable Controller
C R

Modular Chassis Based PLCs

The vast majority of PLCs installed today are modular chassis based systems consisting of: 1. Processor Module (CPU) 2. Input & Output Modules 3. Chassis 4. Power Supply

Modular Chassis-less PLC Systems

Also available from many vendors are Chassis less but still Modular PLC systems. These systems still require a Processor, I/O Modules, and Power Supply, but in place of a chassis these components mount directly onto a panel, din rail, and many use a tongue and grove system to allow easy insertion and removal

Choosing PLC Hardware

PLC Application Considerations

Inputs/Outputs
Type,
AC, DC, sourcing, sinking, etc.

Functions required
Instruction set
Messaging PID PTO, PWM

Number of
10, 16, 20, 32, 156

Memory
Type
Flash or Battery backed

Arithmetic Communications
DeviceNet, Ethernet Remote I/O, DH+

Size
1k, 6k, 12k, 16k, 64k

Report generation

SOURCING vs. SINKING

SOURCING Pushbutton (PNP)

SINKING Pushbutton (NPN)

+VDC

+ +
DC Power Supply DC Power Supply

DC COM

SOURCING vs. SINKING DC Inputs

SOURCING (PNP)
Field Device

SINKING (NPN)
+VDC IN1

+
DC Power Supply

+
DC Power Supply

DC Input Module
DC COM

Field Device

DC Input Module
IN1

Rules

RULES
Field devices on the positive side (+VDC) of the field power supply are sourcing field devices. Field devices on the negative side (DC COM) of the field power supply are sinking field devices. Sourcing field devices must be connected to sinking I/O cards and vice versa. Sinking field devices must be connected to sourcing I/O cards and vice versa.

PLC Applications

Installed and Running Systems in RI

Conveyors Curtain rods Deodorants Donuts Duplex Receptacles Fibers Filters Forged Parts Glass Goggles Grinding and Polishing Heat Treating Metal Products Jails Lenses Nails Natural Gas Paper Pharmaceuticals Plastics Plating Plating Machines Power Generation Power Supplies Product Assembly Machines Rubber products Seafood Processing Soda Staples Warehouse Automation Waste Water Systems Drinking Water Systems Water Heaters Web Handling (paper/plastic) Wire / Cable

Typical PLC Application

Solenoid 1
Ingredient A

Motor

Solenoid 2
Ingredient B

Sensor 1

Sensor 2

Solenoid 3

Operation of Mixer (Sequence of Control)

Solenoid 1
On = Sol 3 is off, and Motor is off, and Sensor 2 is off, and Auto Switch is on Off = Sol 3 is on, or Motor is on, or Sensor 2 is on

Solenoid 3
On = Sol 1 is off, and Sol 2 is off, and Motor has run for 30 sec. Off = Solenoid 3 has been on for 60 sec.
Solenoid 1
Ingredient A

Solenoid 2
On = Sol 3 is off, and Motor is off, and Sensor 2 is on Off = Sol 3 is on, or Motor is on, or Sensor 1 is on

Motor

Solenoid 2
Ingredient B

Motor
On = Sensor 1 is on, and Solenoid 2 is off, and Solenoid 1 is off Off = Solenoid 3 on

Sensor 1

Sensor 2

Solenoid 3

PLC Applications: Packaging

De-Palletizing, Washing, Filler, Capper, Case Packaging, Wrapping, Cartoning, Labeling, & Bagging Machines

PLC Application: SCADA & RTU

Supervisory Control and Data Acquisition (SCADA)/Remote Terminal Unit (RTU)
puts the remote site report data at your fingertips, but also provides affordable remote communications and control, minimizing the likelihood of remote site issues.

PLC Applications: Material Handling

Control of rollerbed conveyors or towveyors, and mobile equipment including transfer vehicles, elevated transfer vehicles, lifts and hoists, and stacker cranes.

PLC Applications: Distribution

Start and stop conveyors, control traffic at merge points, redirect packages at divert points, and control a wide assortment of OEM machines such as palletizers and accumulators.

PLC Programming

Programming PLCs
The purpose of a PLC Program is to control the state of PLC outputs based on the current condition of PLC Inputs Different PLCs support different languages, but the most popular PLC language is know as Ladder Logic. PLC Ladder Logic purposely resembles Relay Logic

Ladder Logic Concepts

Read / Conditional Instructions

Start (Rung #1)

Write / Control Instructions

|| || || || || || |/| |/| |/|

() () () ()

End (Rung #5)

||

|/|

()

Ladder Logic Concepts

Read / Conditional Instructions

Write / Control Instructions

|/|
T

||
F

()
F

No Logical Continuity

|/|
T

|/|
T
Logical Continuity

()
T

Logical AND Construction

IF input 4 AND input 5 have power THEN energize output 0

I/4 I/5 O/0

On

||
T

||
T

()
T

Logical Continuity

Logical OR Construction

IF input 4 OR input 5 have power THEN energize output 0

I/4

T
Logical Continuity

O/0 On

||
F I/5

()

||

I/4

F
Logical Continuity

O/0

On

||
T I/5

()

||

Complex Construction

I/4

I/0

I/1

||
I/5

|/|
I/1

||
I/7

|| |/|

I/9 I/10 O/0

|| ()

I/8

||

|/|
I/2

|/|
I/3

|| ||
I/11

I/1

|/|

||

Read Instructions

Supply Voltage
LS 1

Unused

Unused

COM

I/0

I/1

I/2

I/3

I/4

COM

I/5

I/6

I/7

I/8

I/9

The instruction is: If the input device is The input bit is Examine ON Examine OFF

-| |XIC False True

-|/|XIO True False

Open (0) Closed (1)

Logic 0 Logic 1

Write Instruction
|| |/| ()

Rung State TRUE

Output Bit ON

Output Terminal ENERGIZED

OTE Output Energize

-( )FALSE OFF De-energized

L1

L2/N

GND

VAC VDC

O/0

VAC VDC

O/1

VAC VDC

O/2

VAC VDC

O/3

VAC VDC

O/4

O/5

Supply Voltage

Putting it Together

Supply Voltage

PB1

Unused

Unused

COM

I/0

I/1

I/2

I/3

I/4

COM

I/5

I/6

I/7

I/8

I/9

L1

L2/N

GND

VAC VDC

O/0

VAC VDC

O/1

VAC VDC

O/2

VAC VDC

O/3

VAC VDC

O/4

O/5

Supply Voltage

I/8

O/0

||

()

Addressing Example

L1 PB1 LS1 PS2 SOL6

L2
I/5 I/6 I/7 O/0

||

||

||

()

DEVICE PB1 LS1 PS2

ADDRESS HHP Logix I/5 I:0/5 I/6 I/7 O/0 I:0/6 I:0/7 O:0/0

SOL6

Relay Logic to Ladder Logic

PB1 LS1 SOL2 I/4 I/6 O/0

||
LS1 PB2 CR3

||
I/5

()
B/0

I/7

||
I/8

||

()

LS3
B/0 CR3 |/| LS4 M1

||
|/|
I/9 O/1

||

()

INPUT Address Assignment: PB1- I/4 PB2- I/5 LS1- I/6 LS2- I/7 LS3- I/8 LS4- I/9

OUTPUT Address Assignment: SOL2- O/0 M1- O/1

Advanced Instructions

SEQUENCERS SHIFT REGISTERS DATA HANDLING HIGH SPEED COUNTER

SUBROUTINES

Advantages of a PLC

Basic PLC Advantages

Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to change

Source: A-Bs Micro Solutions Presentation

Advantages over Relays

All the capabilities of the earlier systems Dramatic performance increase over the relay logic systems Greater reliability Little maintenance due to no moving parts No special programming skills required by maintenance personnel Physical size of the PLC system is much smaller than the conventional relay based logic And most importantly much lower cost
Source: C.Maynard@curtin.edu.au

Advantages over SBCs (single board computers)

SBCs have high design costs
Contract or Staff with overhead and maintenance issues associated with each

SBCs are Repair / Service nightmare for customers

Depending on markets served supplier must develop/support services

SBCs requires high level of technical expertise by technicians

Specialized circuit boards require specialized equipment and technical staff

SBCs not stocked through local distributors

Suppliers sell the controller imbedded, replacement parts are not readily available even in emergency situations

SBCs typically do not meet worldwide standards

Certifications cost money, typically a single controller does not warrant the investment. Volumes are not high enough and re-certification on each revision is unrealistic

SBCs typically a Domestic product

Because of these issues many manufacturers limit themselves to a single market.
Source: A-Bs Micro Solutions Presentation

Advantages over Computer based Software

Maintenance personnel already experienced in PLC troubleshooting and servicing relay latter logic programming, not PC software Better power failure response Cost advantages for simple machine control Higher reliability that minimizes the expense of shutdown, troubleshooting, repair, & startup Industrially hardened packaging Long availability and support for product models without the rapid obsolescence of PCs.