PROGRAMMABLE

LOGIC
CONTROLLER
 Control Systems Types

 Programmable Logic Controllers

 Distributed Control System
 PC- Based Controls
 Introduction

 The PLC is an assembly of solid state digital logic

elements design to make logical decisions and
provide outputs.
 Programmable Logic Controllers

 Sequential logic solver

 PID Calculations.
 Advanced Subroutines
 BIT Operations.
 Data Transfer.
 Text Handling.
 Programmable Logic Controllers

Applications :
 Machine controls, Packaging, Palletizing, Material handling, similar
Sequential task as well as Process control
Advantages of PLC :
 They are fast and designed for the rugged industrial environment.
 They are attractive on Cost-Per-Point Basis.
 These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)
 These Systems are upgraded to add more Intelligence and Capabilities
with dedicated PID and Ethernet Modules.
Disadvantages of PLC :
 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
 Programmable Logic Controllers

PLC Types
 Nano (Small)
 Micro (Medium)
 Large

Basic criteria for PLC Types

 Memory Capacity
 I/O Range
 Packaging and Cost per Point
 P L C Components

 Central Processing Unit (CPU)

 Input Output Modules
 Power Supply
 Bus system
 Programming Device IN CPU OUT m

MODULE MODULE

PROGRAM
DEVICE
 P L C : Central Processing Unit

 It is a micro-controller based circuitary. The CPU consists of following

blocks :
Arithmatic Logic Unit (ALU), Program memory
Process image memory (Internal memory of CPU)
Internal timers and counters
Flags
 CPU performs the task necessary to fulfill the PLC funtions. These tasks
include Scanning, I/O bus traffic control, Program execution, Peripheral
and External device communication, special functions or data handling
execution and self diagnistics.
 PLC : Input module

 These modules act as interface between real-time status of

process variable and the CPU.
 Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)
 Digital input module : Typical input to these modules is 24 V DC,
115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off status
PLC : Input module
L1 120 V ac L2

PB L1
Input status
input 1 indicator
field
device
2

L2

Input module
terminal board
 PLC : Output module

 These modules act as link between the CPU and the output devices
in the field.
 Analog output module : Typical output from these modules is 4-20
mA, 0-10 V
Ex : Control Valve, Speed, Vibration
 Digital output module : Typical output from these modules is 24 V
DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off
control
PLC : Output module L2
L1 120 V ac

L1
Output status
indicator
1

2
Output field
device
3

L2 Module blown
Fuse indicator

Output module
 I/O SPECIFICATION

 INPUT VOLTAGE – Magnitude and type of voltage

 ON-STATE INPUT VOLTAGE RANGE – voltage at which signal is
recognized
 Nominal current per input – Min. current to operate input circuit
 AMBIENT TEMP RATING – Max temp of surrounding the I/O
module
 INPUT DELAY – Time duration for input signal to be on before
known as valid input. ( 9-ms to 25ms)
 NOMINAL OUTPUT VOLTAGE – It is min and max o/p operating
voltage.e.g. Rated 120 v ac o/p ckt. Works in 92 to 138 v range.
 MAX O/P CURRENT RATING – Max current a single o/p or
module can safely carry under load
 OFF –STATELEAK CURRENT PER O/P – Max value of leak current
flows through the o/p in OFF position
 ELECTRICAL ISOLATION – Max volts between I/o and logic ckt.
 P L C : Power Supply

 The power supply gives the voltage required for electronics

module (I/O Logic signals, CPU, memory unit and
peripheral devices) of the PLC from the line supply.
 The power supply provides isolation necessary to protect the
solid state devices from most high voltage line spikes.
 As I/O is expanded, some PLC may require additional power
supplies in order to maintain proper power levels.
 P L C : Bus System

 It is path for the transmission of the signal . Bu system is

responsible for the signal exchange between processor
and I/O modules
 The bus system comprise of several single line ie wires /
tracks
Relay Connection

L1 L2 L3
M
L1
CR CL M M M

CR T1 T2 T3
2
M

4
M

L2 MOTOR
 Advantage of PLC Over Relay Style

RELAY PLC
1-Hard wiring 1-Less wiring

2-Changes difficult 2-Easy modification

3-More power 3-Low power

4-More maintenance 4-Solid state reliability

5-Difficult to expand -Ease of expansion

 PLC Cycle

 Sense the Input

 Process the Logic
 Give Output

Programmable
controller

Inputs Outputs

Machine
or
Process
 PLC Signal Flow
Input Module Processor Memory Output Modules

Input Data Output

Image Table Image Table
I:0/6 O:0/7
I:0/6
O:0/7
I:1/4 O:1/5

Input Devices Output Devices

Ladder Program

I:0/6 O:0/7

I:1/4 O:1/5
I:1/4 O:1/5

Programming Terminal
 PLC Architecture Evolution
 Mid - 1970s : Discrete Machine Control

Programming
Terminal

Connection is Point to Point

PLC
Programming Language :
Connection is Point to Point
- Relay ladder logic
- Flexibility in altering
Control system operation
I/O
 PLC Architecture Evolution
 Early - to - Mid 1980 : Discrete and Process Control

MS - DOS
Reasonable Computer
Running PLC
Programming Software

PLC
Programming Language :

- Ladder Program
- PID
- Data Storage
I/O
 PLC Architecture Evolution

 Late 1980’s to early 1990’s : Discrete and Process

Control Windows

PC running
PLC Programming Software
Connection in networked allowing
Multiple PLC

PLC PLC

PLC became a part of the

developing enterprise resource
I/O system
 PLC Architecture Evolution

Today : Distributed I/O Modules

PL
C

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

 PLC Architecture Evolution

Today : Hot Redundant System

TAPS
SPLITTERS
Remote
I/O Network

FIBER OPTIC LINK

Remote I/O
 PLC Architecture Evolution
Today : Ethernet Technology in PLCs

Workstation Workstation Workstation Workstation

Switched Hub

Controller

Controller
Controller Controller
 PLC Architecture Evolution

Today : Wireless communication

PLC

Wireless Modem

Remote
Platform

Wireless Modem

PLC

HMI PC
Display
 PLC Systems of various vendors

Siemens
 S5 -110U, 115U, 135U
 S7 - 200, 300, 400
Allen Bradley
 Micrologix 1000, 1200, 1500
 SLC 5/01, 5/02, 5/03
 PLC 5/10, 5/25 and 5/40
Modicon
 Nano
 Micro
 Premium
 Quantum
 Configuration of PLC : Modicon

Built in display for I/O Programming Terminal PC Connection

(in-rack, AS-i) and Diag

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter TSX37-22

Unitelway Port for connection PCMCIA communications port

of up to 5 Slaves
PCMCIA memory expansion port
 Configuration of PLC : Siemens

CPU

I/O Modules
External Power
Supply
 Configuration of PLC : Allen Bradley

CPU

I/O Modules
Power Supply
 Configuration of PLC : GE FANUC

I/O Modules Back plane

CPU
 PLC Programming Standards

The open, manufacturer-independent programming standard

for automation is IEC 61131-3. You can thus choose what configuration
interface you wish to use when writing your application :

 Ladder Diagram
 Statement List
 Instruction List
 Function Block Diagram
 Sequential Function Chart
 Structured Text
 Scan Rate

 The completion of one cycle of the sequence is

called- SCAN

 Time required for one cycle is called SCAN

TIME
 PLC DCS Selection Criteria

 Cost of hardware, software, Integration Engineering,

Design, Installation, Start-up and Commissioning,
Validation documentation and Execution, Training, Spare
parts, Maintenance, System service contract and system life
cycle.
 Reliability, Flexibility, Scalability and Validatability.
 Ease of Database configuration, Graphics development,
Interlocks and Batch processing.
 Integration of High-level Application.
 Control Philosophy for Centralized versus Remote
Operator Console or both.
 Compliance with an Industry batch standard such as ISA
SP88 and new Communication Protocol.
Memory Types

 ROM (Read Only Memory)

 RAM (Random Access Memory)
 PROM (Programmable ROM)
 EPROM (Erasable PROM)
 EAROM- Electrically alterable ROM
 EEPROM-Electrically erasable PROM
Binary System

 BIT – Each digit of a binary number

 BYTE – Group of 8 bit
 WORD – Group of one or more byte
 LSB – Least significant bit or smallest
value
7 6 5 4 3 2 1 0
 MSB – Most significant bit or largest
value 8 BIT WORD
MSB LSB

BYTE BYTE
18 BIT WORD
 PLC : Terminology

 INPUT is referred by – Ixxyy

 OUTPUT is referred by – Qxxyy
 TIMER is referred by – T xyyzzzz
 FLAGS are referred by – M xxxx
 COUNTERS are referred by – C xxxx