P2:

Explain the system hardware and

software requirements for a
programmable controller application
 Learning Objectives

• Revisit the basics programmable controller

structure
• Understand the hardware and software used for
programmable controller
• Be able to identify and explain the hardware and
software required for the given programmable
controller application
A programmable logic controller (PLC) is an industrial
solid-state computer that monitors inputs and outputs,
and makes logic-based decisions for automated
processes or machines.

Components of PLC
There are four components of PLC as follows:

1. Processor or Central Processing Unit (CPU)

2. Programming unit, Software

3. Input module

4. Output module
Input
Input Devices
Devices Input
Input Module
Module Micro-
Micro- Output
Output Output
Output Devices
Devices
Processor
Processor Module
Module

Memory
Memory

Power
Power Supply
Supply

CPU

Fig 2 : Components of PLC

Fig : PLC system
 Input Devices
 Input devices provide input signal to the PLC.
Generally this input is from switches and sensors .
For PLC system, there are two types of inputs: Analog and Digital

 Analog input is a continuous signal and changes with time. e.g. temperature,
voice/sound, pressure, level, voltage, current etc

http://www.technologystudent.com/elec1/anadig1.htm

https://learn.sparkfun.com/tutorials/analog-vs-digita
https://www.st-andrews.ac.uk/~www_pa/Scots_Guide/info/signals/analog/analog.htm
 Digital signal
It has discrete values.
It assumes only fixed values.(doesn’t change with
time)
An electronic sensor is an electronic device used to measure a physical quantity such as
temperature, pressure or loudness and convert it into an electronic signal.

The physical quantity that are sensed and or monitored are :


Temperature


Pressure


Flow rate


Level


Position (linear and angular)


Depth


Speed


Magnetic field


Viscosity
 Quantity

 Density

 Acidity

 Content (e.g. the carbon dioxide in a flue gas)

 Voltage

 Current

 Torque

 Power
 The switches that are usually connected to PLC
are as follows:
 Mechanical switch
 Proximity switch
 Limit switch
 Photoelectric sensors
 Encoders
 Voltage sensing relays
http://technocritical.com/industrial-electronics/plc-systems/inputoutput-system
Fig: Range of sensors
 Input Module

• The input module converts the input signals

from sensors/switches into signals that are
acceptable by PLC.
• Each input point has a unique address.
• It provides isolation and signal conditioning
functions.
Opto couplers:
It is component that has an LED and
phototransistor in one package.
When LED is given pulse, it emits light which is
received by photo transistor.
Opto coupler basically isolates the two
device/unit by electrical isolation.
PLC Input Module structure
 Signal Conditioning

• Signal conditioning circuits include

amplification, filtering, Analog to Digital
Converters etc.
Analog to Digital Converter (ADC)
 Central Processing Unit (CPU)

 CPU is the “brain” of PLC system.

 CPU has three main parts:
1. Microprocessor
2. Memory
3. Power supply
 Microprocessor

• Microprocessor is a multipurpose and

programmable device that performs the
following actions:
• Read the input.
• Perform Arithmetic, logic and control
operations as per the program stored in
memory.
• Communicate the actions to the output
device.
Basic PLC operation

Read
Read Inputs
Inputs

Solve
Solve Logic
Logic

Write
Write Output
Output

Fig: PLC scan cycle

 Data Bus

Data Bus
BUF BUF

C
BUF
R
Test Processor
W
C
R Clock
ALU
Test ID Reset
Write
Address Bus BUF
Read

A B
IR

PC AL

BUF BUF

Address Bus

Fig: Internal structure of the processor

 Memory Operation

• Write: The process of putting new information into a memory

location is called writing.
• Read: The process of retrieving information from a memory
location is called reading.

Read only Memory (ROM) Random Access Memory (RAM)

Only read operation Can be read or write
Used to store operating system Used to store user program,
temporary data
 PLC Memory
Memory in PLC is used to store instructions(or programs) and execute
them to control the field devices.

Executive Memory Application Memory

•Used to store operating system, firmwareUsed to store user program

•Permanent Memory Temporary data

•Not accessible to the user Accessible to the user

•Its ROM. Its RAM

 Memory

• Memory is a set registers to store information.

Volatile Non-Volatile
Data is lost when power source is Data is retained even though
removed when power source is removed
Used to store temporary data Used to store system program,
operating system
 Power supply

 It is very important part of PLC system.

 It provides internal DC voltages to the system
components.
 Most PLCs, however, require a 120 VAC or 220
VAC power source, while a few controllers will
accept 24 VDC.
 Programming Unit
• In order to direct PLC for action, one needs to
feed the program to PLC. This programming is
done by programming terminal which has
necessary software.
• The software also aids in monitoring and
debugging.
 Output Module
• The output module contains switches activated by
the CPU in order to connect two terminals and so
allow current to flow in the external circuit.
• The output device can be a valve
(hydraulic/pnuematic), motor, light/bulb.
• Output terminals are numbered and these
numbers are used in the program.
 Typical Opto-isolated Output Module Circuit

V+

Status LED

Load
From CPU
internal Circuit

Opto - Isolator

0V
 Output Devices

Output devices are switched on by the PLC. They

are as follows:
• DC motors(e.g.to start the conveyer belt)
• AC motors(e.g. to start the pump)
• Solenoid valve in hydraulic or pneumatic
system
• Linear electric actuator
• Lights/Indicators
• Alarms (for fire or levels)
• Heating elements( heater in hydraulic tank)
 Output Devices
• The type of output ports of the PLC depends
on the type of devices connected to be
switched ON or OFF. Basic types are:
• Relay type (for AC and DC switching)
• Transistor type (restricted to DC only)
• Triac type (for AC switching only)
 Output voltage levels

For a small PLC, all the output might be of one type e.g. 240 AC, 1 A.
 A solenoid valve is an electromechanical device
used for controlling liquid or gas flow. The solenid
valve is controlled by electrical current, which is
run through a coil.

Solenoid valve
http://www.elec-intro.com/cms/plus/view.php?aid=7670
http://notesnet.blogspot.com/2012/04/industrial-training-report.html
http://www.slideshare.net/priyahada/plc-and-scada-project-ppt
A contactor is an electrically controlled switch used for switching a
power circuit, similar to a relay except with higher current ratings.
http://plctraining1.blogspot.com/2013/01/plc-input-and-output-devicessignal.html
http://www.nptel.ac.in/courses/112102011/11
 : A Simple PLC Application

http://www.aboutplcs.com/click/images/click_w_pb_stacklight_sm.gif
.Identify the input and out to PLC

Input : two switches one to sense the object and other

for motor
Output : motor
Automatic Door Control
Silo Control
 Lift/Elevator

Inputs: push button switch and limit switch(to detect the position of the
elevator), speed sensor, load cell
output :motor
Spraying Robot using PLC
 Input Voltage Level

 The input voltage levels for PLC are standard

voltages as shown below:
 For small PLCs, 24V is a generally a standard.