Automation : Typical installation . . . .

SCADA Software
Communication Cable

Control Hardware Control Panel

Field Cabling

Junction Box
Field Cabling

Sensors Placed in the field

Control Systems Types

Programmable Logic Controllers Distributed Control System PC- Based Controls

Introduction

The PLC is microprocessor based specialized computer that carries out control functions of many types and levels of complexity. Its purpose is to monitor crucial process parameters and adjust process operations accordingly. It can be programmed, controlled and operated.

Programmable Logic Controllers

Applications : Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control Advantages of PLCs

Flexibility, Reliability Large quantity of contacts Online/ offline modifications In-house simulation & testing of project Speed in operation Ladder or Boolean programming methods Ease of maintenance / troubleshooting Simplicity of ordering control system components Documentation, Security

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

Various Brands of PLCs

Allen

Bradley Siemens Modicon Mitshubishi GE Fanuc Omron

USA Germany France Japan USA Japan

Ranges in Allen Bradley

Programming Software: RS Logix 500 & RS Logix 5000
PICO Mirco Logix SLC PLC Compact Logix Flex Logix Control Logix

Ranges in Siemens
PLC S5 S7-200 S7-300 S7-400 Programming Software Dos based Microwin Sematic Manager Sematic Manager

Ranges in Modicon
PLC Nano Micro Premium Quantum Atrium Programming S/W PL7 Pro PL7 Pro PL7 Pro Concept Concept

Types of PLCs
Compact
Modular Distributed

Compact PLCs

Modular PLCs

CPU

I/O Modules
Power Supply

Distributed PLCs with Remote I/O

STZ 10

Remote I/O

1
ATS05

2
ATS05

3
ATS05

4
ATS05

P L C Components

Central Processing Unit (CPU) Input Output Modules Power Supply Bus system Programming Device
IN CPU OUT

MODULE PROGRAM DEVICE

MODULE

P L C : Central Processing Unit

It is a micro-controller based circuitry. 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 functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnostics.

How CPU Functions

Up Keep
Read Inputs

Comn with Network

Read Registers

Write to Output

Read User Program

Scan Cycle of CPU

Scan Cycle Depends upon No of I/Os More I/Os More scan time Application Decides the Scan time of a PLC Scan time in normal applications is 1 ms to 2 ms & in bigger applications 100 ms to 200 ms

Features of CPUs

Execution Speed .1 ms/1ms/10ms I/O Handling capacity Memory capacity Instruction sets (Normal, advance) Language support (FB, LD) Support for application specific module Integrated functionality

PLC Input Modules

These modules act as interface between realtime status of process variable and the CPU

Digital (Contacts, Switches, Limit switch,Push

buttons, Pressure switch, pump / valve on-off status) Typical modules is 24 V DC, 115 V AC, 230 V AC (0 or 1, Closed or open, True or false)

Thermocouple) 4-20ma, 0-10v, -10-+10v, 0-5v, 0-20ma, -20+20ma. Note: There are modules which can handle all are called universal modules

Analog (Pressure, Flow, Level, Tx, RTD

Digital Input Module

No

of channels: 4,8,16,32, 64 24vdc, 230v ac, 110dc Source, sink or both Isolated or un-isolated common

Digital Input Module- Internal

5v dc Inverter Current limiting resister O/P high

Start Stop S/W

Opto coupler

Com

In case one diode is parallel to another diode in opposite polarity. It can act as source or sink both

Note
When

diode conducts, infra red light falls on the base of the transistor, which conducts and inverter makes O/P high Diode transistor pair is called optical isolation (produces 1.5kv isolation) In case of higher voltages only card is damaged, functioning of the entire plant is saved.

Digital Input Module-External

L1 PB input field device 120 V ac L1 1 2 3

L2

Input status indicator

4
L2 Input module terminal board

Digital Output Module

These modules act as link between the CPU and the output devices in the field No of channels: 4,8,16,32, 64 24vdc, 230v ac, 110dc

Solenoid Valves, lamps, Actuators, dampers, Pump/valve on off control

Isolated or un-isolated common Relay type (both ac & dc), TTL Type (only dc), Triac type (only ac)

Note: contact life of a relay is generally 1 million operations, use of

semiconductor switching in triac & TTL increases life and switching response is faster.

In Triac changing over is done at zero crossing. Advantage: Negative spikes produced by inductive loads, which are harmful for electronic ckts are reduced. Amount of back emf is drastically reduced

Transistor- Transistor Logic (TTL)

Triac outputs

Digital Output Module

0V diode

In dc modules a parallel diode is placed to reduce noise /back emf

24 V

Load Com Isolated Com Com

In isolated type modules common is different for all loads

Load

Analog Input Module

No of channels: 2, 4,8,16 (rarely 16 channels) Isolated or un-isolated common Type of input: Thermocouple, RTD, Voltage 2 wire, 4 wire Resolution

Analog Input Module

PT-100 Ohm 24v dc Note: A/D converter comes with 16, 14, 12, 18 bit resolution

4 Wire TX

_
4-20 mA

TX

+
Low pulse filter ckt
A/D converter

Scaling

Example: Microscopes resolution is good if we can see each part of an organism

+ _

4-20 mA TX 24V dc

2 Wire TX

Analog Input Module

Resolution:
Allen Bradley uses natural binary conversion. Higher the resolution higher the cost & depends upon how minute data can be monitored 12 bit resolution = 4096 bits. Data to be measured will be divided into 4096 parts. Most of Analog Input modules use 16 bit. Digital information is at bit level Analog information is at word level

Analog Output Module

No of channels: 2, 4,8,16 (rarely 16 channels) Isolated or un-isolated common Current, Voltage Resolution 12 bit, 14 bit, 15 bit, 16 bit output is 4-20 mA, 0-10 V Ex : Control Valve, Speed, Vibration
Note: For Robotic operation you need finer control, hence needed high resolution. For Normal Control valve operation less resolution may be used

Analog Output Module

50% Opening

+
I/P Converter

PID Alogrithm

_
50% Opening

Digital Form

Constant Current Source

D/A Converter 0-32767

Constant current source will give 12 mA for opening 50%

Output module- connections

L1 120 V ac L2

L1

Output status indicator

1 2 3 4 L2

Output field device

Module blown Fuse indicator

Output module

Application Specific Modules

Stepper Control modules Servo Control modules Common modules
Modbus profibus Device Net ASi Bus (2 wire,Very high speed comn carries power & signal both)

DG

Synchronization modules etc.

Sinking/Sourcing

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 . Bus system is responsible for the signal exchange between processor and I/O modules The bus system comprise of several single line ie wires / tracks

PLC Cycle
Sense

the Input Process the Logic Give Output

Programmable controller

Inputs Machine or Process

Outputs

PLC Signal Flow

Input Module Processor Memory Data Output Input Image Table Image Table I:0/6 I:0/6 I:1/4 O:1/5 Output Devices O:0/7 O:0/7 Output Modules

Input Devices
Ladder Program I:0/6 O:0/7 O:1/5 O:1/5

I:1/4

I:1/4

Programming Terminal

PLC Architecture in 1970s

Discrete Machine Control

Programming Terminal
Connection Point to Point

PLC
Programming Language :
Connection Point to Point - Relay ladder logic - Flexibility in altering - Control system operation

I/O

PLC Architecture in 1980s

Discrete and Process Control
MS - DOS

Reasonable Computer Running PLC Programming Software

PLC
Programming Language :
- Ladder Program - PID - Data Storage

I/O

PLC Architecture in 1990s

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 system

I/O

PLC Architecture Today

Distributed I/O Modules
PLC

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

PLC Architecture Today

Hot Redundant System

TAPS SPLITTERS Remote I/O Network FIBER OPTIC LINK

PLC Architecture today Ethernet Technology in PLCs

Workstation

Workstation

Workstation

Workstation

Switched Hub

Controller Controller

Controller

Controller

PLC Architecture today

Wireless communication
PLC
Wireless Modem

Remote Platform
Wireless Modem PLC

HMI Display

PC

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

Ladder Basics
Ladder is widely used language & is close to Electrical basics. In 50-60% places in a ladder: NO, NC or (XIC, XIO in case of Allen Bradley) are used.

If s/w closed at this add CPU interprets it as True condition If s/w Open at this add CPU interprets it as False condition If s/w Open at this add CPU interprets it as True condition If s/w Closed at this add CPU interprets it as False condition

Comparison & use of XIO, XIC

Start Start P Stop Relay Auxiliary Start Stop Relay Auxiliary Stop Relay

Motor

Auxiliary

Basic Relay Logic

Basic Start/ Stop circuit with latch

AND Gate, Relay and PLC Equivalent

OR Gate, Relay and PLC Equivalent

NOT Gate, Relay and PLC Equivalent

Slot 0

Slot 1

Slot 2

Slot 3

Slot 4

Slot 5 Slot 6

Slot 7

Addressing Scheme in AB PLC

File type: slot add .word add CPU generally is in Slot 0 Slot 1 I :1.0/0 to Slot 2 I:2.0/0 to Slot 3 O:3.0/0 to Slot 4 I:4.0/0 to Slot 5 I:5.0 to Slot 6 O:6.0 to Slot 7 I:7.0 to O:7.0 to /bit add

I:1.0/15 I:2.0/7 O:3.0/15 I:4.0/31 I:5.3 O:6.3 I:7.1 O:7.1