PROGRAMMABLE

LOGIC
CONTROLLER
 Control Systems
Types

 Programmable Logic Controllers

 Distributed Control System
 PC- Based Controls
 PLC

 The PLC is an assembly of solid state

digital logic elements design to make
logical decisions and provide outputs.
 PLC is programmed interface between
input sensor &output device.
Programmable Logic
Controllers
 Sequential logic solver
 PID Calculations.
 Advanced Subroutines
 BIT Operations.
 Data Transfer.
 Text Handling.
Programmable Logic
Controllers
Applications :
 Machine controls, Packaging, 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 more Capabilities with dedicated
PID and Ethernet Modules.
Disadvantages of PLC :
 PLC one time cost is high
 To maximize PLC performance a number of IO Modules to be
PLC
Components(Hardware)
 Central Processing Unit (CPU)
 Input Modules
 Output Modules
 Power Supply
 Bus system
 Rack(Rail)
I/P O/P
mod
CPU
mod
m

POWER
SUPPLY
 Central Processing Unit
 It is a micro-controller based circuitry. The CPU
consists of following blocks :
Arithmetic Logic Unit (ALU), Program memory
Process image memory (Internal memory of CPU)
Internal timers ,counters and Flags .
 CPU performs the task necessary to fulfill the PLC
functions. i.e. Scanning I/O bus traffic control, Program
execution, Peripheral and External device
communication, data handling and self diagnostics.
 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
 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
 Digital output module : Typical output from these modules
is 24 V DC, 115 V AC, 230 V AC
 Ex. : Solenoid Valves, lamps, Actuators, Pump valve on
off control
 I/O MODULE SPECIFICATION

 COST
 INPUT VOLTAGE
 ON-STATE INPUT VOLTAGE RANGE
 AMBIENT TEMP RATING
 INPUT DELAY –
 NOMINAL OUTPUT VOLTAGE
 MAX O/P CURRENT
 ELECTRICAL ISOLATION –
 Power Supply
 The power supply gives the voltage required for
electronics module (I/O, CPU, memory unit) 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.
 Bus System

 It is path for the transmission of the

signal between power supply
module,processor and I/O modules.
 The bus comprise of several single
line i.e. wires /tracks
Advantage of PLC Over
Relay
RELAY PLC
1-More wiring 1-Less wiring

2-Changes difficult 2-Changes easy

3-More power 3-Low power

4-More maintenance 4-Solid state reliability

5-Difficult to expand 5 -Easy to expand

 PLC Cycle

 Sense the Input

 Process the Logic
 Give Output

Inputs CPU Outputs

 PLC Signal Flow
Input Module Processor Memory Output Modules

I/p
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 Device

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
◆ 1970s : Discrete Machine Control

Programming
Terminal

Connection is Point to Point

PLC

Programming
Connection is Point to Point Language :

- Relay ladder logic

- Flexibility in
I/O altering
Control system
 PLC Architecture Evolution
◆ 1985 : Discrete and Process Control

Reasonable Computer
MS - DOS
Running PLC
Programming Software

PLC
Programming
Language :

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

◆ 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

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
 LOGIX PLATFORM
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

 Ladder Diagram
 Function Block Diagram
 Sequential Function Chart
 Structured Text Language
 Scan Rate

 The completion of one cycle of the

sequence is called- SCAN

 Time required for one cycle is called

SCAN TIME
 PLC Selection Criteria

 Cost of hardware,
 I/O requirement
 CPU memory
 Spare parts& Maintenance,
 Reliability,
 Flexibility&
 Integration of High-level Application.
 Compatible 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 i.e.0

or1
◆ BYTE – Group of 8 bits
◆ WORD = Two bytes=16 bits
◆ DOUBLE WORD =Two word
=4bytes=32bits
7 6 5 4 3 2 1 0

8 BIT WORD

BYTE BYTE
16 BIT WORD
 PLC : Terminology

◆ INPUT is referred by – I
◆ OUTPUT is referred by – Q or O
◆ TIMER is referred by – T
◆ FLAGS are referred by – M or B
◆ COUNTERS are referred by – C
 PLC : Protocol

◆ It is a set of rules for data transmission when

PLC is connected to network
◆ RS-232 (Recommended standard)
◆ RS-485
◆ MPI(Multi point Interface)
◆ Profibus
◆ DH(Data Highway)
◆ Ethernate
◆ Controlnet