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PLC 131022133632 Phpapp02 PDF
PLC 131022133632 Phpapp02 PDF
PLC 131022133632 Phpapp02 PDF
Subject Faculty :
Prof. Ram Murat Singh
Objectives :
Rules &
guidelines
Why Automation ?
Higher productivity
etc…
History of Process Control & Automation
PLC Control
Electronics Control
Hard-Wire Control
Manual Control
1. PLC - Introduction
• Less wiring.
EUROPEAN: 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
Leading Brands Of PLC
JAPANESE: 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
Areas of Application :
• Manufacturing / Machining
• Food / Beverage
• Metals
• Power
• Mining
• Petrochemical / Chemical
PLC Size :
Small: • It covers units with up to 128 I/O’s and memories
up to 2 Kbytes.
POWER
SUPPLY
I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
From E T E
To
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms.
PROGRAMMING
etc. DEVICE Motors
etc.
Major Components of a Common PLC
Power Supply:
I/O Modules:
Processor :
Programming Device :
Current Buffer,
FROM Limiting OPTO-- Filter, TO
INPUT Resistor ISOLAT hysteresi PROCESSOR
DEVICE OR s Circuits
I/O Module
AC Input Module
IS NEEDED TO:
CONVERTS THE • Prevent voltage
AC INPUT TO DC transients from
AND DROPS THE damaging the
VOLTAGE TO processor.
LOGIC LEVEL •Helps reduce the
effects of electrical
noise
Rectifier, Buffer,
FROM Filter,
Resistor OPTO-- TO
INPUT Hysteresis
Network ISOLAT PROCESSOR
Circuits
DEVICE OR
29
I/O Module
DC/AC Output Module IS NEEDED TO:
• Prevent voltage
transients from
damaging the
processor.
•Helps reduce the
effects of electrical
noise
Amplifier
FROM RELAY
TTL OPTO-- TO
PROCESSOR TRIAC
Circuits ISOLA OUTPUT
X’SISTO
TOR DEVICE
R
I/O Circuits
DIFFERENT TYPES OF I/O CIRCUITS
• These are usually low- voltage and low-current and are used
to drive indicating lights and other non-inductive loads. Noise
suppression may or may not be included on this types of
modules.
3. Discrete Inputs :
INPUTS
MOTOR
CONTACTOR
LAMP
PUSH BUTTONS
PLC
INPUT DEVICES:
Push Button
Limit Switch
Thumbwheel SW
Level SW
Flow SW
OUTPUT DEVICES:
Motor
Solenoid
LED Display
Heater Coil
Lamp
Allen--Bradley 1746-
Allen 1746-1A16
L2 I= Input
L1
Module
I:2 slot # in rack
0
P. B SWITCH Module
Terminal #
Address I:2.0/0
LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM
CONTACTOR
L1 N.
L2 O
MOTOR
L2
C •SOLENOI
L1
D
FIELD •VALVES
WIRING •LAMP
•BUZZER
OUTPUT MODULE
WIRING
L1 O:4
L2
CONTACTOR 0
LADDER PROGRAM
Discrete Input
OFF PLC
Logic 0
Input
Module
24 V dc
IN
OFF PLC
Logic 1
Input
Module
24 V dc
Analog Input
Level Transmitter IN
PLC
Analog
Tank Input
Module
Digital Output
OUT
PLC
Lamp
Digital
Output
Module
Analog Output
OUT
E Supply air
PLC 0 to 10V P
Analog
Output
Module
Pneumatic control valve
Processor
The processor module contains the PLC’s microprocessor, its supporting
circuitry, and its memory system.
The memory system in the processor module has two parts: a system
memory and an application memory.
Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing, timing,
counting, and arithmetic.
•System memory is generally built from read-only memory
devices.
APPLICATION
•The application memory is divided into the data table area
•Data Table and user program area.
•The data table stores any data associated with the user’s
•User Program control program, such as system input and output status data,
and any stored constants, variables, or preset values. The
data table is where data is monitored, manipulated, and
changed for control purposes.
•The user program area is where the programmed
instructions entered by the user are stored as an application
control program.
Memory Designs
VOLATILE.
A volatile memory is one that loses its stored information when power is
removed.
RAM memory must have battery backup to retain or protect the stored
program.
Memory Designs
Several Types of RAM Memory:
1.MOS
2.HMOS
3.CMOS
PROM may be written into only once after being received from the PLC
manufacturer; programming is accomplish by pulses of current.
The current melts the fusible links in the device, preventing it from being
reprogrammed. This type of memory is used to prevent unauthorized
program changes.
Memory Designs
EPROM, Erasable Programmable Read Only Memory
The EPROM chip has a quartz window over a silicon material that contains
the electronic integrated circuits. This window normally is covered by an
opaque material, but when the opaque material is removed and the
circuitry exposed to ultra violet light, the memory content can be erased.
Field Control
Input
Elements
Process / Machine
PLC Operating Principle
In-
In-put scan
Self test
Start
Communication
Out-
Out-put scan
PLC Operation
Basic Function of a Typical PLC
Read all field input devices via the input interfaces, execute the user
program stored in application memory, then, based on whatever control
scheme has been programmed by the user, turn the field output devices on
or off, or perform whatever control is necessary for the process application.
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
PHASE 1 – Input Status scan
• A PLC scan cycle begins with the CPU reading the status of its inputs.
The time it takes to implement a scan cycle is called SCAN TIME. The scan
time composed of the program scan time, which is the time required for
solving the control program, and the I/O update time, or time required to
read inputs and update outputs. The program scan time generally depends
on the amount of memory taken by the control program and type of
instructions used in the program. The time to make a single scan can vary
from 1 ms to 100 ms.
PLC Communications
Common Uses of PLC Communications Ports
Monitoring data and alarms, etc. via printers or Operator Interface Units
(OIUs).
PLC Communications
Serial Communications
Common Standards
RS 232
Local Area Network provides a physical link between all devices plus
providing overall data exchange management or protocol, ensuring that each
device can “talk” to other machines and understand data received from them.
Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
Specifications
Several factors are used for evaluating the quality and performance of
programmable controllers when selecting a unit for a particular application.
These are listed below.
NUMBER OF I /O PORTS
This specifies the number of I/O devices that can be connected to the
controller. There should be sufficient I/O ports to meet present requirements
with enough spares to provide for moderate future expansion.
Working of PLC
II
CPU
•User Program memory IV
Field Field
signals Controls
PLC Programming
PLC is software driven equipment like computer
Slot numbers
0 1 2 3 4 ---------------- 30 31
0
1
2
CPU
CPU 3
5
6
7
Channel Nos.
PROGRAMMING
Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
Coils
A B C
Rung
A C
Rung
A C
Rung
statement list
1. PLC - Introduction
Ladder diagram
Writing Program
• Circuit Diagram • Ladder Diagram (LAD)
I 1.1 I 1.3
I 1.2 I 1.3
Q 4.1
Writing Program
• Circuit Diagram • Control System Flowchart (CSF)
I 1.0
I 1.0 I 1.2
&
I 1.1
I 1.1 I 1.3
>=1
I 1.2
Q 4.1
Q 4.1 I 1.3 & =
Writing Program
• Circuit Diagram • Statement List (STL)
03 50
break contact
(contact repos)
01 02
corresponding 50 rung
03
ladder diagram
50 50
02
Parallel + 01
40 01
02 40
02
textual expression
1 2 3 4
50 !N 1 & 2 STR 3 & N 4 STR N 5
5 6 & 6 / STR & STR = 50
0 1 4 5 12
50 !0 & 1 STR 2 & 3 / STR STR 4
2 3 6 7 & 5 STR N 6 & 7
00 01
literal expression:
FUN 02 200
!00 & 01 FUN 02 = 200
IEC 61131 does not prescribe the minimum requirements for a compiler /
interpreter such as number of rungs per page nor does it specifies the minimum
subset to be implemented.
Therefore, it should not be used for large programs made by different persons
It is very limited when considering analog values (it has only counters)
Criteria
NUMBER OF I /O PORTS
This specifies the number of I/O devices that can be connected to the
controller. There should be sufficient I/O ports to meet present requirements
with enough spares to provide for moderate future expansion.
Specifications
OUTPUT-PORT POWER RATINGS
SCAN TIME
This is the speed at which the controller executes the relay-ladder logic
program. This variable is usually specified as the scan time per 1000 logic
nodes and typically ranges from 1 to 200 milliseconds.
Specifications
MEMORY CAPACITY