EVOLUTION OF PLC

PLC means Programmable logic controller. It is basically a controller which

performs logics and the logics are programmable. Hence to understand the
PLC we have to understand first the meaning of controller, logics and
programmable.

CONTROLLER

As the name suggests the controller performs control function. This means
there is a parameter which need to be controlled at a particular value desired
by the user. For example we want to control the temperature of water in a
gaiser or say control room temperature using air coolers. In these
applications we find that there are two variables.

The temperature of the water or room which can vary and need to be
controlled. Unless the measurement of this variable is done it cannot be
controlled. This variable is known as process variable or measured
variable.

Then the user has a desire in his mind to control this temperature of water or
room at a particular point. This variable is known as
setvariable/setpoint or desired variable.

Control action means controlling of the measured variable equal to set

variable by taking necessary corrective action. The device that performs this
is known as controller.

A look at the control action shows that a controller is basically a comparator.

It compares the values of measured variable and set variable and takes
corrective action based on their difference. This difference is called error
and the output of the controller is known as manipulated variable.
Logics

Logic basically refers to true or false condition in general, In industrial

applications it refers to a particular state of an equipment with no ambiguity.
For example on or off, open or closed etc. All these status are clear and
distinct. Industrial equipments have the following states.

ON state ------ The equipment is running

OFF state ----- The equipment is stopped.
Trip state------- The equipment has stopped against a fault

The difference between a stop and trip is as follows.

A stopped equipment can be started as and when required where as a tripped

equipment can be started only after rectification of fault.

In industrial applications these states are known as logics.

A PLC is basically a logic controller. It takes care of the on/off/trip states

of an equipment as per user requirement.

Evolution of logic controller

The above logics(instructions as to how to start/stop/trip) need to be

implemented and the implementation techniques evolved with time are as
follows.

The earliest implementation of logics were carried out using relays and
switches. The relays and switches were hardwired as per the requirement of
the user. This premier logic controller is known as relay based system.

Any system for that matter need the following.

A source to drive the system. For example power supply, air supply etc.

Minimum of one input and minimum of one output if it is a control system.

Inputs to logic control system

Toggle switches, Selector switches, Relay contacts, Push button Actuators,

thumb wheel switches, dip switches, process switches such as pressure
switch thermostat level switch flow switch etc.

Outputs of a logic control system

The outputs are normally relays solenoid valves timers counters indicating
lamps etc.

All inputs of a logic system are contacts in nature and all outputs are coil in
nature. Hence the logic control system is commonly known as coil and
contact system.

In a relay based system the logics were configured by connecting the

coils(outputs) and contacts(inputs) using hardwires. Hence the relay based
system which is the mother of all logic controllers is known as
hardwired logic controller. With all the advancement in technologies this
systems is time tested and still popular with the user.

Advantages

Simple and rugged

Economical for small applications
Donot require any special tools or equipments for maintenance
Donot require highly skilled people for operation and maintenance

Disadvantages

Operates at high voltages

Consumes more power and generates heat
Occupies large space for a medium and large scale applications
Trouble shooting is difficult
Expensive for medium and large scale applications
Changing of logic calls for rewiring and hence cumbersome
Malfunctioning due to moving parts such as contacts relays etc
Control circuit and power circuit

A glance at the above circuit shows the following

There is a power source across P and N
The switch performs on-off action
The fan is the load
The circuit containing on/off/trip operation is known as control circuit.
The circuit through which the load current flows is known as power circuit
In this case since the load and the switch are in series the control circuit and
power circuit are one and the same.

Such a configuration is possible only in the case of small loads operating at

low voltages say 230v.

In case of higher voltages and high loads the control circuit and power
circuit are separated as shown below.

Series circuit in a relay based system

Parallel circuit in a relay based system

It can be seen from the above that a series and parallel circuits are basically
AND logic gate and OR logic gate.It is possible to construct other gates such
as nor,nand,exclusive or etc using relay system.

Nand gate
Not gate

Nor gate
Ex-or gate
Keeping in mind the disadvantages of relay based system a change in
technology was eagerly awaited and the same came upon the advent of
INTEGRATED CHIPS.

Types of Integrated circuits

Diode-diode logic--- ------------------------- DDL)

Diode-Transistor logic----------------------- DTL) supply voltage 5v
Transistor-transistor logic--------------------TTL)3
CMOS logic supply 3 to 15v dc
Solid state logic controllers
Solid state logic controllers were made by configuring the logic required on
a printed circuit board and then soldering the components as per the
circuit diagram.

Advantages of solid state system

Operating on low voltage dc and consumes less power

Occupies less space
Investment cost very low
No moving components
Less heat generated
Good speed of response
Disadvantages
Logics are configured on the printed circuit board and hence change in logic
calls for board replacement.

Programmable Logic Contollers

These are microprocessor based systems and as such has all the advantages
of solid state systems. Further the logics are programmed through software
Hence configuration of logics is simple and flexible.