Programmable Logic Controller

Programmable Logic Controller

“PLC”

Definition(according to NEMA* standard ICS3-1978):

“A digitally operating electronic apparatus which uses a
programming memory for the internal storage of
instructions for implementing specific functions such as
logic, sequencing, timing, counting and arithmetic to
control through digital or analog modules, various types
of machines or process.”

*NEMA: “National Electrical Manufacturers Association”

Subsequent development resulted in a system featuring:
• The simple
connection of binary
signals
• The requirements as
to how these signals
were to be connected
was specified in the
control program
• With the new systems
it became possible for
the first time to plot
signals on a screen
and to store these in
electronic memories
 Leading PLC manufacturers list
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
PLC Advantages
• Flexibility
– In the past, each different electronically controlled production machine required its own
controller; 15 machines might require 15 different controllers.
– Now it is possible to use just one model of a PLC to run any one of the 15 machines.
– Each of the 15 machines under PLC control would have its own distinct program (or a
portion of one running program).
• Implementing Changes and Correcting Errors
– With a wired relay-type panel, any program alterations require time for rewiring of
panels and devices.
– When a PLC program circuit or sequence design change is made, the PLC program can
be changed from a keyboard of a program loader in a matter of minutes.
– No rewiring is required for a PLC-controlled system.
– Also, if a programming error has to be corrected in a PLC control program, a change can
be typed in quickly.
• Large Quantities of Contacts
– The PLC has a large number of contacts for each coil available in its programming.
– Suppose that a panel-wired relay has four contacts and all are in use when a design
change requiring three more contacts is made, time would have to be taken to procure and
install a new relay or relay contact block.
– Using a PLC, however, only three more contacts would be typed in. Contacts are now a
“software” component
PLC Advantages (Continued)
• Lower Cost
– Increased technology makes it possible to condense more functions into smaller and less
expensive packages.
– Now a PLC can be purchased with numerous relays, timers, and counters, a sequencer,
and other functions for a few hundred dollars.
• Pilot Running
– A PLC programmed circuit can be evaluated in the lab. The program can be typed in,
tested, observed, and modified if needed, saving valuable factory time.
• Visual Observation
– A PLC circuit's operation can be seen during operation directly on a screen.
– The operation or mis-operation of a circuit can be observed as it happens.
– Logic paths light up on the screen as they are energized.
– Troubleshooting can be done more quickly during visual observation.
• Reliability and Maintainability
– Solid-state devices are more reliable, in general, than mechanical systems or relays and
timers. Consequently, the control system maintenance costs are low and downtime is
minimal.
• Documentation
– An immediate printout of the true PLC circuit is available in minutes, if required.
– There is no need to look for the blueprint of the circuit in remote files.
– The PLC prints out the actual circuit in operation at a given moment.
– Often, the file prints for relay panels are not properly kept up to date. A PLC printout is the
circuit at the present time; no wire tracing is needed for verification.
PLC Disadvantages

• Fixed Program Applications

– Some applications are single-function applications. It does not pay to use a PLC that
includes multiple programming capabilities if they are not needed.
– Their operational sequence is seldom or never changed, so the reprogramming available
with the PLC would not be necessary.

• Fail-Safe Operation
– In relay systems, the stop button electrically disconnects the circuit; if the power fails, the
system stops.
– This, of course, can be programmed into the PLC; however, in some PLC programs, you
may have to apply an input voltage to cause a device to stop. These systems may not be
fail-safe.
 Characteristics of a PLC System
There are seven distinct characteristics in a PLC system, these are:

1. It is field programmable by the user. This characteristic allows the user to write and
change programs in the field without rewiring or sending the unit back to the
manufacturer for this purpose.

2.It contains preprogrammed functions. PLCs contain at least logic, timing, counting,
and memory functions that the user can access through some type of control-oriented
programming language.
3.It scans memory and inputs and outputs (I/O) in a deterministic manner. This critical
feature allows the control engineer to determine precisely how the machine or process
will respond to the program.
4.It provides error checking and diagnostics. A PLC will periodically run internal tests
of its memory, processor, and I/O systems to ensure that what it is doing to the machine
or process is what it was programmed to do.
5.It can be monitored. A PLC will provide some form of monitoring capability, either
through indicating lights that show the status of inputs and outputs, or by an external
device that can display program execution status.
6.It is packaged appropriately. PLCs are designed to withstand the temperature,
humidity, vibration, and noise found in most factory environments.
7.It has general-purpose suitability. Generally a PLC is not designed for a specific
application, but it can handle a wide variety of control tasks effectively.
Types of PLC Construction:

• Compact PLC
- it covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- Capable of providing simple to advance levels
or machine controls

• Modular PLC
-The most sophisticated units of the PLC family.
They have up to 8192 I/O and memories up
to 750 Kbytes.
- Can control individual production processes or
entire plant.
Basic Elements of a PLC

•Power Supply
•Processor (CPU)
•Memories
•Input/output modules
•Programming Port
•PLC Bus
•Expansion Models
Power Supply
The basic function of the power supply is to
convert the field power into a form more suitable
for Use electronic devices that comprise the PLC

In large PLC systems, this power supply

does not normally supply power to the
field devices.

In small and micro PLC systems, the

power supply is also used to power field
devices.
 Processor Module
This module is the prime essence of a PLC system

It consists of a microprocessor which is

sometimes specially designed for the
purpose of being implemented in a PLC
system design for implementing the
logic, and controlling the
communications among the modules.

The processor module accepts input data

from various sensing devices via Input Processor
modules, executes the stored user program, Module
and sends appropriate output commands
to control devices via output modules.
Processor Module Details
A detailed block diagram of the processor section of a
PLC is shown in Figure below.
This section consists of four major elements: (1) power
supply, (2) memory, (3) central processing unit (CPU), and
(4) I/O interface.
Memories

•The program memory receives and holds the downloaded

program instructions from the programming device
-This memory is usually an EEPROM (electrically erasable
programmable ROM) or a battery-backup RAM, both of which are
capable of retaining data

Data memory is RAM memory used as a “scratch pad” by the

processor to temporarily store internal and external program-
generated data
For example, it would store the present status of all switches
connected to the input terminals and the value of internal counters
and timers.
Memory Designs
VOLATILE.
A volatile memory is one that loses its stored
information when power is removed.

Even momentary losses of power will erase any

information stored or programmed on a volatile
memory chip.

Common Type of Volatile Memory

RAM. Random Access Memory(Read/Write)

Read/write indicates that the information stored in the
memory can be retrieved or read, while write
indicates that the user can program or write
information into the memory.
Memory Designs
Several Types of RAM Memory:

1.MOS
2. HMOS
3. CMOS

The CMOS-RAM (Complimentary Metal Oxide Semiconductor) is

probably one of the most popular. CMOS-RAM is popular because
it has a very low current drain when not being accessed
(15microamps.), and the information stored in memory can be
retained by as little as 2Vdc.
Memory Designs
NON VOLATILE.
A non volatile memory is one that does not lose its stored information when
power is removed.

•EPROM, Erasable Programmable Read Only Memory

Ideally suited when program storage is to be semi-permanent or additional

security is needed to prevent unauthorized program changes.

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.

The EPROM chip is also referred to as UVPROM.

Memory Designs

NON VOLATILE

EEPROM, Electrically Erasable

Programmable Read Only Memory

Also referred to as E2PROM, is a chip that can be programmed

using a standard programming device and can be erased by the
proper signal being applied to the erase pin.
EEPROM is used primarily as a non-volatile backup for the normal
RAM memory. If the program in RAM is lost or erased, a copy of
the program stored on an EEPROM chip can be down loaded into
the RAM.
Battery backed CMOS RAM can
also be classified as non-volatile
I/O Section

Consists of input modules

and output modules.

Input module connects to :

Field sensors: switches, flow, level, pressure, temp.
transmitters, etc.

Output modules connect to:

Field output devices: motors, valves, solenoids, lamps, or
audible devices
I/O Section

Input Module

Forms the interface

by which input field
devices are connected
to the controller.

The terms “field” and “real world”are used to distinguish

actual external devices that exist and must be physically
wired into the system.
I/O Section

Output Module

Forms the interface

by which output field
devices are connected
to the controller.

PLCs employ a relay

or an optical isolator
which uses light to
electrically isolate the
internal components
from the input and
output terminals.
 Programming Device
PC with appropriate
software

The computer monitor is used to display the logic on

the screen. The personal computer communicates with the PLC
processor via a serial or parallel data communications
link.
A personal computer (PC) is the most commonly used programming device.

The software allows users to create, edit, document,

store and troubleshoot programs.
If the programming unit is not in use, it may be unplugged

and removed. Removing the programming unit will not

affect the operation of the user program.
Programming Device

Hand-held unit
with display

•They are compact, inexpensive, and easy to use, but

are not able to display as much logic on screen as a
computer monitor.
•Hand-held programming devices are sometimes used to program small PLCs.

Hand-held units are often used on the factory floor for

troubleshooting, modifying programs, and transferring
programs to multiple machines.
 PLCs Versus Personal Computers

Same basic architecture

PLC
-operates in the industrial
environment
-is programmed in relay
ladder logic
-has no keyboard, CD drive,
monitor, or disk drive
-has communications ports,
and terminals for input and
output devices
PC
-capable of executing several
programs simultaneously, in
any order
-some manufacturers have
software and interface cards
available so that a PC can do
the work of a PLC
 PLC Size Classification
Criteria
- number of inputs and outputs (I/O count)
- cost Allen-Bradley PLC-5
Family
- physical size - handles several
thousand I/O points

Allen-Bradley SLC-500 Family

- handles up to 960 I/O points

Micro PLC
- handles up to
32 I/O points
Nano PLC
- smallest sized PLC
- handles up to 16 I/O points
Areas of Application

 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical