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Lecture-5 Plcs
Lecture-5 Plcs
Lecture-5 Plcs
Industrial Electronics
Lecture-5
Programmable Logic Controller
1
Outline
Introduction to PLCs
Structure of PLC
Input/output System
Programming Concepts
Definition of PLC
3
PLC’s Are...
• Dissimilar to Microcontrollers:
– Intended for Industrial Applications
– I/O Designed to interface with Control Relays
– Emphasis on Maximum Reliability
Advantages of PLC
1. Flexibility
v Universal Controller - can replace various independent/
standalone controller.
2. Implementing Changes and Correcting Errors
v Do not have to rewiring relay panel.
v Change program using keyboard.
3. Large Quantity of Contact
v Large number of' Soft Contact' available.
4. Lower Cost
v Advancement in technology and open architecture of PLC will
reduce the market price.
5. Pilot Running (Simulation Capability)
v A program can be simulated or run without actual input
connection.
5
Advantages of PLC
6. Visual Observation.
Can observe the opening and closing of contact switch on
CRT .
Operator message can be programmed for each possible
malfunction.
7. Speed of Operation
Depends on scan time -millisecond.
Asynchronous operation.
8. Ladder or Boolean Programming Method.
Easy for 'Electrician ,
9. Reliability
In general -very reliable
10. Simplicity of Ordering Control Sys. Components
One package with Relay, Timers, Control Block, etc.
6
Advantages of PLC
11. Documentation
Printout of ladder logic can be printed easily
12. Security
Software lock on a program (Password)
13. Ease of Changes by Programming
Ability to program and reprogram, loading and
down loading
7
Leading Brands Of PLC
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 8
Areas of Application
Manufacturing / Machining
Food / Beverage
Metals
Power
Mining
Petrochemical / Chemical
9
PLC Size
POWER
SUPPLY
I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
To
SENSORS T E
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
11
Major Components of a Common PLC
POWER SUPPLY
I/O MODULES
12
Major Components of a Common PLC
PROCESSOR
PROGRAMMING DEVICE
13
Programming Device
Types:
14
I/O Module
DC INPUT MODULE
IS NEEDED TO:
USE TO · Prevent voltage
DROP THE transients
VOLTAGE from damaging
TO LOGIC the processor.
LEVEL ·Helps reduce
the effects of
electrical noise
Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits
16
17
I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC · Prevent voltage
INPUT TO DC AND transients
DROPS THE from damaging
VOLTAGE TO LOGIC the processor.
LEVEL ·Helps reduce
the effects of
electrical noise
Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresi
PROCESSOR
DEVICE s Circuits
18
19
20
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 ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE
21
22
I/O Circuits
23
I/O Circuits
3. Discrete Inputs
Circuits of this type are used to sense the status of limit
switches, push buttons, and other discrete sensors.
Noise suppression is of great importance in preventing
false indication of inputs turning on or off because of
noise.
24
I/O Circuits
4. Analog I/O
25
I/O Circuits
26
Discrete Input
A discrete input also referred as digital input is an input that is
either ON or OFF are connected to the PLC digital input. In the
ON condition it is referred to as logic 1 or a logic high and in
the OFF condition maybe referred to as logic 0 or logic low.
Level Transmitter IN
PLC
Analog
Tank Input
Module
28
Digital Output
OUT
PLC
Lamp
Digital
Output
Module
29
Analog Output
OUT
E Supply air
PLC 0 to 10V P
Analog
Output
Module
Pneumatic control valve
30
Processor
31
PLC Operation
32
PLC Operation
• While the PLC is running, the scanning process includes
the following four phases, which are repeated continuously
as individual cycles of operation:
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
33
PHASE 1 – Input Status scan
· A PLC scan cycle begins with the CPU reading the
status of its inputs.
35
PLC Communications
o
Changing resident PLC programs - uploading/downloading
from a supervisory controller (Laptop or desktop computer).
o
Forcing I/O points and memory elements from a remote
terminal.
o
Linking a PLC into a control hierarchy containing several
sizes of PLC and computer.
o
Monitoring data and alarms, etc. via printers or Operator
Interface Units (OIUs).
36
PLC Communications
Serial Communications
Common Standards
RS 232
NUMBER OF I /O PORTS
39
Selecting a PLC
Criteria
SCAN TIME
42
Specifications
MEMORY CAPACITY
43
PLC Status Indicators
•Power On
•Run Mode
•Programming Mode
•Fault
Troubleshooting
Contacts:
a. Normally open -| |-
b. Normally closed -|/|-
c. Off-on transitional -||-
d. On-off transitional -| |-
Coil: ()
a. Energize Coil -( )-
b. De-energize -(/)-
c. Latch -(L)-
d. Unlatch -(U)-
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.
49
Coils
50
Simple Relay Circuit
51
Circuit representation in Ladder Logic
52
Boxes
53
AND OPERATION
A B C
Rung
54
OR OPERATION
A C
Rung
55
NOT OPERATION
A C
Rung
56
Multi Input/Output Rungs
57
TIMERS AND COUNTERS
Input
True False True
Timers: RTO counting stop counting
resume
a. Retentive on delay -(RTO)-
RTF stop counting stop
b. Retentive off delay -(RTF)-
c. Reset -(RST)-
RTO reach PR value, output ON
Counter: RTF reach PR value, output OFF
END OF LECTURE-5
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