What is a Programmable

Logic Controller (PLC) ?

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Agenda
History
PLC Overview
Hardware
Inputs/Outputs
Operation
Programming Software
Communication
What you need to know when specifying a PLC
Glossary
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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First Programmable Logic Controllers were designed and
developed by Modicon as a relay replacer for GM and Landis.
These controllers eliminated the need for rewiring and adding
additional hardware for each new configuration of logic.
The new system drastically increased the functionality of the
controls while reducing the cabinet space that housed the logic.
The first PLC, model 084, was invented by Dick Morley in 1969.
The first commercial successful PLC, the 184, was introduced
in 1973 which was designed by Michael Greenberg.
History of the PLC
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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What is a PLC?
Inputs
Outputs
The Basic Block
A PROGRAMMABLE LOGIC CONTROLLER is a solid state control system
that continuously monitors the status of devices connected as inputs.
Based upon a user written program, stored in memory, it controls the status
of devices connected as outputs.
CPU
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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What is a PLC with Distributed I/O?
CPU
Inputs
Inputs
Outputs
Outputs
Remote
Getting Complex
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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What is a PLC with Distributed Control?
CPU
Remote
Getting Really Complex
CPU
Inputs
Inputs
Inputs
Outputs
Outputs
Outputs
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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CR
Isolation
Barrier
Isolation
Barrier
Central
Processor
Unit
(CPU)
MEMORY
program data
High
Voltage
High
Voltage
Low Voltage
AC Power Supply
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DC Power Supply or
Communications
Port
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Inside a PLC
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Inside a PLC
The CPU contains an Executive program that tells
the PLC how to:
Execute the control Instructions
Users Program
Communicate with other devices
Other PLCs, Programming devices, I/O devices, etc.
Perform Housekeeping activities
Diagnostics, etc
This program is stored in nonvolatile memory
Meaning that the program will not be lost if power is removed
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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What are Inputs?
Switches and Pushbuttons
Sensing Devices
Limit Switches
Photoelectric Sensors
Proximity Sensors
Condition Sensors
Pressure Switches
Level Switches
Temperature Switches
Vacuum Switches
Float Switches
Encoders
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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What are Outputs?
Valves
Motor Starters
Solenoids
Actuators
Control Relays
Horns & Alarms
Stack Lights
Fans
Counter/Totalizer
Pumps
Printers
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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PLC Operating Cycle
Four Steps in the PLC Operations
Input Scan
Scan the state of the Inputs
Program Scan
Processes the program logic
Output Scan
Energize/de-energize the outputs
Housekeeping
This step includes communications, Internal
Diagnostics, etc.
The steps are continually repeated - processed in a loop
START
Input
Scan
Program
Scan
Housekeeping
Output
Scan
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Programming the PLC
Types of Programming Software Languages
Ladder Logic (LL)
IEC Format
Function Block Diagram (FBD)
Structured Text (ST)
Instruction List (IL)
Ladder Diagram (LD)
Sequential Function Chart (SFC) - also known as Grafcet
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Ladder Logic
Read / Conditional
Instructions
Write / Control
Instructions
| | |/|
| | |/|
| |
| | |/| ( )
| |
| |
Start (Rung #1)
End (Rung #4)
( )
( )
( )
Inputs Outputs
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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IEC - Function Block Diagram (FBD)
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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IEC - Structured Text (ST)
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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IEC - Instruction List (IL)
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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IEC - Ladder Diagram (LD)
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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IEC - Sequential Function Chart (SFC)
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Communication
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Protocols
A set of rules for data exchange (format and timing of data) in a
communications system
Stack / profile = selected set of protocols for a communication
application
Communication Relationships
Master / Slave - request / response & response only
Peer-to-Peer - client / server, publisher / subscriber
Communication Architectures
Star (point-to-point)
Bus, Ring, LAN (multidrop)
Communication Basics
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Ethernet
Modbus Plus
Modbus
S908
LonWorks
Interbus
Profi-bus
DeviceNet
Uni-Telway
Communication Protocols
CAN-Open
ASi
Seriplex
FIPIO/FIPway
RIO
HART
DIO
ControlNet
ASCII
Protocols are similar to languages -
Devices must support the same protocol to understand each other
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Quantity, Type and Location of I/O
Number of Inputs and output points
AC or DC voltage
Analog or Discrete
Concentrated or spread out (distributed)
Communication Requirements
Protocol/Network used
Devices to communicate with (HMI, other PLCs, etc)
Speed of Application
Response time required (throughput) of the system
How fast does the process change
What you need to know when specifying a PLC
What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager
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Control Architecture Philosophy
Centralized Control, Distributed Control or combination
Redundancy - CPUs, Power Supplies, etc
Programming Software
IEC vs. 984
Installed base / what is currently being used
User Logic
Size and complexity of Program
Feedback control used
etc.
What you need to know when specifying a PLC