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Programmable Logic Controller
Programmable Logic Controller
PROGRAMMABLE LOGIC CONTROLLER
What is a PLC?
PLC (Programmable Logic Controller) is a device that was invented to
replace the necessary sequential relay circuits for machine control.
The PLC works by looking at its inputs and depending upon their
state, turning on/off its outputs.
The user enters a program, usually via software, that gives the
desired results.
Programmable Logic
Controllers
A PLC is a solid state / industrial computer that performs discrete or
sequential logic in a factory environment.
It was originally developed to replace mechanical relays, timers,
counters
A sequence of instructions is programmed by the user to the PLC
memory. Its purpose is to monitor crucial process parameters and
adjust process operations accordingly.
On/Off
Control
It performs Timing
functions
as: Counting
Arithmetic
Various Brands of PLCs
Allen Bradley( USA)
Siemens (Germany)
Modicon (France)
Mitshubishi (Japan)
GE Fanuc (USA)
The PLC mainly consists of
The Processor
The processor consists of one or more standard or custom microprocessors and other integrated
circuits that perform the logic, control, and memory functions of the PLC system.
The processor reads the inputs, executes logic as determined by the application program,
performs calculations, and controls the outputs accordingly
The processor operates on DC power (± 5V), that is supplied by the power supply. Internal DC
power is also routed through the processor and operates a portion of the I/O and devices
connected to the service port of the PLC.
The processor controls the operating cycle or processor scan. This operating
cycle consists of a series of operations performed sequentially and repeatedly.
Initially when turned on the first time it will check it’s own hardware and software for faults.
Step 1, CHECK INPUT STATUS, First the PLC takes
a look at each input to determine if it is on or off.
In other words, is the sensor connected to the
first input on? How about the second input? How
about the third... It records this data into its
memory to be used during the next step.
Step 2, EXECUTE PROGRAM, Next the PLC executes your program one
instruction at a time. Maybe your program said that if the first input was on
then it should turn on the first output. Since it already knows which inputs are
on/off from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input. It will store the
execution results for use later during the next step.
Step 3, UPDATE OUTPUT STATUS, Finally the PLC updates the status of the
outputs. It updates the outputs based on which inputs were on during the
first step and the results of executing your program during the second step.
Based on the example in step 2 it would now turn on the first output
because the first input was on and your program said to turn on the first
output when this condition is true.
After the third step the PLC goes back to step one and repeats the steps
continuously. One scan time is defined as the time it takes to execute the 3 steps
listed above.
This process typically repeats 10 to 100 times per second
Memory
Program memory
Data memory
System memory
I/O System
The I/O system provides the physical connection between the process equipment and the
microprocessor.
This system uses various input circuits or modules to sense and measure the physical
quantities of the process, such as motion, level, temperature, pressure, flow, and position.
In response to the status sensed or the values measured, the processor controls various
output modules. These modules drive field devices such as valves, motors, pumps, and
alarms to exercise control over a machine or a process.
PLC forms
Compact form
Modular form
modular forms
• modular PLC just an expanded form of compact applying selecting
features of all plc component to increase flexibility and be suitable to
process control requirement
Choosing PLC
Number of logical inputs and outputs.
Memory ‐ Often 1K and up. Need is dictated by size of ladder logic program. A ladder element will
take only a few bytes, and will be specified in manufacturers documentation.
Number of special I/O modules ‐ When doing some exotic applications, a large number of special
add‐on cards may be required.
Scan Time ‐ Big programs or faster processes will require shorter scan times. And, the shorter the scan
time, the higher the cost. Typical values for this are 1 microsecond per simple ladder instruction
Communications ‐ Serial and networked connections allow the PLC to be programmed and talk to
other PLCs. The needs are determined by the application.
Software ‐ Availability of programming software and other tools determines the programming and
debugging ease.
The process of selecting a PLC can be broken into the steps
listed below.
1.Understand the process to be controlled
2. If not already specified, a single vendor should be selected
3. Plan the ladder logic for the controls
4. Count the program instructions. Use the instruction times
and memory requirements for each instruction to determine if
the PLC has sufficient memory, and if the response time will be
adequate for the process.
Once the basic control application has been defined, the user
should begin evaluating the controller requirements, including:
• input/output
• type of control
• memory
• software
• peripherals
• physical and environmental
Determining the amount of I/O required is typically the first step in selecting a controller
Remember that the controller should allow for future expansion and spares (typically 10% to 20% spares),
although spares do not affect the choice of PLC size.
Discrete Inputs/Outputs.
Analog Inputs/Outputs.
Special Function Inputs/Outputs (e.g., positioning, fast input, frequency,etc.)
Remote Inputs/Outputs
Siemens
PLC & TIA
Siemens PLC family
Logo
S7‐200 / s7‐1200
S7‐300 / s7‐1500
S7‐400
Siemens software
Micro win
WINCC
Simatic S7
PLCSIM
TIA (with versions )
S7‐1200
CPU’S
Memory could be used as :
oTransfer card
oProgram card
oFirmware update
In_out addressing