PLC

PROGRAMMABLE LOGIC CONTROLLER

 PLC
PLC is a digital computer designed for
• Multiple inputs and outputs

• Extended temperature ranges

• Immunity to electrical noise

• Resistance to vibration and impact

 PLC
• Similar to a Microcontroller:
–Microprocessor Based
–Onboard Memory for Storing Programs
–Special Programming Language: Ladder
Logic
–Input/Output Ports
 PLC
• Dissimilar to Microcontrollers:
–Intended for Industrial Applications
–I/O Designed to interface with
Control Relays
–Emphasis on Maximum Reliability
 HISTORY OF PLC
• First PLC was developed by Modicon company
as a relay replacer for General motors,1968
&invented by Dick Morley (father of PLC)

• First commercial successful PLC ,184 by

Michael GreenBerg in 1973
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

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Major Components of a Common PLC
POWER SUPPLY

Provides the voltage needed to run the primary

PLC components

I/O MODULES

Provides signal conversion and isolation

between the internal logic-low level signals
inside the PLC and the field’s high level signal.
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Major Components of a Common PLC
PROCESSOR

Provides intelligence to command and govern the

activities of the entire PLC systems.

PROGRAMMING DEVICE

used to enter the desired program that will determine

the sequence of operation and control of process
equipment or driven machine.
Programming Device
Types:

 Hand held unit

With LED / LCD
display
Desktop type

with a CRT
display

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INPUT MODULE

• Input modules converts signals from discrete or analog

input devices to logic levels acceptable to PLC’s
processor.

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 I/O Modules
• Input Modules: Input Signals can be AC or DC,
Analog or Digital

• Output Modules: Outputs are either AC or DC

• Modern PLC’s have Expansion Ports to

Increase the Number of Available Inputs and
Outputs
DC INPUT MODULE
IS NEEDED TO:
 Prevent voltage
USED TO transients from
DROP THE damaging the
VOLTAGE processor.
TO LOGIC Helps reduce the
LEVEL effects of
electrical noise

Current
FROM Limiting OPTO-
INPUT Resistor ISOLATO
DEVICE R

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AC INPUT MODULE

IS NEEDED TO:
CONVERTS THE AC  Prevent voltage
INPUT TO DC AND transients from
DROPS THE damaging the
VOLTAGE TO LOGIC processor.
LEVEL Helps reduce the
effects of
electrical noise

Rectifier, Buffer,
FROM Resistor OPTO-
Filter
TO
INPUT Network ISOLATOR
PROCESSOR
DEVICE

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OUTPUT MODULE
• Output modules converts signal from the processor to
levels capable of driving the connected discrete or
analog output devices.

PLC OPTO SIGNAL FIELD

PROCESSOR ISOLATOR CONVERSION DEVICES

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 Fixed I/O

• PLC’s with fixed I/O typically come in

a complete unit that contains the
processor, I/O section, and power
supply.
 Modular I/O

• Modular in nature, more flexible

than fixed I/O units.
• The I/O rack or chassis is a
framework or housing into which
modules are inserted.
Fixed
Modular
PLC Size
1. SMALL - covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- these PLC’s are capable of providing
simple to advance levels

2. MEDIUM - have up to 2048 I/O’s and memories up

to 32 Kbytes.

3. LARGE - the most sophisticated units of the PLC

family. They have up to 8192 I/O’s
and memories up to 750 Kbytes.
- can control individual production
processes or entire plant.
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Selecting a PLC

Criteria
• Number of logical inputs and
outputs.
•Memory
• Number of special I/O modules
•Scan Time
• Software
 ADVANTAGES OF PLC
• FLEXIBILITY…In the past each different electronically
controlled machine required its own controller. With PLC,
one PLC can easily run many machines.

• IMPLEMENTING CHANGES AND CORRECTING

ERRORS…With a wired relay type panel, any program
alterations need time for rewiring of panels and devices. No
rewiring is required for a PLC controlled system.

• LARGE QUANTITIES OF CONTACTS

• LOWER COST.. relays, timers, counters, all devices would be

available with PLC.
 ADVANTAGES OF PLC
• PILOT RUNNING…The program can be typed in, tested, modified,
observed in the office saving the factory time.

• VISUAL OBSERVATION…logic paths light up on the screen as they

are energized.

• SPEED OF OPERATION…The speed for the PLC logic operation is

determined by scan time, which is a matter of milliseconds.

• LADDER OR BOOLEAN PROGRAMMING METHOD

• RELIABILITY
 DISADVANTAGES OF PLC
• NEWER KNOWLEDGE

• FIXED PROGRAM and PROGRAM

APPLICATIONS

• ENVIRONMENTAL CONSIDERATIONS…
High heat, vibration interference with the
electronic devices in PLC, which limit their use
 PLC Memory Organization
• Memory Map
PLC Memory Organization
• Data file organization
Output Status ….File 0
there can be only one output status file
per processor file
Input Status ….File 1…only one
Processor file …File 2 …only one per
processor file
Contains information on how your
PLC’s operating system works
PLC Memory Organization
 Bit file…file 3
used to store single bits in a 16 bit word format.
Each bit file will have upto 256 sixteen bit words.
There can be many bit files for a single processor
file.
 Timer File…file 4…stores timer data…
upto 256 timer elements for a single processor
file
 Counter File…file 5…stores counter data
PLC Memory Organization
Control file…file 6…used to store status
information for bit shift, FIFO, LIFO,
sequencer instructions and certain ASCII
instructions.
Integer file…file 7…16 bit word representing
one whole number…used to store integers
..can be many integer files for a single
processor file
 PLC Memory Organization
• Input Table File Operation
 INPUT STATUS FILE
• A group of words in the memory that are
organized to store input data

• Each screw terminal on each input module has

one memory location in the input status file
for storing the ON or OFF status of the
connected field input device
 PLC Memory Organization
• Output Table File Operation
 OUTPUT STATUS FILE
• Once the user program has been solved the
resulting ON or OFF state of each output point
is stored in the output status file.
• Each 16-point output module has one 16 bit
word holding the ON or OFF status of each of
the module’s 16-output screw terminals.
• This status data is stored in the output status
file waiting to be sent to the output module’s
switching circuitry
 BAUD RATES
• various parts of a PLC system require
different computer operational rates
for proper operation.
• 4800,2400,1200,600
• Baud rates vary for each
manufacturer and its individual PLC
device
 SCANNING

Check the input

status

Execute the program

Update the output

status
 SCANNING
• Input Scan…
Records the status of the data of input devices.

• Program Scan…
Instructions are executed sequentially

• Output Scan…
Energizes the output devices that have their status
bits set to 1
 CONVENTIONAL LADDER RUNG
• ELECTRICAL CONTINUITY
 PLC LADDER RUNG
• LOGICAL CONTINUITY
 What is a Rung?

• A rung of ladder diagram code can contain

both input and output instructions

Input Instruction Output Instruction

 Series Vs Parallel Operations
• Ladder Diagram input instructions perform logical AND and
OR operations
• Paralleling outputs allows multiple operations to occur based
on the same input criteria

A C D E

B AND F

Branches
OR
 Ladder Logic Execution
• Rungs of Ladder diagram are solved from Left to
right and top to bottom
• Branches within rungs are solved top left to
bottom right
Ladder Rung

A D E
Left Power Rail Right Power Rail
B
Branch
F G H
P S
I J K
R
 PROPER CONSTRUCTION OF PLC
LADDER DIAGRAMS
• A contact must always be inserted in slot 1 in
the upper left
• A coil must be inserted at the end of the rung

• No.of contacts per matrix is limited.

eg. 11 across and 7 down
 PROPER CONSTRUCTION OF PLC
LADDER DIAGRAMS
• Only one output may be connected
to a group of contacts
• Contacts must be ‘’nested’’ properly
• Contact Progression should be
straight across
• All contacts must run horizontally. No
vertically oriented contacts are allowed
UNIT TWO

TRANSDUCERS
 TRANSDUCERS
• PASSIVE
Depend on the external power
supply

• ACTIVE
Do not depend on the external
power supply
CHARACTERISTICS OF TRANSDUCERS
• Linearity

• Accuracy

• Repeatability

• Sensitivity
• Size
• Cost
• Dynamic Range
RTD
Resistance
temperature
detector
WIRE RTD AND FILM RTD
 PT-100

• Platinum RTD most commonly

used in industries

• Resistance is 100 ohms at zero

degree centigrade
 RTD RESISTANCE
• α = Temperature coefficient
MEASUREMENT USING RTD
Three wire RTD
RESISTANCE TEMPERATURE
CHARACTERISTICS
 ADVANTAGES
• LINEARITY

• WIDE OPERATING RANGE

• Platinum RTD can typically measure
temperatures up to 850 °C

• BETTER STABILITY AT HIGH TEMP

 DISADVANTAGES
• PASSIVE TRANSDUCER

• HIGH COST

• LEAD WIRE COMPENSATION NEEDED

• CAN BE AFFECTED BY CONTACT

RESISTANCE,SHOCK,VIBRATION
 APPLICATIONS
• Air conditioning and refrigeration

• Air, gas and liquid temperature

measurements

• For measurements in industrial

environments
THERMISTOR

THERMALLY
SENSITIVE
RESISTOR
 USED IN FORM OF
DISK,WASHERS,BEADS,RODS
 NTC
• Metallic oxides of materials like cobalt, copper, iron
and nickel, Manganese, chromium
PLOT
 CHARACTERISTICS

• -55 to 150degree centigrade

• 0.5ohms to 0.75megaohms

• Resistance decreases by 5 % for each

degree rise in temp
 Advantages
• Fast response over narrow
temperature range
• Good sensitivity in the NTC region

• Small size, Low cost

• Contact and lead resistance problem

do not occur due to large resistance
value
 Disadvantages
• Nonlinear
 Applications

• Used in microwave ovens

• Used in nuclear environments since chemically

stable

• Used in thermal relay circuits

THERMOCOUPLE
THERMOCOUPLE
 COLD JUNCTION TEMPERATURE
COMPENSATION

• ICEBATH

• REFERENCE TEMPERATURE
 THERMOCOUPLE:SEEBECK EFFECT
• When any two metals are connected together, a
voltage is developed which is a function of the
temperatures of the junctions and (mainly) the
difference in temperatures.

• The electrons in a conductor move from the higher

temperature to the lower temperature part of the
conductor.
 Types of thermocouples
• Type J…Iron –constantan

• Type k…Chromel –Alumel

• Type T…Copper –constantan

• Type S…Platinum-Platinum/Rhodium

• Type E…Chromel -constantan

 Advantages
• -270 to 2700 degree centigrade

• Bridge circuit not required

• Speed of response is high

• Rugged construction
 Disadvantages

• Signals need to be amplified

• Nonlinear

• Stray voltage pickups are possible

THERMOPILE
COMPARISON