Programmable Logic Controller

EVOLUTION OF PLC HARD WIRED CONTROL HARD WIRED SOLID STATE CONTROLLER PROGRAMMABLE LOGIC CONTROLLER HARD-WIRED CONTROL THE CONTROL TASKS WERE SOLVED WITH CONTACTOR OR RELAY CONTROL. CIRCUIT DIAGRAM HAD TO BE DESIGNED. ELECTRICAL COMPONENT INSTALLED. WIRING LIST CREATED. WIRE THE COMPONENTS NECESSARY TO PERFORM A SPECIFIC TASK.

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HARD-WIRED CONTROL
THE CONTROL TASKS WERE SOLVED WITH CONTACTOR OR RELAY CONTROL. CIRCUIT DIAGRAM HAD TO BE DESIGNED. ELECTRICAL COMPONENT TO BE INSTALLED. WIRING LIST TO BE CREATED. WIRE THE COMPONENTS NECESSARY TO PERFORM A SPECIFIC TASK.

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HARD-WIRED CONTROL ADVANTAGE
RELATIVELY SIMPLE LOW INITIAL COST SMALL LOGIC COULD BE IMPLEMENTED MUCH FASTER.

DISADVANTAGE
CHANGE IN FUNCTION OR SYSTEM EXPANSION REQUIRED EXTENSIVE COMPONENT CHANGE AND REWIRING. SPACE REQUIRED IS MORE. DIAGNOSTICS BECOMES DIFFICULT FOR COMPLEX LOGIC

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HARDWIRED SOLID STATE CONTROLLER SYSTEM CONSISTING OF ELECTRONIC LOGIC DEVICES HARDWIRED IN A SPECIFIC CONFIGURATION. ADVANTAGES SMALLER IN SIZE COMPARED TO RELAY LOGIC LOW POWER CONSUMPTION. ALLOWS ON LINE TESTING OF I/O CIRCUITS MANUALLY OR AUTOMATICALLY. DISADVANTAGES DISCRETE COMPONENTS. CONTROLLED ENVIRONMENT NEEDED. NO WATCH DOG TIMER AVAILABLE.

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DEFINITION :
A PROGRAMMABLE CONTROLLER IS A SOLID STATE CONTROLLER THAT MONITORS THE STATUS OF DEVICES CONNECTED AS INPUTS. BASED UPON A USER WRITTEN PROGRAM, STORED IN ITS MEMORY, IT CONTROLS THE STATUS OF DEVICES CONNECTED AS OUTPUTS.

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PLC INTRODUCTION:
MODICON INTRODUCED THE FIRST PLC IN 1969 AS A REPLACEMENT FOR THE MASSIVE, HARDWIRED RELAY PANELS USED IN MANUFACTURING PLANTS TO CONTROL MACHINE TOOLS AND ASSEMBLY LINES. THE NOVEL FEATURE OF THIS NEW DEVICE IS THAT IT IS PROGRAMMABLE. IT SAVES FACTORY FLOOR SPACE BY REPLACING THE RELAY BASED SYSTEM. IT IS ALSO RE-PROGRAMMABLE FOR A DIFFERENT APPLICATION. AN IMPROVEMENT OVER HARD-WIRED SYSTEMS.

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ADVANTAGES
COST EFFECTIVE FOR CONTROLLING COMPLEX SYSTEMS. FLEXIBLE AND CAN BE REAPPLIED TO CONTROL OTHER SYSTEMS QUICKLY AND EASILY. COMPUTATIONAL ABILITIES ALLOW MORE SOPHISTICATED CONTROL. TROUBLESHOOTING AIDS MAKE PROGRAMMING EASIER AND REDUCE DOWNTIME. RELIABLE COMPONENTS MAKE THESE LIKELY TO OPERATE FOR YEARS BEFORE FAILURE. PLCS HAVE INTEGRATED DIAGNOSTICS AND OVERRIDE FUNCTIONS. DIAGNOSTICS ARE CENTRALLY AVAILABLE.

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ARCHITECTURE
Communication Port
PUSH BUTTON PROXIMITY SWITCH

I N P U T S

CENTRAL PROCESSOR

O U T P U T S

SOLENOID VALVE LAMP

High Voltage MEMORY

High Voltage

Program Low Voltage AC Power Supply 85264 VAC, 50/60Hz OR

Data

DC power Supply

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PLC OPERATING CYCLE
START House Keeping
Input Scan

Output Scan

Program Scan

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INPUT PROCESSING:
DURING I/P SCAN THE PLC READS THE ON/OFF STATUS OF INPUTS & STORES THEM IN THE I/P IMAGE MEMORY BEFORE EXECUTION OF PROGRAM.THIS INFORMATION IS STORED & HELD VALID TILL THE NEXT SCAN OF INPUT MODULE.NO CHANGE IN STATUS IS ACKNOWLEDGED IN BETWEEN SCAN SEQUENCE.

Inputs
I/P MODULE

Read in
I/P IMAGE MEMORY IN CPU

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PROGRAM PROCESSING:
THE PLC EXECUTES THE USER PROGRAM TAKING INTO CONSIDERATION THE STATUS FROM IMAGE MEMORIES & NOT THAT OF ACTUAL PHYSICAL ELEMENTS. DEPENDING UPON THE LOGIC,THE O/P IMAGE MEMORY IS UPDATED AS THE PROGRAM EXECUTION PROGRESSES & RESULT IS CONVEYED TO THE CPU MEMORY FOR INTERMEDIATE STORAGE. I/P IMAGE MEMORY IN CPU LOGIC PROCESSING IN UMC O/P IMAGE MEMORY IN CPU

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OUTPUT PROCESSING:

ON COMPLETING THE EXECUTION OF ALL INSTRUCTIONS (LOGIC SCAN) THE ABOVE STORED OUTPUT IMAGE MEMORY IS TRANSFERRED TO OUTPUT MODULE WHICH WILL PHYSICALLY CHANGE THE STATUS OF THE OUTPUT ON THE PLC MODULE. O/P IMAGE MEMORY IN IN CPU

Write out

O/P MODULE

Output

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FLOW CHART:
A FLOW CHART IS A GRAPHICAL TOOL USED TO CREATING THE STRUCTURE OF A PROGRAM. A FLOW CHART OF A SINGLE SCAN ALWAYS BEGINS WITH READING THE INPUTS & UPDATING THE INPUT IMAGE,OR BUFFER,& ENDS WITH READING THE OUTPUT IMAGE & UPDATING THE OUTPUTS. THE FLOW OF INFORMATION,PRODUCT,TIME CAN ALSO SHOWN AS LINE LEADING FROM ONE EVENT OR PROCESS TO ANOTHER.

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FLOW CHART OF A PLC SCAN
READ INPUTS

UPDATE INPUT IMAGE

EVALUATE LADDER LOGIC UPDATE OUTPUT IMAGE

READ OUTPUT IMAGE

UPDATE OUTPUTS

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PLC LADDER LOGIC IS A COMPUTER PROGRAM USED TO REPRESENT THE LOGIC TO BE EXECUTED. THE LADDER LOGIC IS EXECUTED SEQUENTIALLY AND REPETITIVELY. THE INPUT CANNOT PRODUCE AN RESPONSE UNTIL THE PLC HAS COMPLETED THE SEQUENCE OF OPERATION

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RELAY LOGIC LADDER LOGIC

REPRESENTATION OF REPRESENTATION OF LOGIC IS FROM TOP LOGIC IS FROM LEFT TO TO BOTTOM RIGHT THE EXECUTION OF THE EXECUTION OF LOGIC IS LOGIC IS SIMULTANEOUSLY SEQUENTIALLY AND REPETITIVELY CALCULATION,COMP CALCULATION,COMPAR ARISION IS NOT ISION IS POSSIBLE IN POSSIBLE IN RELAY LADDER LOGIC LOGIC

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APPLICATION EXAMPLE:
START\STOP CIRCUIT FOR MOTOR: THIS IS USED TO START A DEVICE WITH A MOMENTARY INPUT. ONCE START PUSHBUTTON IS PRESSED,THE INPUT ENERGIZE INSTRUCTION WILL STAY ON UNTIL THE MOMENTARY STOP PUSHBUTTON IS PRESSED. OPERATION: TURN ON AN OUTPUT WITH A MOMENTARY INPUT, & KEEP IT ON UNTIL INSTRUCTED TO TURN IT OFF.

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START THE MOTOR BY PRESSING THE START PUSHBUTTON. KEEP THE MOTOR RUNNING UNTIL STOP PUSHBUTTON IS PRESSED.

STOP I0

START
I1

O/0

( )
O/0

MOTOR STARTER

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Ladder Logic:
The logic used to perform this consist of one rung. In this example the stop push button is normally closed switch but is programmed as a normally open instruction.

Rung 0
Before any instructions are activated N.O. instruction I\O is true(since a N.C. pushbutton is wired to a input terminal I\O & that pushbutton has not been pushed) & N.O. instruction I\I is false.

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RUNG 0 WHEN THE START PUSH BUTTON IS PRESSED N.O. INSTRUCTION I\I BECOMES TRUE, ENERGISING OUTPUT O\0. THE TRUE STATUS OF CONTROL INSTRUCTION O\0 IS REFLECTED IN N.O.CONDITION INSTRUCTION O\0,WHICH IS PROGRAMMED IN PARALLEL WITH THE START INSTRUCTION. THIS KEEPS THE OUTPUT ON EVEN WHEN I\I IS NO LONGER TRUE. WHEN THE STOP BUTTON IS PRESSED,N.O. INSTRUCTION I\O BECOMES FALSE, & THE OUTPUT IS DE-ENERGISED.

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Typical Input Card Circuit:

Opto Isolation 1 2

Processing Circuit 3

To-Processor 4

Field device & Input Filtering

LED Indication

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Typical Output Card Circuit:
Output Driving Circuit

Processing Circuit
1 2

Opto Isolation
3

Processor (CPU)

LED Indication

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APPLICATIONS OF PLC:
BUILDING CONTROLS: ANTI- THEFT SYSTEMS, ESCALATORS, GARAGE DOOR OPENERS, INDUSTRIAL ELEVATORS AND LIFTS, LIGHTING CONTROL. CHEMICAL PROCESSING EQUIPMENT: ANODIZING EQUIPMENT, ASPHALT EQUIPMENT & CHEMICAL KILNS. CIVIL ENGINEERING APPLICATIONS: AUTOMATIC WINDOW WASHERS, LOCK CONTROLS, PARKING LOT CONTROL, RAILROAD CROSSING CONTROL, STREET LIGHTING & TRAFFIC CONTROL. FURNACES , BURNERS , AND DRYERS: BOILER & BURNER MANAGEMENT , DRYING EQUIPMENT, INDUSTRIAL PROCESS FURNACES. GENERAL INDUSTRY EQUIPMENT: AIR COMPRESSOR, BOTTLE FILLERS, INDUSTRIAL CENTRIFUGES, LABELLING MACHINERY, PACKING MACHINERY& VACUUM SYSTEMS.

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MAGNETIC FORCE MOES SPRING CONTACT DOWM WHEN THE COIL IS ENERGISED SPRING CONTACT

NORMALLY CLOSED CONTACT

NORMALLY OPEN CONTACT

COIL

RELAY

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RELAY
REMOTE CONTROLLED SWITCH. CONTACTS ARE ACTIVATED BY ENERGISING THE COIL. COIL CREATES A MAGNETIC FIELD WHICH MOVES THE SPRING DOWNWARD ENERGISING THE COIL BREAKS THE NC CONTACT AND MAKES THE NO CONTACTS. SPRING RETURNS TO ITS INITIAL POSITION WHEN THE COIL IS DE-ENERGISED

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TASK :- DUST SILO MOTOR TO BE RUN IN BOTH FORWARD AND REVERSE DIRECTION

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RELAY LOGIC FOR ROTATING MOTOR IN FORWARD AND REVERSE DIRECTION
P STOP PUSH BUTTON FORWARD PUSH BUTTON

REVERSE PUSH BUTTON (RL-1) (RL-2)

REVERSE CONTACT

FORWARD CONTACT

FORWARD RELAY (RL-1) N

REVERSE RELAY (RL-2)

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LADDER LOGIC FOR ROTATING MOTOR IN FORWARD AND REVERSE DIRECTION
24 V +
I 1.1 I 1.3 O 0.2 O 0.1

24 V -

I 1.2

I 1.3

O 0.1

O 0.2

I 1.1 I 1.3 O 0.2 O 0.1 I 1.2 I 1.3 O 0.1 O 0.2

FORWARD PUSH BUTTON INPUT STOP PUSH BUTTON INPUT REVERSE NC CONTACT FORWARD OUTPUT COIL REVERSE PUSH BUTTON INPUT STOP PUSH BUTTON INPUT FORWARD NC CONTACT REVERSE OUTPUT COIL