Introduction to PLCs

Lecture 7
Engineering 475
Automated Production Systems

Relay Logic Control System

Relay logic control systems
were the dominate industrial
control method prior to
approximately 1970.
Because of its similarity to a
ladder, the figure is known
as a ladder diagram.

Geller, Fig. 1.1

Programmable Logic Controllers

Programmable Logic Controllers (PLCs) are digital
devices that are used to control the state of output
ports based on the state of input ports. They greatly
simplify and increase the capability of relay logic
control systems.

Allen-Bradley
MicroLogix
Controller

Allen-Bradley PICO Controllers

Allen-Bradley SLC500 Controller

Components of a PLC
Power
Supply

Input
Ports

Processor

Output
Ports

These basic components are contained in a single unit or

as separate modules which connect to a common bus.

I/O Wiring
The primary difference between different models of PLCs are the
number and type of inputs and outputs that the PLC can
accommodate.
I1
O1
I2
O2
I3
O3
I4
O4
PLC
I5 Model XYZ O5
I6
O6
I7
O7
I8
O8
com
com

AC Input Modules
All input switching elements are
connected to a single hot wire.
The AC supply neutral wire is
connected to a COM port on the PLC.
i
The port address serves to identify a
particular input device.
The AC input module senses the 120
VAC input and converts it to a logic
level (0-5 vdc) signal required by the
processor.
Typical AC Input Module

Sinking DC Input Module

In this configuration, the

switches connected to the
input ports see the PLC as
the source of the current
flowing through them.
The forward biased diode
is optically isolated from
the PLC circuitry.
The logic level voltage (0-5
vdc) seen by the processor
is due to the bipolar
transistor.

Sourcing DC Input Module

The switches connected to
the input ports see the port
as a sink for the current to
flow to.
The forward biased diode is
optically isolated from the
biloar transistor which
generates a logic level (0-5
vdc) for the processor.

Triac-Driven 120 VAC Output

Module
Not that all outputs are
optically isolated from the
PLC circuitry by solid state
triac relays.
i

The outputs are arranged in a

sink configuration and have
internal fuses to limit the
current through the triac.

Sinking DC Output Module

Similar operation as an AC
output module, except the
triac is replaced by a bipolar
transistor.

The transistor is forward

biased in a sink type output
module.

Sourcing DC Output Module

In a sourcing DC
output module, the
devices are connected
to a DC common wire.
i

The solid state relay is

switched on using a
logic level (0-5 vdc)
signal from the
processor.

System Design
The first step in designing a PLC based control system is to
identify the type and numbers of inputs and outputs.
This will drive the type of PLC and I/O modules that need
to be purchased.
The number of I/O ports required generally expands as the
design progresses. It is always best to buy more ports than
you think is required at the beginning.
The cost of the PLC and the I/O modules is generally small
compared to the design time required to add more capability
in the future.

System Design
(Continued)
The identification of the number and type of I/O ports
required requires a system schematic.
A fluid system schematic is generally developed first.
Once the fluid system schematic is established, the
control elements needed to control the directional control
valves, motors, etc., can be determined and a control
system schematic is developed.

Assignment
Write a three to five page report that discusses the
different types of PLCs available through AllenBradley. Pay special attention to the numbers and types
of I/O ports that can be handled by the different devices.
Determine the basic electrical devices used in an AC
input module. Write a short report (one-two pages) that
describes how these modules work.