PROGRAMMABLE

LOGIC
CONTROLLER

Control Systems Types

Programmable Logic Controllers

Distributed Control System
PC- Based Controls

Introduction

The PLC is an assembly of solid state digital logic

elements design to make logical decisions and
provide outputs.

Programmable Logic Controllers

Sequential logic solver

PID Calculations.
Advanced Subroutines
BIT Operations.
Data Transfer.
Text Handling.

Programmable Logic Controllers

Applications :

Machine controls, Packaging, Palletizing, Material handling, similar

Sequential task as well as Process control

Advantages of PLC :

They are fast and designed for the rugged industrial environment.
They are attractive on Cost-Per-Point Basis.
These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)
These Systems are upgraded to add more Intelligence and Capabilities
with dedicated PID and Ethernet Modules.

Disadvantages of PLC :

PLC were Designed for Relay Logic Ladder and have Difficulty with
some Smart Devices.
To maximize PLC performance and Flexibility, a number of Optional
Modules must be added

Programmable Logic Controllers

PLC Types

Nano (Small)
Micro (Medium)
Large
Basic criteria for PLC Types

Memory Capacity
I/O Range
Packaging and Cost per Point

P L C Components

Central Processing Unit (CPU)

Input Output Modules
Power Supply
Bus system
Programming Device
IN

CPU

OUT

MODULE

MODULE
PROGRAM
DEVICE

P L C : Central Processing Unit

It is a micro-controller based circuitary. The CPU consists

of following blocks :
Arithmatic Logic Unit (ALU), Program memory
Process image memory (Internal memory of CPU)
Internal timers and counters
Flags
CPU performs the task necessary to fulfill the PLC
funtions. These tasks include Scanning, I/O bus traffic
control, Program execution, Peripheral and External
device communication, special functions or data handling
execution and self diagnistics.

PLC : Input module

These modules act as interface between real-time status of

process variable and the CPU.
Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
(mV)
Digital input module : Typical input to these modules is 24 V
DC, 115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off
status

PLC : Input module

L1

120 V ac
PB

input
field
device

L2

L1
1
2
3

4
L2
Input module
terminal board

Input status
indicator

PLC : Output module

These modules act as link between the CPU and the output
devices in the field.
Analog output module : Typical output from these modules
is 4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration
Digital output module : Typical output from these modules is
24 V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump
valve on off control

PLC : Output module

L1

120 V ac

L2

L1

Output status
indicator
1
2
3

Output field
device

4
L2

Output module

Module blown
Fuse indicator

I/O SPECIFICATION

INPUT VOLTAGE Magnitude and type of voltage

ON-STATE INPUT VOLTAGE RANGE voltage at which signal is
recognized
Nominal current per input Min. current to operate input circuit
AMBIENT TEMP RATING Max temp of surrounding the I/O module
INPUT DELAY Time duration for input signal to be on before known
as valid input. ( 9-ms to 25ms)
NOMINAL OUTPUT VOLTAGE It is min and max o/p operating
voltage.e.g. Rated 120 v ac o/p ckt. Works in 92 to 138 v range.
MAX O/P CURRENT RATING Max current a single o/p or module
can safely carry under load
OFF STATELEAK CURRENT PER O/P Max value of leak current
flows through the o/p in OFF position
ELECTRICAL ISOLATION Max volts between I/o and logic ckt.

P L C : Power Supply

The power supply gives the voltage required for

electronics module (I/O Logic signals, CPU, memory
unit and peripheral devices) of the PLC from the line
supply.
The power supply provides isolation necessary to
protect the solid state devices from most high voltage
line spikes.
As I/O is expanded, some PLC may require additional
power supplies in order to maintain proper power
levels.

P L C : Bus System

It is path for the transmission of the signal . Bu system

is responsible for the signal exchange between
processor and I/O modules
The bus system comprise of several single line ie wires
/ tracks

Relay Connection

L1

L1

L2

L3

T1

T2

T3

M
CR

CL

1
2

CR
M

3
4
M
L2

MOTOR

Advantage of PLC Over Relay Style

RELAY
1-Hard wiring

PLC
1-Less wiring

2-Changes difficult

2-Easy modification

3-More power

3-Low power

4-More maintenance

4-Solid state reliability

5-Difficult to expand

-Ease of expansion

PLC Cycle

Sense the Input

Process the Logic
Give Output
Programmable
controller

Inputs

Outputs
Machine
or
Process

PLC Signal Flow

Input Module

Processor Memory

Output Modules

Data Output
Input
Image Table
Image Table
I:0/6

O:0/7

I:0/6

O:0/7
I:1/4

O:1/5

Input Devices

Output Devices

Ladder Program

I:1/4

I:0/6

O:0/7

I:1/4

O:1/5
O:1/5

Programming Terminal

PLC Architecture Evolution

Mid - 1970s : Discrete Machine Control

Programming
Terminal
Connection is Point to Point

PLC
Programming Language :
Connection is Point to Point

I/O

- Relay ladder logic

- Flexibility in altering
Control system operation

PLC Architecture Evolution

Early - to - Mid 1980 : Discrete and Process Control

MS - DOS

Reasonable Computer
Running PLC
Programming Software

PLC
Programming Language :
- Ladder Program
- PID
- Data Storage

I/O

PLC Architecture Evolution

Late 1980s to early 1990s : Discrete and Process

Control
Windows

PC running
PLC Programming Software
Connection in networked allowing
Multiple PLC

PLC

I/O

PLC
PLC became a part of the
developing enterprise resource
system

PLC Architecture Evolution

Today : Distributed I/O Modules
PLC

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

PLC Architecture Evolution

Today : Hot Redundant System

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK

PLC Architecture Evolution

Today : Ethernet Technology in PLCs

Workstation

Workstation

Workstation

Workstation

Switched Hub

Controller
Controller

Controller

Controller

PLC Architecture Evolution

Today : Wireless communication
PLC
Wireless Modem

Remote
Platform
Wireless Modem
PLC

HMI
Display

PC

PLC Systems of various vendors

Siemens

S5 -110U, 115U, 135U

S7 - 200, 300, 400

Allen Bradley

Micrologix 1000, 1200, 1500

SLC 5/01, 5/02, 5/03
PLC 5/10, 5/25 and 5/40

Modicon

Nano
Micro
Premium
Quantum

Configuration of PLC : Modicon

Built in display for I/O
(in-rack, AS-i) and Diag

Programming Terminal PC Connection

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter
Unitelway Port for connection
of up to 5 Slaves

TSX37-22
PCMCIA communications port

PCMCIA memory expansion port

CPU

I/O Modules
External Power
Supply

CPU

I/O Modules
Power Supply

Configuration of PLC : GE FANUC

I/O Modules

CPU

Back plane

PLC Programming Standards

The open, manufacturer-independent programming
standard for automation is IEC 61131-3. You can thus choose
what configuration interface you wish to use when writing your
application :

Ladder Diagram
Statement List
Instruction List
Function Block Diagram
Sequential Function Chart
Structured Text

Scan Rate

The completion of one cycle of the

sequence is called- SCAN

Time required for one cycle is called SCAN

TIME

PLC DCS Selection Criteria

Cost of hardware, software, Integration Engineering,

Design, Installation, Start-up and Commissioning,
Validation documentation and Execution, Training, Spare
parts, Maintenance, System service contract and system
life cycle.
Reliability, Flexibility, Scalability and Validatability.
Ease of Database configuration, Graphics development,
Interlocks and Batch processing.
Integration of High-level Application.
Control Philosophy for Centralized versus Remote
Operator Console or both.
Compliance with an Industry batch standard such as
ISA SP88 and new Communication Protocol.

Memory Types

ROM (Read Only Memory)

RAM (Random Access Memory)
PROM (Programmable ROM)
EPROM (Erasable PROM)
EAROM- Electrically alterable ROM
EEPROM-Electrically erasable PROM

Binary System

BIT Each digit of a binary number

BYTE Group of 8 bit
WORD Group of one or more byte
LSB Least significant bit or smallest
value
7 6 5 4 3 2 1 0
MSB Most significant bit or largest
value
8 BIT WORD

MSB

LSB
BYTE

BYTE
18 BIT WORD

PLC : Terminology

INPUT is referred by Ixxyy

OUTPUT is referred by Qxxyy
TIMER is referred by T xyyzzzz
FLAGS are referred by M xxxx
COUNTERS are referred by C xxxx