INTRODUCTION TO PLCS

Advantages of PLCs

Less wiring.
Wiring between devices and relay contacts are done in
the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming easier and
reduce downtime.
Reliable components make these likely to operate for
years before failure.
PLC Origin

- Developed to replace relays in the late 1960s

- Costs dropped and became popular by 1980s
- Now used in many industrial designs
Major Components of a Common PLC
POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
To
SENSORS T E OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
 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- level signals inside the PLC and the fields
high level signal.
 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.
I/O Module
The I/O interface section of a PLC connects it to
external field devices.

The main purpose of the I/O interface is to condition the

various signals received from or sent to the external input
and output devices.

Input modules converts signals from discrete or analog

input devices to logic levels acceptable to PLCs processor.

Output modules converts signal from the processor to

levels capable of driving the connected discrete or analog
output devices.
I/O Module
DC INPUT MODULE
IS NEEDED TO:
USE TO Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL Helps reduce the
effects of electrical
noise

Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits
I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC Prevent voltage
INPUT TO DC AND transients from
DROPS THE VOLTAGE damaging the
TO LOGIC LEVEL processor.
Helps reduce the
effects of electrical
noise

Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits
9
10
I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
XSISTOR
DEVICE
12
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC
 Allen-Bradley 1746-1A16

L1 L2 I= Input
Module
I:2 slot # in rack

P. B SWITCH 0 Module
Terminal #
Address I:2.0/0

LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM
 CONTACTOR
L2 L1 N.O

MOTOR
L2
C SOLENOID
L1 VALVES
FIELD WIRING LAMP
BUZZER

OUTPUT MODULE
WIRING
L1 O:4 L2

CONTACTOR 0
LADDER PROGRAM
Discrete Input
A discrete input also referred as digital input is an input that is
either ON or OFF are connected to the PLC digital input. In the
ON condition it is referred to as logic 1 or a logic high and in the
OFF condition maybe referred to as logic o or logic low.

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

Processor
The processor module contains the PLCs microprocessor, its supporting
circuitry, and its memory system.

The main function of the microprocessor is to analyze data coming from field
sensors through input modules, make decisions based on the users defined
control program and return signal back through output modules to the field
devices. Field sensors: switches, flow, level, pressure, temp. transmitters, etc.
Field output devices: motors, valves, solenoids, lamps, or audible devices.

The memory system in the processor module has two parts: a system memory
and an application memory.
 Memory Map Organization
System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all system
activities, such as execution of the users control program,
communication with peripheral devices, and other system
SYSTEM activities.
The system memory also contains the routines that implement
the PLCs instruction set, which is composed of specific control
functions such as logic, sequencing, timing, counting, and
arithmetic.
System memory is generally built from read-only memory
devices.

APPLICATION
The application memory is divided into the data table area and
Data Table user program area.
The data table stores any data associated with the users control
User Program program, such as system input and output status data, and any
stored constants, variables, or preset values. The data table is
where data is monitored, manipulated, and changed for control
purposes.
The user program area is where the programmed instructions
entered by the user are stored as an application control program.
PLC Operation
Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute
the user program stored in application memory, then, based
on whatever control scheme has been programmed by the
user, turn the field output devices on or off, or perform
whatever control is necessary for the process application.

This process of sequentially reading the inputs, executing

the program in memory, and updating the outputs is known
as scanning.
While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as
individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
PLC Communications
Common Uses of PLC Communications Ports

Changing resident PLC programs - uploading/downloading

from a supervisory controller (Laptop or desktop computer).

Forcing I/O points and memory elements from a remote

terminal.

Linking a PLC into a control hierarchy containing several

sizes of PLC and computer.

Monitoring data and alarms, etc. via printers or Operator

Interface Units (OIUs).
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards

RS 232

Used in short-distance computer communications, with the

majority of computer hardware and peripherals.
Has a maximum effective distance of approx. 30 m at 9600

baud.
PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all

devices plus providing overall data exchange management or
protocol, ensuring that each device can talk to other
machines and understand data received from them.

LANs provide the common, high-speed data communications

bus which interconnects any or all devices within the local
area.

LANs are commonly used in business applications to allow

several users to share costly software packages and
peripheral equipment such as printers and hard disk storage.
PLC Communications
RS 422 / RS 485

Used for longer-distance links, often between several PCs

in a distributed system. RS 485 can have a maximum
distance of about 1000 meters.
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be

connected to the controller. There should be sufficient I/O
ports to meet present requirements with enough spares to
provide for moderate future expansion.
Selecting a PLC

Criteria

Number of logical inputs and outputs.

Memory
Number of special I/O modules
Scan Time
Communications
Software
A Detailed Design Process

1. Understand the process

2. Hardware/software selection
3. Develop ladder logic
4. Determine scan times and memory requirements
 Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying sufficient

voltage and current to drive the output peripheral connected
to it.

SCAN TIME

This is the speed at which the controller executes the relay-

ladder logic program. This variable is usually specified as the
scan time per 1000 logic nodes and typically ranges from 1 to
200 milliseconds.
Specifications
MEMORY CAPACITY

The amount of memory required for a particular application is

related to the length of the program and the complexity of the
control system. Simple applications having just a few relays
do not require significant amount of memory. Program length
tend to expand after the system have been used for a while. It
is advantageous to a acquire a controller that has more
memory than is presently needed.