(six month training on PLC and SCADA)

PLC BASED
INDUSTRIAL
PNEUMATIC
ACTUATOR AND
SCADA
INTRODUCTION
 PLC (programmable
logic controller) is a
device which is use for
industrial application ,
to control complex
consumer electronic
products. Plc is the
most demandable
technology in
consumer market as it
efficiently control
industrial equipments.
CONTENTS
 PLC BASICS
 PLC BLOCK DIAGRAME
 PLC COMPONENTS
 PLC APPLICATION
 LADDER LOGIC
 LADDER PROGRAMMING
 PLC BASED INDUSTRIALPNEUMATIC
ACTUATOR
 SCADA
PLC BASICS
 A programmable logic
controller (PLC) or
programmable controller
is a digital computer used
for automation of
electromechanical
processes, such as control
of machinery on factory
assembly lines,
amusement rides, or
lighting fixtures.
PROGRAMABLE LOGIC
CONTROL
 A PLC is an example of a
hard real time system
since output results must
be produced in response
to input conditions within
a bounded time,
otherwise unintended
Operation will result.
FUNCTIONALITY
 The functionality of the
PLC has evolved over
the years to include
sequential relay control,
motion control,
process control,
distributed control syste
ms
and networking.
MAJOR TYPES OF INDUSTRIAL
CONTROL SYSTEMS
 PLC
They are based on the Boolean logic operations whereas some models use timers and some have
continuous control. These devices are computer based and are used to control various process
and equipments within a facility. PLCs control the components in the DCS and SCADA systems
but they are primary components in smaller control configurations.
 *DCS
Distributed Control Systems consists of decentralized elements and all the processes are
controlled by these elements. Human interaction is minimized so the labor costs and injuries can
be reduced.

*Embedded Control
In this control system, small components are attached to the industrial computer system with the
help of a network and control is exercised.

*SCADA
Supervisory Control And Data Acquisition refers to a centralized system and this system is
composed of various subsystems like Remote Telemetry Units, Human Machine Interface,
Programmable Logic Controller or PLC and Communications
FEATURE
 The main difference
from other
computers is that
PLCs are armored
for severe conditions
(such as dust,
moisture, heat, cold)
and have the facility
for extensive
input/output (I/O)
arrangements.
Discfription of Function of PLC
 These connect the PLC to sensors and
actuators. PLCs read limit switches,
analog process variables (such as
temperature and pressure), and the
positions of complex positioning
systems. Some use machine vision.
 On the actuator side, PLCs operate
electric motors, pneumatic or hydraulic
cylinders, magnetic relays, solenoids, or
analog outputs. The input/output
arrangements may be built into a simple
PLC, or the PLC may have external I/O
modules attached to a computer
network that plugs into the PLC.
ADVANTAGES
 Rugged and designed to withstand
vibrations, temperature, humidity, and
noise.

* Have interfacing for inputs and outputs
already inside the controller.

* Easily programmed and have an easily
understood programming language
DISADVANTAGES
Too much work required in connecting wires.

- Difficulty with changes or replacements.

- Difficulty in finding errors; requiring

skillful work force.

- When a problem occurs, hold-up time is

indefinite, usually long
PLC APPLICATION
 *In automated system, PLC controller is
usually the central part of a process
control system.
*To run more complex processes it is
possible to connect more PLC
controllers to a central computer
BLOCK DIG OF PLC
 Input and Output Units (I/O)
 Inputs are wired to sensing devices such as
button keypads, selector switches, photocells,
motion detectors, etc. If an input senses that
a sensor is closed, the input converts the
voltage to a logic 1 signal understood by the
CPU to be ON. A logic 1 signal indicates an
On or CLOSED state, and a logic 0 signal
indicates an OFF or OPEN state.
 Ouputs are wired to switching devices such
as lights, garage doors, heating systems, and
other household appliances. Outputs switch
the supplied control voltage that energizes or
de-energizes the switching devices. If an
output is turned ON by the CPU, the control
voltage is switched to activate the switching
device.
 Central Processing Unit (CPU)
 Within the CPU are the digital processor,
memory, and power supply. These components
interact to solve application logic and pass
control signals to the outputs. The CPU reads
the converted input signals, executes the user
logic program stored in its memory, then writes
the appropriate output signals to the switching
devices. The application program is written in a
language called ladder logic.
 System Block Diagram
 The block diagram shows the major
components of a PLC. The PLC monitors
the state of the sensing devices by receiving
signals from its inputs, solves a user logic
program stored in its CPU, and then directs
switching device activity by sending control
signals to its outputs.
LADDER LOGIC

Ladder programming fed to plc to

perform task by codes software.
 Programming language that is used to
control Allen Bradley SLC-500 system
known as ladder logic. There are three
basic elements associated with the
organization ladder logic:
• Rungs
• Instructions
• Branches
 INSTRUCTIONS
Ladder Logic Instruction is divided into 2 parts:

• Input instructions:
Displayed on the left side of the ladder. Check, comparison, or the
specific conditions.

• Output instructions:
Published on the right side.

The key point about the instructions:

• Added instructions displayed on the left side of the rungs while the
output instructions are always displayed on the right side of the rungs.

• A rung does not require any input instructions, but must contain at
least one output instruction
 BRANCHES
Branches used in ladder logic to create different
paths that directly read the state of inputs and
outputs.

Bit instructions.
Bit instructions are instructions that ladder logic
instructions execute or change a single bit of data
table files. Here are three types of bit instructions:
Conditional input instructions.
Non-retentive output instructions.
Retentive output bit instructions.
PLC PROJECT TO CONTROL
PNEUMATIC ACTUATOR
 Sample PLC Project
This is a simple project to control a
pneumatics actuator. PLC pneumatics
actuator project. First things first - you all
you need to do is list down all the physical
(real world) inputs and outputs. As in this
project, the physical inputs are the “START”
button which is addressed at 0.00 and the
reed switches which are addressed at 0.01
for backward reed switch and 0.02 for
forward reed switch.
 Physical outputs are the solenoid valve (SV)
which controls the air flow into the
pneumatics cylinder actuator and the alarm.
As in the case, the SV used is of 3-2 way
type which means that when the valve is in
ON state, it will allow air to make the
actuator goes forward, and when the valve is
in OFF state, it will allow air to make the
actuator goes backward. The SV is
addressed at 100.00 and the alarm is at
100.01
FLOW CHART
 The program will set the solenoid valve and forward error
timer ON once start button and backward reed switch are
ON. The pneumatics actuator will then move forward within
10 seconds until it reaches forward reed switch. If it does
not reach forward reed switch in 10 seconds, alarm will ON.

When the actuator reaches forward reed switch, the

backward error timer will ON, the forward error timer and
solenoid valve will turn OFF so the actuator will
automatically move backward. If the actuator does not
reach backward reed switch in 10 seconds, alarm will be
triggered. Once it reaches backward reed switch withing 10
seconds, 1 cycle has been completed and the program
ends.
 When the actuator reaches forward reed
switch, the backward error timer will ON,
the forward error timer and solenoid valve
will turn OFF so the actuator will
automatically move backward. If the
actuator does not reach backward reed
switch in 10 seconds, alarm will be
triggered. Once it reaches backward reed
switch withing 10 seconds, 1 cycle has
been completed and the program ends
LADDER LOGIC
CONTROL OF
PNEUMATIC
ACTUATOR
 pneumatic actuator
systems, which use
compressed air to
transmit motion
PLC APPLICATIONS
 Snack Foods

 Glass Fiberglass

 Material Conveying Extrusion

Systems

 Building Products
Why PLC and SCADA
 REAL TIME
OPERATING SYSTEMS.

 EFFICENT EFFICENCY
TO CONTROL
INDUSTRIAL
COMPLEX SYSTEMS
EFFECTIVE
 COST EFECTIVE.
SCADA
 Where Programming Comes In
 All of this requires that physical conditions be translated into
machine language and then signals that humans can read, record
and analyze. Thus a full fledged SCADA system has to comprise of
both hardware and software elements. Today’s sophisticated
SCADA systems include input/output signal devices, control
equipment, HMI (Human Machine Interface), networking,
communication systems, databases and software.
 Thus SCADA system development involves programming at various
levels. Data collected at the RTU has to be converted into signals,
and for interpreting this data an operator requires HMI. Often the
data also has to be compiled and stored (history databases) for
recognizing trends and analysis work. Thus customized database
systems have to be developed. Networks, communication systems
etc bring in more varied requirements for programming
PLC AND SCADA FUTURE
 RELIABLE
 USE IN SNSTIVE
AREAS
 CONTROL COMLEX
INDUSTRIAL SYSTEMS