UNIT-1

PROGRAMMABLE LOGIC
CONTROLLER AND SCADA
 RELAY LOGIC SYSTEM
• A major application of relay logic is the control of routing and
signalling on railways.
• This safety critical application uses interlocking to ensure
conflicting routes can never be selected and helps reduce
accidents.
• Interlockings operated solely by electrical circuitry may be
operated locally or remotely, with the large mechanical levers of
previous systems being replaced by buttons, switches or toggles
on a panel or video interface.
•
 RELAY LOGIC SYSTEM

• Such an interlocking may also be designed to operate without a

human operator.

• These arrangements are termed automatic interlockings, and the

approach of a train sets its own route automatically, provided no
conflicting movements are in progress.
 RELAY LOGIC SYSTEM
• Elevators are another common application - large relay logic circuits
were employed from the 1930s but have been progressively
superseded with modern solid-state controls in recent years.

•
• Relay logic is also used for controlling and automation purposes in
electro-hydraulics and electro-pneumatics.
 RELAY LOGIC INTERLOCK
SYSTEM

Relay or switch interlock system

Mechanical interlock system
 RELAY LOGIC DESIGN
• In general, the following suggestions apply to designing a relay logic
diagram:
• 1. Define the process to be controlled.
• 2. Draw a sketch of the operation process. Make sure all the
components of the system are present in the drawing.
• 3. Determine the sequence of operations to be performed.
• 4.List the sequence of operational steps in as much detail as possible.
Write out the sequence in sentences, or put them in table form.
• 5. Write the relay logic diagram from the sequence of operation
 PROGRAMMABLE LOGIC CONTROLLER
• A programmable logic controller (PLC) is a specialized
computer used to control machines and process.
• A PLC is a user friendly computer that carries out
control functions of many types and levels of
complexity.
• It uses a programmable memory to store instructions
and execute specific functions that include On/Off
control, timing, counting, sequencing, arithmetic, and
data handling.
 Evolution of PLC
First PLC :
• First PLC systems evolved from conventional computers is the late 1960s
and early 1970s.

Applications:
First PLC was installed primarily in automotive plants.

Drawbacks:
1. The programs were complicated and required a highly trained
programmer to make the changes.
2. Reprogramming procedures are more difficult.
Second PLC :
• Through the late 1970s improvements were made in PLC programs to
them somewhat more user friendly.
• The introduction of microprocessor based PLCs were introduced in
1978.
Applications:
The PLC was installed in Robotics and Automation devices.
Advantages:
PLC programs written in high level languages became more
understandable to more people and PLCs became more affordable.
Third PLC :

• In the 1980s, the PLC came into exponentially increasing use.

• Some large electronics and computer, companies and some diverse
corporate electronics divisions found that the PLC had become their
greatest volume product.
• Early stage machine tool industry used CNCs nowadays it is replaced
by PLC.
Applications: Medical equipment, security control system, etc.
 Advantages of PLC over Relay
Logic Control
• Increased Reliability: Once a program has been written and tested it can
be downloaded to other PLCs.
• More Flexibility: Original equipment manufacturers (OEMs) can provide
system updates for a process by simply sending out a new program.
• Lower Costs: Originally PLCs were designed to replace relay control logic.
The cost savings using PLCs have been so significant that relay control is
becoming obsolete, except for power applications.
• Communications Capability: A PLC can communicate with other
controllers or computer equipment.
• Faster Response Time: PLCs operate in real-time which mean that an
event taking place in the field will result in an operation or output taking
place.
• Easier To Troubleshoot: PLCs have resident diagnostic and override
functions that allow users to easily trace and correct software and
hardware problems.
• Maintainability: Maintenance costs are low and downtime is minimal.
• Visual Observation: A PLC circuits operation can be seen during
operation directly on a CRT screen. The operation or mis operation of a
circuit can be observed as it happens.
• Security: A PLC program change cannot made unless the PLC is properly
unlocked and programmed. Relay panels tends to undergo
undocumented changes.
• Ease of Changes by Reprogramming: A PLC can be reprogrammed
quickly.
• Documentation: An immediate printout of the true PLC circuit is
available in minutes.
 DISADVANTAGES OF PLC

1.There's too much work required in connecting wires.

2.There's difficulty with changes or replacements.

3.It's always difficult to find errors; And require skillful work force.

4. When a problem occurs, hold-up time is indefinite, usually long.

Parts of a PLC
 Input/ Output Section OF PLC

• Input/ Output Section: The input section or input

module consists of devices like sensors, switches, and
many other real-world input sources.
• The input from the sources is connected to the PLC
through the input connector rails.
• The output section or output module can be a motor
or a solenoid or a lamp or a heater, whose functioning
is controlled by varying the input signals.
CPU or Central Processing Unit:
• It is the brain of the PLC.
• It can be a hexagonal or an octal microprocessor.
• It carries out all the processing related to the input
signals in order to control the output signals based on
the control program.
• PLC is the open architecture –other devices can be
connected and accept the program made by other
manufacturers.
 PROGRAMING DEVICE AND
POWERSUPPLY OF PLC

• Programing Devices:It is the platform where the program or

the control logic is written. It can be a handheld device or a
laptop or a computer itself.

• Power supply:It generally works on a power supply of about

24 V DC used to power input and output devices.
 PROGRAM AND DATA MEMORY
• The memory is divided into two parts- The data memory and the
program memory.
• Program Memory: The program information or the control logic is
stored in the user memory or the program memory from where the
CPU fetches the program instructions.

• Data Memory:The input and output signals and the timer and counter
signals are stored in the input and output external image memory
respectively.
PLC OPERATION
PLC OPERATION
 PLC OPERATION
• The input sources convert the real-time analog electric
signals to suitable digital signals and these signals are
applied to the PLC through the connector rails.(bus).

• These input signals are stored in the PLC external image

memory in locations known as bits. This is done by the CPU
• The control logic or the program instructions are written onto the
programming device through symbols or through mnemonics and
stored in the user memory.
• The CPU fetches these instructions from the user memory and
executes the input signals by manipulating, computing, processing
them to control the output devices.
 PLC OPERATION
• The execution results are then stored in the external image
memory which controls the output drives.
• The CPU also keeps a check on the output signals and keeps
updating the contents of the input image memory according
to the changes in the output memory.
• The CPU also performs internal programming functions like
setting and resetting of the timer, checking the user memory.
Architecture of a PLC
 I/O Configurations of PLC
• The architecture of the PLC is based on the same principle as those
employed in computer.
• I/O Configurations and I/O Sections:
1.Fixed I/O Configuration:
• Fixed I/O is typical of small PLCs that comes in one package.
No separate removable units.
• The processor and I/O are packaged together.
• The main advantage of this type of package is lower in cost.
 FIXED I/O PLC
• The number of available I/O points varies and usually can
be expanded by buying additional units of fixed I/O.

• Disadvantage of fixed I/O:

• Lack of flexibility
• If any part in the unit fails, the whole unit has to be
replaced.
FIXED I/O PLC CONFIGURATION
 Modular I/O PLC

• Modular I/O PLC is divided by compartments into which separate

modules can be plugged.
• This feature greatly increases the unit’s flexibility.
• We can choose from all the modules available, and mix them in
any way as we desire.
• When a module slides into the rack, it makes an electrical
connection with a series of contacts (RAIL) - called the backplane.
• The back plane is located at the rear of the rack.
• The PLC processor is also connected to the backplane and can
communicate with all the modules in the rack.
MODULAR PLC CONFIGURATION
 I/O Sections
• Input section: Forms the interface by which input field devices are
connected to the controller. Input devices such as pushbuttons, limit
switches, sensors, selector switches, and thumbwheel switches are
hardwired to terminals on the input modules.
• Output section: Forms the interface by which output field devices are
connected to the controller. Output devices such as small motors,
motor starters, solenoid valves, and indicator lights are hardwired to
the terminals on the output modules.
• Power supply :
• DC power to other modules that plug into the rack.
• For large PLC systems, this power supply does not
normally supply power to the field devices.
• With large systems, power to the field devices is
provided by the external AC or DC supplies.
• For small and micro PLC systems, the power supply is
also used to power field devices.
• Central Processing Unit (CPU)
The CPU is the brain of the system. It consists of three sub parts
 CPU
• Microprocessor: A processor usually consists of a microprocessor for
implementing the logic, and controlling the communications among
the modules.
• Memory: The area of the CPU in which data & information is stored
and retrieved. Holds the system software and user program.
• Power supply: The electrical supply that converts AC voltage to
various optional DC supplies. In the process, the power supply filters
and regulates the DC voltages to ensure proper computer operation.
• Programming Devices :The programming device is used to enter the
desire program into the memory of the process.
1. Personal computer
2. Handheld devices

Handheld programming devices are

sometimes used to program small
PLCs, because they are inexpensive
and easy to use. Once plugged into
the PLC, they can be used to enter
and monitor programs.
INPUT SUPPLY TO CPU
 OPTICAL ISOLATOR
• When the pushbutton is closed, 120V ac is applied to the bridge
rectifier .
• This produces a low level direct current (dc) voltage(1.4V), which is
applied the zener diode.
• The Zener diode act s an voltage regulator in the reverse bias and the
voltage is passed to the LED of the optical isolator.
• . When light from the LED strikes the photo transistor, it switches into
conduction and the status of the phototransistor(switch) is
communicated in logic or low level dc voltage to the processor.
 OPTICAL ISOLATOR

• The optical isolator not only separates the higher ac input voltage
from the logic circuits but also prevents damage to the processor due
to line voltage transients.

• Optical isolation also helps reduce the effects of electrical noise,

common in the industrial environment, which can cause erratic
operation of the processor.
 Input / Output Modules
Generally I/O modules are divided into two types:
1. Discrete Input / Output module
2. Analog Input / Output module.

Discrete Input / Output module :

• This type of interface connects field input devices of the ON/OFF
nature such as selector switches, pushbuttons, and limit switches.
• Likewise, output control is limited to devices such as lights, small
motors, solenoids, and motor starters that require simple ON/OFF
switching.
AC DISCRETE INPUT MODULE
Block diagram of AC discrete
input module
AC Discrete Output Module
 AC DISCRTE OUTPUT VOLTAGE
• When the processor calls for an output, a voltage is applied across the
LED of the isolator.
• The LED then emits light, which switches the phototransistor into
conduction. This in turn switches The Triac into conduction, which in tum
turns on the lamp.
• Since the triac conducts in either direction, the output to the lamp is
alternating current.
• Fuses are generally required for the output module, and they are
provided on a per circuit basis, thus allowing for each circuit to be
protected and operated separately. Some modules also provide visual
indicators for fuse status
 Analog Input / Output Module
• Analog input interface modules contain the circuitry necessary to
accept analog voltage or current signals from analog field devices.
• These inputs are converted from an analog to a digital value by an
analog-to-digital (A/D) converter circuit.
• The conversion value, which is proportional to the analog signal is
expressed as a 12-bit binary or as a 3-digit binary-coded decimal
(BCD) for use by the processor.
• Analog input sensing devices include temperature, light, speed,
pressure, and position transducers.
Analog Input Module
 ANALOG CONTINUOUS INPUT
MODULE
• A typical analog input interface module connection to a
thermocouple.
• A varying dc voltage in the millivolt range proportional to the
temperature being monitored is produced by the thermocouple
• This voltage is amplified and digitized by the analog input module
and then sent to the processor on command from a program
instruction.
• Because of the low voltage level of the input signal, a shielded cable
is used in wiring the circuit to reduce unwanted electrical noise
signals that can be induced in the conductors from other wiring.
 ANLOG INPUT MODULE
• Voltage input modules are available in two types: unipolar and bipolar.
• Unipolar modules can accept only one polarity for input. For example,
if the application requires the card to measure 0 to + 10 V, a
unidirectional input module(card) would be used.
• The bipolar card will accept input of positive and negative polarity. For
example if the application produces a voltage between-10 V and +10 V.
a bidirectional input card would be used because the measured
voltage could be negative or positive.
• Current input modules are normally designed to measure current in
the 4-mA to 20-mA range.
Analog Output Module
 ANALOG OUTPUT MODULE
• . In this application the PLC controls the amount of fluid placed in a
holding tank by adjusting the percentage of the valve opening.
• The valve is initially open 100% as the fluid level in the tank
approaches the preset point.
• The processor modifies the output, which adjusts the valve to
maintain a set point.
 ANALOG OUTPUT MODULE
• The analog output interface module receives from the
processor digital data .
• The digital data is passed through a digital-to-analog (D/A)
converter circuit to produce the necessary analog form.
• Analog signal is send to an analog field device.
 INPUT DEVICES FOR PLC
Input Symbo Description
Devices l
Push button
Normally Open (NO)(0): pushbutton makes
a circuit CONTACT when it is pressed(1)
and returns to its open position when the
button is released.
NC PUSHBUTTON:CLOSED(0), OPEN (1)
The break-make pushbutton is used for
interlocking controls. In this switch the top
section is NC, while the bottom section is
NO. When the button is pressed, the
bottom contacts are
closed as the top contacts open
 INPUT DEVICES FOR PLC
Input devices Symbol Description
Limit switch They are often used in
the control of machine
processes to govern
the starting, stopping,
or
reversal of motors,
liquid level control
system.
Input Devices
Output Control Devices
SCADA
 SUPERVISORY CONTROL
• Supervisory control is what we actually see in
the PLC , SCADA , DCS systems. Which is controlling whole plant or
more than one field devices through a master system.
• There will be many types of field devices in a plant, each of the
devices will have controllers to control the control action. We can’t
install a signal controller to control the whole plant, it’s logic less. But
can connect all the controller to a single master device. So a human
can verify the process variable and set the setpoint to each controller
distinctly.
 Temperature control system
A single controller supervisory control example
• Here, a computer “supervises” the furnace’s temperature by
communicating setpoint values to the temperature indicating
controller (TIC) over a digital network interface such as Ethernet.
• From the temperature controller’s perspective, this is a remote
setpoint signal, as opposed to a local setpoint value which would be
set by a human operator at the controller faceplate.
• Since the heat-treatment of metals requires particular temperature
ranges and rates of change over time, this control system relieves the
human operator of having to manually adjust setpoint values again
and again during heat-treatment cycles. Instead, the computer sets
different setpoint at different stages according to the needs.
• The supervisory control system can include many such controllers and
can be connected to a single master computer or supervisory
computer.
 Supervisory Control And Data
Acquisition System(SCADA)
• SCADA is an acronym for supervisory control and data acquisition, a
computer system for gathering and analyzing real time data.
• SCADA systems are used to monitor and control a plant or equipment
in industries such as telecommunications, water and waste control,
energy, oil and gas refining and transportation.
 FUNCTIONS OF SCADA
• Data Acquisition
• Data Communication
• Data Presentation
• Control
SCADA system is divided into five main components /
parts:
i) Master Terminal Unit (MTU),
ii) Remote Terminal Unit (RTU),
iii) Human Machine Interface (HMI),
iv) SCADA communication media or link, and
v) Field instrumentation
SCADA APPLICATIONS
SCADA System
The basic functions carried out by an SCADA system are:

• Channel scanning
• Conversion into engineering units
• Data processing.
 Channel Scanning
• The microprocessor scans the channels to read the data, and this
process is called polling.
• The channel selection may be sequential or in any particular order
decided by the designer. It is also possible to assign priority to some
channels over others, i.e. some channels can be scanned more
frequently than others.
• POLLING
 • Interrupt Scanning

When any parameter exceeds the

limits then the limit checking circuit
would send interrupt request to
microprocessor which in turn would
monitor all parameters till, the
parameter values, come back within
pre-specified limits.
Conversion to Engineering Units
• For an 8-bit ADC working in unipolar mode the output ranges
between 0 and 255. An ADC output value will corresponds to a
particular engineering value based on the following parameters.
• Calibration of transmitters.
• ADC mode and digital output lines.
• The transmitter output should be in the range of 0-5 V or 4-20 mA
range.
• Depending on the input range of measured value for transmitter, a
calibration factor is determined. If a transmitter is capable of
measuring parameter within the input range Xl and X2 and provides
0-5 V signal at output then calibration factor is

• If we are converting this signal to digital through an 8-bit

ADC (Input range 0-5 V) in unipolar mode then 5 V = 255
and 0 V =0, i.e.1 Volt =255/5.
• Thus the conversion factor is ADC output
255/5 = X2- Xl / 5 engineering units.
ADC output 1 = X2- Xl / 255 engineering units.
• If the ADC output is Y then the corresponding value in engineering
units will be
Y(X2 - Xl) / 255.
• Conversion factor is therefore (X2- Xl ) / 255.
Data Processing