Basic PLC

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Objectives
Describe the major components of a common PLC. Interpret PLC specifications. Apply troubleshooting techniques. Convert conventional relay logic to a PLC language. Operate and program a PLC for a given application.

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PLC Origin

- Developed to replace relays in the late 1960s - Costs dropped and became popular by 1980s - Now used in many industrial designs

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Historical Background
The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968 Their primary goal To eliminate the high costs associated with inflexible, relay-controlled systems.

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Major Components of a Common PLC

POWER SUPPLY

From SENSORS
Pushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

PROCESSOR

O U T P U T

M O D U L E

To OUTPUT
Solenoids, contactors, alarms etc.

PROGRAMMING DEVICE

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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.

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Programmable Controller Development

1968 1969 Programmable concept developed Hardware CPU controller, with logic instructions, 1 K of memory and 128 I/O points Use of several (multi) processors within a PLC - timers and counters; arithmetic operations; 12 K of memory and 1024 I/O points Remote input/output systems introduced Microprocessors - based PLC introduced

1974

1976 1977

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Programmable Logic Controllers

( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

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Leading Brands Of PLC

AMERICAN 1. 2. 3. 4. 5. 6. 7. EUROPEAN 1. 2. 3. 4. Allen Bradley Gould Modicon Texas Instruments General Electric Westinghouse Cutter Hammer Square D Siemens Klockner & Mouller Festo Telemechanique
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Leading Brands Of PLC

JAPANESE 1. 2. 3. 4. Toshiba Omron Fanuc Mitsubishi

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Areas of Application

Manufacturing / Machining Food / Beverage Metals Power Mining Petrochemical / Chemical

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PLC Size
- it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/Os and memories up to 32 Kbytes. 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant. 1. SMALL
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Tank Used to Mix Two Liquids

MOTOR

A
FS

FLOAT SWITCH

SOLENOIDS

SOLENOID

C
TIMER

1 -MINUTE

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Tank Used to Mix Two Liquids

A tank is used to mix two liquids. The control circuit operates as follows: 1. When the start button is pressed, solenoids A and B energize. This permits the two liquids to begin filling the tank.

2. When the tank is filled, the float switch trips. This deenergizes solenoids A and B and starts the motor used to mix the liquids together. 3. The motor is permitted to run for one minute. After one minute has elapsed, the motor turns off and solenoid C energizes to drain the tank.
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Tank Used to Mix Two Liquids

4. When the tank is empty, the float switch de-energizes solenoid C. 5. A stop button can be used to stop the process at any point. 6. If the motor becomes overloaded, the action of the entire circuit will stop. 7. Once the circuit has been energized it will continue to operate until it is manually stopped.

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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.

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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.

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Programming Device
Types:

Hand held unit with LED / LCD display

Desktop type with a CRT display

Compatible computer terminal

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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.
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I/O Module
DC INPUT MODULE
USE TO DROP THE VOLTAGE TO LOGIC LEVEL IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

FROM INPUT DEVICE

Current Limiting Resistor

OPTOISOLATOR

Buffer, Filter, hysteresis Circuits

TO PROCESSOR

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I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

FROM PROCESSOR

TTL Circuits

OPTOISOLATOR

Amplifier RELAY TRIAC XSISTOR

TO OUTPUT DEVICE

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OUTPUTS INPUTS
CONTACTOR LAMP PUSHBUTTONS

MOTOR

PLC

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Analog Input An analog input is an input signal that has a continuous signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level transmitter monitors the level of liquid in the tank. Depending on the level Tx, the signal to the PLC can either increase or decrease as the level increases or decreases.
Level Transmitter
IN

Tank

PLC Analog Input Module

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Digital Output

A discrete output is either in an ON or OFF condition. Solenoids, contactors coils, lamps are example of devices connected to the Discrete or digital outputs. Below, the lamp can be turned ON or OFF by the PLC output it is connected to.
OUT

PLC

Lamp
Digital Output Module

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PLC Communications
Programmable Controllers and Networks
Dedicated Network System of Different Manufacturers
Manufacturer Allen-Bradley Gould Modicon General Electric Mitsubishi Square D Texas Instruments Network Data Highway Modbus GE Net Factory LAN Melsec-NET SY/NET TIWAY

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A Detailed Design Process 1. Understand the process 2. Hardware/software selection 3. Develop ladder logic 4. Determine scan times and memory requirements

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Examples of PLC Programming Software: 1. Allen-Bradley Rockwell Software RSLogix500 2. Modicon - Modsoft 3. Omron - Syswin 4. GE-Fanuc Series 6 LogicMaster6 5. Square D- PowerLogic 6. Texas Instruments Simatic 6. Telemecanique Modicon TSX Micro

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PROGRAMMING

Normally Open (NO)

Normally Closed (NC)

Power flows through these contacts when they are closed. The normally open (NO) is true when the input or output status bit controlling the contact is 1. The normally closed (NC) is true when the input or output status bit controlling the contact is 0.

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Coils

Coils represent relays that are energized when power flows to them. When a coil is energized it causes a corresponding output to turn on by changing the state of the status bit controlling the output to 1. That same output status bit maybe used to control normally open or normally closed contact anywhere in the program.

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AND OPERATION

A
Rung

Each rung or network on a ladder program represents a logic operation. In the rung above, both inputs A and B must be true (1) in order for the output C to be true (1).

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OR OPERATION

A
Rung B

In the rung above, it can be seen that either input A or B is be true (1), or both are true, then the output C is true (1).

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NOT OPERATION

A
Rung

In the rung above, it can be seen that if input A is be true (1), then the output C is true (0) or when A is (0), output C is 1.

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