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Programmable Logic Controllers (PLC)Programmable Logic Controllers (PLC)
Composed by
Ramesh
December 27, 2008
Edited by
Sarath S Nair
www.technologyfuturae.com
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INTRODUCTIONINTRODUCTION
� First PLC is introduced by Bedford Associates founded by Richard Morley in 1968.
� PLC was known as the Modular Digital Controller from which the MODICON company derived its name.
� Programmable Logic Controllers were developed to provide a replacement for large relay based control panels.
�These systems were inflexible requiring major rewiringor replacement whenever the control sequence was to be changed.
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Contd…
�Maintainable by technicians and electrical personnel.
�To support this the programming language of Ladder
Logic was developed.
�Ladder Logic is based on the relay and contact
symbols technicians were used to through wiring
diagrams of electrical control panels.
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OVERVIEWOVERVIEW
� What is a PLC ?
– Advantages
– Disadvantages
– Real world Relay Replacement
– Example of a Motor Control
� How to program a PLC ?
– Ladder diagrams
– Examples
– Signal Processing
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What is a Programmable Logic Controllers (PLC) ?What is a Programmable Logic Controllers (PLC) ?
A special computer for logic controls using ladder logic
programming.
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Contd…
�A digital computer used for industrial automation
processes.
� PLC is designed for multiple inputs and output
arrangements
� Programs to control machine operation� Programs to control machine operation
� PLC is an example of a real time system.
�Armored for severe conditions compared to PC’s.
�Relay logic replacement
� Process Inputs and Outputs
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Advantages of PLC’sAdvantages of PLC’s
�Easy to maintain
�Easy to program
�Reliable in industrial environment
�Compact�Compact
�Long lasting
�Scalable
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Disadvantages of PLC’sDisadvantages of PLC’s
�Handling large amount of Data.
�Displaying Data.
�Handling Databases.
�Complex data handling.�Complex data handling.
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History
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PLC a Real World Relay ReplacementPLC a Real World Relay Replacement
�Real world Parts:
�Switch
�Bell
�RelayRelay
�Relay
Switch controlling AC circuit or bell
Relay
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Contd…
Relay Coil Symbol Relay Normally open Contact
Symbol
PLC Input Symbol PLC Output Symbol
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Example of a Motor ControlExample of a Motor Control
STARTSTOP
output
EQUIVALENT DIAGRAMS
START STOP
output
EQUIVALENT DIAGRAMS
Normally Open
Contact
Normally
Closed Contact
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Basic PLC Components needed to replace relay control panels
will be presented. These include:
�Isolated power supply.
�Digital Input and Output pins ( DI/0).
�Micro-controller.�Micro-controller.
�Memory.
(Note: Advanced features such as Timers, Interrupts, Counters,
etc. will be discussed latter)
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PLC ExecutionPLC Execution
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How to program PLCs?How to program PLCs?
�Using a specialized Ladder Logic Software
Allen-Bradley uses RsLogix 500 software to program
SLC, Micrologix and so on.
�Omron uses Cx Programmer software for its
SYSMAC PLCs.SYSMAC PLCs.
�Other manufacturers has their own software.
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LADDER LOGICLADDER LOGIC�Ladder logic is a method of drawing electrical logicschematics.
�A graphical language popular for PLCs Controllers.
� Invented to describe logic made from relays.
�Language resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them.
�Rule-based language, rather than a procedural language.
�Executed sequentially by software, in a loop.
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EXAMPLESEXAMPLES
Relay Logic
Ladder Logic
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PLC SIGNAL PROCESSPLC SIGNAL PROCESS
� Inputs: describe the status of the process to the
controller (external).
� States: discrete modes the controller can be in
(internal).
� State transitions: functions of the current state and
the inputs.
�Outputs: actions initiated by the controller based on
the current state (external).
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Contd…
�Through inputs the PLC monitors sensors either digital or analog.
�Photo eye
�Proximity sensor
�Pressure switch�Pressure switch
�The output is to control processes either digital or analog.
�Motor
�Control a valve
�Light
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CONCLUSIONCONCLUSION
� PLC’s are replacement of Relay based systems.
� Ladder Logic is develop to program this specialize devices using graphical symbols.
� Easy to maintain and program but does not handle complex data manipulation.
� Each manufacture has its own custom software to program PLC’s.
� Inputs are external signal from processes for the PLC to monitor. Ex: sensors
� Outputs are internal signal from PLC to control a particular process. Ex: motors.
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How to start with PLC
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�������� ���������� ���������� ������������� ���������� ���������� ������������� ���������� ���������� ������������� ���������� ���������� �����
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Programmable Logic Controller
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Overview
�What is PLC
�Allen Bradley PLC (How to work with RSLogix 500 software)
�Different functions & Ladder diagram
�Examples
�Tutorials
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Definition
A programmable logic controller is a
device which performs discrete or
continuous logic in process plant or
factory environment.
What is PLC
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�Programmable logic controller (Programmable
controller)
�Solid state system
� It was developed in late 1960’s or early 1970’s
�Designed to perform logic function
�It came to replace electromechanical relays.
�Early the I/O of PLC is digital value
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�Now a days analog I/O also possible with help of
ADC/DAC inside PLC
schematic diagram of PLC
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history
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Some of the Advantage of PLC
� Low cost(relay cost is higher than PLC)
� High Reliability (generally solid state devices are more reliable)
� Maintenance easy than relay� Maintenance easy than relay
� Flexibility
� Size is reduced
� Ease of programming
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Types of Programming PLC
� Hand held device
� Dedicated desktop (keyboard with symbols)� Dedicated desktop (keyboard with symbols)
� Computer
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RSLogix 500 starter
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Register used
�N7- integer (Ex: N7:0 , N7:1…………..)
�F8 - float (Ex: F8:0 , F8:1…………..)
�T4 – timer (Ex: T4:0 , T4:1……….)
�C5 – counter (Ex: C5:0 , C5:1…………..)
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How to address I/O’s�Maximum 12- I/O is externally connect
�Software I/O more than 12
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��������� ��������� &Ladder diagram &Ladder diagram
basics
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Contacts & coils�Rung branch
�Examine if close
�Examine if open
�Output energize
� Output latch
�Output unlatch
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Some examplesAND LOGIC USING SIMPLE LD
A B AB
0 0 0
0 1 0
1 0 0
1 1 1
Truth table
1 1 1
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OR LOGIC USING SIMPLE LD
A B AB
0 0 0
0 1 1
1 0 1
Truth table
1 0 1
1 1 1
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Level application������ ������� ������ ������� �������� ������� �����
��� 0000 ����� 0500 1000
���� 0001
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Program scan
���� 1 ���� 2-100���� 101-1000
���� 1001 ���� 1002 ���� 1050
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Tank level control
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Latch
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Latch
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Timer/ counter
�Timer On delay
� Timer OFF delay
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�Retentive timer ON delay
�Up counter
�Down counter�Down counter
� Reset
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Some examples
ON delay
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Reset
OFF delay
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�����
�������
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Compare
�Equal
�Limit test
�Not equal
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�Less than
�Greater than
�Less than or equal
�Greater than or equal
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Some examples
Equal
Limit test
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Limit test
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Not equalequal
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Compute/math
�Addition
�Subtraction
�Multiplication�Multiplication
�Division
�Square root
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Some examples
Addition
Register
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Move / logic function�Move
�Masked move
�AND logic
�OR logic
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�X-OR logic
�NOT
�Clear
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Some examples
Move
AND
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Clear
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Tutorials
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Tabulate the logic truth table & Draw
the ladder diagram for the following
1. XOR GATE
2. Y = X1 AND X2 AND [NOT X3] OR [NOT
X4 AND X5]X4 AND X5]
3. Y = (A+B)(C+E+FD) S
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References
• Amunrud, A., (2002). Programmable Logic Controller. Retrieved on December 27,
2008, from: http://www.coe.montana.edu/ee/courses/ee/ee367/pdffiles/aamunrud.pdf
• PLCs.net, (2008). Learn PLCs. Retrieved on December 27, 2008, from:
http://www.plcs.net/
• http://www.searcheng.co.uk/articles/plc/intro.html
• Wikipedia, (2008). Programmable Logic Controller. Retrieved on December 27, 2008, • Wikipedia, (2008). Programmable Logic Controller. Retrieved on December 27, 2008,
from: http://en.wikipedia.org/wiki/Programmable_logic_controller