ECX PLC and

Distributed Control
Systems
Module-I
Internal Structure and Operation of PLC

[Link] RAJA, APEEE, TCE

1.1 Definition, concepts

and Need for PLC

[Link] RAJA, APEEE, TCE

What is PLC?
Specialized

computer used to control

machines and processes.
Solid state device designed to perform
logic functions previously accomplished
by electromechanical relays
Replaces conventional electromechanical
Relays, Timers, and Counters
Electrician friendly industrial computer
Works by looking at its inputs and
depending upon their state, turning
on/off its outputs.
[Link] RAJA, APEEE, TCE

What is PLC? Contd..

Used

in many "real world"

applications,
like
Machining,
packaging, material handling,
automated assembly or number
of other industries.
If you are not using

PLC, you are wasting

money and time.
[Link] RAJA, APEEE, TCE

Where PLC ?
Complex

Process

Sequence

with

process

automation

and

timings
Industrial

control
Industries

like Automobile, Chemical,

Sugar, Cement, Refinery,
Power
stations, Food Processing etc.,
[Link] RAJA, APEEE, TCE

Benefits
Increased

Reliability
More Flexibility
Lower Cost
Communication Capability
Faster Response Time

[Link] RAJA, APEEE, TCE

Benefits Contd..
Easier

to troubleshoot
Compact in Size
Simple Programming
Simplified wiring
Maintainability
Lower Power consumption
Ease of Expandability

[Link] RAJA, APEEE, TCE

1.2 Difference between

PLC and computer, PLC
size and applications

[Link] RAJA, APEEE, TCE

PLC Size
Nano PLC -Micro PLC

16 I/O
32 I/O

Elevator, car washes, mixing machines.

Small

PLC -- 128 I/O and 2KB

Simple to advanced level of machine control

Medium

PLC 2048 I/O and 32 KB

Temperature, Pressure, Flow ,Weight ,position

and any type of Process control

Large PLC16,000 I/O and 2 MB

unlimited applications ,Control individual

production processes or entire plants
[Link] RAJA, APEEE, TCE

APPLICATIONS
Single-ended

small size PLC

One PLC controls one process.

No communications
Multi

task medium size PLC

One PLC controls several processes

Communication is available.
Control

management- large PLC

One PLC control several PLCs.

[Link] RAJA, APEEE, TCE

10

PLC Vs Computer
Architecture

of PLC same as PC
PLC designed to operate in industrial
environment (not affected by Electrical
noise inherent or temperature)
Software and Hardware are designed for
easy use by plant electricians and
technicians
Computers
are
complex
computing
machines capable of executing several
programs or tasks simultaneously in any
order
PLC executes program in an orderly and
sequential fashion from first to last
[Link] RAJA, APEEE, TCE
instruction

11

Parts Of PLC

[Link] RAJA, APEEE, TCE

12

Parts
CPU
I/O

Section
Power Supply & Programming
device

[Link] RAJA, APEEE, TCE

13

I/O Module
Input

and Output module

(Interface- field devices are connected)

fixed (small PLC)
modular I/O

Input devices-

Push button, limit switches,

sensors, on-off switch, thumb wheel switch, selector
switch etc.,

Output

devices -Small motors, motor starter,

solenoid valve, indicator light, etc.,

[Link] RAJA, APEEE, TCE

14

PLC I/O Connection-Fixed

[Link] RAJA, APEEE, TCE

15

PLC I/O ConnectionModular

[Link] RAJA, APEEE, TCE

16

Power Supply
DC

small PLC
DC or AC large PLC

[Link] RAJA, APEEE, TCE

17

Processor Module
Brain
Microprocessor
Memory

EPROM, EEPROM plus

RAM

[Link] RAJA, APEEE, TCE

18

Scan cycle

[Link] RAJA, APEEE, TCE

19

Input Module

[Link] RAJA, APEEE, TCE

20

Output module

[Link] RAJA, APEEE, TCE

21

PLC Programming
Programming

devices
(used to enter the desired
program in the processor
memory)

Hand held programmer

PC based programmer

[Link] RAJA, APEEE, TCE

22

Hand held Programmer

[Link] RAJA, APEEE, TCE

23

PLC OPERATION
Motor

automatically stir when the

temperature and pressure reach preset
values

[Link] RAJA, APEEE, TCE

24

Electrical Relay Diagram

[Link] RAJA, APEEE, TCE

25

PLC INPUT Module Connection

[Link] RAJA, APEEE, TCE

26

PLC Output Module

Connection

[Link] RAJA, APEEE, TCE

27

PLC Ladder Diagram

[Link] RAJA, APEEE, TCE

28

[Link] RAJA, APEEE, TCE

29

Modifying the Operation

Manual

pushbutton control be
permitted to operate at any
pressure, but not unless the
specified temperature setting has
been reached.

[Link] RAJA, APEEE, TCE

30

Modified relay ladder

diagram

[Link] RAJA, APEEE, TCE

31

Modified ladder logic

diagram

[Link] RAJA, APEEE, TCE

32

Exercise

[Link] RAJA, APEEE, TCE

33

1.3 PLC I/O, Memory,

Programming Devices,
Data recording and
retrieval

[Link] RAJA, APEEE, TCE

34

I/O Section
Eyes,

ears and tongue

Input module
Converts machine signals to PLC
signals.
Output

module

Converts PLC signals to machine

control signals.

Chassis

Hardware assembly
I/O Modules
Processor modules
Power supplies

Different size of chassis - 4,8,12, or 16

slots
Logical

rack

Addressable unit
128 input points and 128 output points
8 words
More than one rack in a chassis

Remote I/O rack

Remote I/O
Locate

I/O modules near to field devices

for minimizing the wiring required.
Communication network
Coaxial cable
Fiber optic cable.
Addressing:

Type - I/p or O/p

Slot physical location of I/O
Word and Bit identify terminal connection

[Link] RAJA, APEEE, TCE

39

[Link] RAJA, APEEE, TCE

40

Bit level address

[Link] RAJA, APEEE, TCE

41

Word level address

[Link] RAJA, APEEE, TCE

42

I/O Module

Discrete I/O Modules

Common

type.
ON/OFF switching nature.

[Link] RAJA, APEEE, TCE

45

Discrete AC I/P Module

[Link] RAJA, APEEE, TCE

47

Discrete AC O/P Module

O/p Wiring Connection

Color Coding

For controlling large loads..

Analog I/O Module

[Link] RAJA, APEEE, TCE

52

Analog Module With TC

Interface

I/O

have infinite number of states.

Not only ON and OFF; Barely ON,
almost totally ON, not quite OFF etc..
Accept analog signals-convert to
Digital by A/D Converter.
Digital signal- 12 bit binary or BCD
code
Current sensing
Voltage sensing
Unipolar i/p module
Bipolar

Analog I/O Ctrl System

Special I/O Modules

High-Speed

Counter Module
Thumb Wheel Module
TTL Module
Encoder-Counter Module
BASIC or ASCII Module
Stepper-Motor Module
BCD Output Module

Special I/O Module

Contd..
PID

Module
Servo Module
Communication Module
High-Level Language
Module(eg:C,Pascal)
Speech Module

Recap
What

Scan cycle
is PLC?
Where PLC?
Programming
Benefits.
devices
PLC size and
PLC operation
I/O Section in
applications
PLC vs Computer detail
Parts of PLC
Remote I/O

I/O Section Fixed

and Modular
CPU
Power Supply &
Programming
device

Addressing format
Discrete I/O
interposing rely
Analog I/O
Special I/O
[Link] RAJA, APEEE, TCE

58

Components Of CPU

The CPU
Processor memory module(s).
Communications circuitry.
Power Supply

Same

type of microprocessor
More than one processor
Control
Logic

Processor Unit

Modes Of Operation
RUN
PROG
REM

RUN Position
Places

the processor in the RUN

Mode
Executes the ladder program and
energises the O/P devices
Prevents You from performing online
program editing
Prevents You from using a
programmer/operator interface
device to change the processor
mode

PROG Position
Places

the processor in the program

mode
Prevents the processor from
scanning or executing the ladder
program and the controller outputs
are de-energised
Allows program entry and editing.
Prevents the programmer/operator
interface device to change the
processor mode

REM Position
Places

the processor in the

Remote mode: either the REMote
Run, REMote program or REMote
Test Mode
Allows To change the processor
mode from a programmer
/operator interface device
Allows online program editing

Memory Design
Physical

space inside the CPU- to

store the program and data.
Storing format- 0s and 1s (bits)
Capacity 1K-1024 bytes

Status table files

[Link] RAJA, APEEE, TCE

67

Types
ROM
RAM
PROM
EPROM
EEPROM

Recording and Retrieving

Data
PLC

can have only one program

in memory at a time.

[Link] RAJA, APEEE, TCE

69

Exercise

[Link] RAJA, APEEE, TCE

70

1.4 Processor Memory

Organization, Program
Scan

[Link] RAJA, APEEE, TCE

71

Processor Memory
User program
Organization

Instructions
Logic machine operations
Entering the Programmed logic ladder diagram

Data table

Status of input & output devices

Timer and counter values

Collection

of Program files
and Data files

Program

files

areas of processor memory

where ladder logic
programming is stored
System program (File 0)
System related information
Type of processor,
I/O configuration,
Processor file name and password

Reserved

(File 1)

reserved by the processor

Not accessible to user

Main ladder program (File 2)

Contains user programmed
instructions

Subroutine ladder program (Files

3-255)
Activated according to subroutine
instructions

Data file memory

organisation
Each

data file is made up of

numerous elements
Each element may be one, two or
three words in length ( A word 16 bits)
Three words timer, counter and
control
Two words floating-point
Single word - others

Data files
output

(file 0)

state of the output terminals

Input

(file 1)

status of the input terminals

Status

(file 2)

Troubleshooting controller and program

operation

Bit

(file 3)

Internal relay logic storage

Timer

(file 4)

Timer accumulated and preset values, status

bits

Counter

(file 5)

counter accumulated and preset values, status

bits

Control

(file 6)

Length, pointer position, status bit

Integer

(file 7)

Bit information
Reserved

(file 8)

Not accessible to the user

Network

communications (file 9)

Used for network communications

User-defined

(files 10-255)

Bit, timer, counter, control

Timer

file

Counter

Control

file

file

[Link] RAJA, APEEE, TCE

80

Typical input/output image

Table file connection

[Link] RAJA, APEEE, TCE

83

Program scan
Each

operating cycle, the processor reads all the

inputs, takes these values and energizes or deenergizes the outputs according to the user
program
Single PLC scan
I/O scan & Program scan
Time

1 -20 ms

Scan process
A

continuous and sequential process of

reading the status of inputs, evaluating
the control logic and updating the outputs

Scanning
Two

basic patterns
to accomplish the
scan function
Horizontal scanning
- Allen Bradely
Vertical scanning AEG Modicon

[Link] RAJA, APEEE, TCE

88

Module-II
PLC Peripherals and
Programming

[Link] RAJA, APEEE, TCE

89

2.1 PLC programming

languages, Basic I/O devices

[Link] RAJA, APEEE, TCE

90

PLC Programming languages

[Link] RAJA, APEEE, TCE

91

Textual language

[Link] RAJA, APEEE, TCE

92

Graphical language
Ladder

diagram language

Most commonly used PLC

language
Boolean

language

AND, OR and NOT logic gate

functions
Function

Chart

Developed in Europe (GRAFCET)

Use function blocks (steps and
transition units) often controlled
by Boolean expressions

Functional block

[Link] RAJA, APEEE, TCE

94