Programmable Logic Controller

* What is PLC ?
- PLC is programmable logic controller.
In sequential Control and Batch Process
PLC is a most usable control strategy.
- Relay Based logic and solid state hard
wire logic are replaced by PLC .
- Now a days , PLC is suitable for continuous
process control , too.
PROGRAMMABLE LOGIC CONTROLLERS

INTRODUCTION
Control engineering has evolved over time. In the past
humans were the main method for controlling a system. More
recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be
switched on and off without a mechanical switch. It is common to
use relays to make simple logical control decisions. The
development of low cost computer has brought the most recent
revolution, the Programmable Logic Controller (PLC). The advent
of the PLC began in the 1970s, and has become the most common
choice for manufacturing controls.
PLC have been gaining popularity on the factory floor and will
probably remain predominant for some time to come. Most of his
is because of the advantages they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly
and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce
downtime.
• Reliable components make these likely to operate for years
before failure.
Symbols of Hardwire Logic
 General Architecture of PLC
- PLC Hardware Cover following given modules:
1. Power supply Module.
2. Communication Module.
3. Input / Output Module.
4. CPU and Memory Module.

- PLC software:
1. Ladder Diagram.
2. Boolean Logic.
3. Functional Blocks.
4. Sequential Function Chart.
 Input / Output Modules :
* Discrete I/O Module:
.
1. AC I/O Module : ( signal range )
120 V AC ( ACI120/ ACO120) and 220 V AC ( ACI 220/ ACO 220 )

2. Direct Current ( dc ) I/O Module:( signal range )

5 volt dc ( DCI 5/ DCO 5 ), 12 volt dc , 24 volt dc , 48 volt dc ,
100 Volt dc .

3. Isolated I/O Module:( signal range )

120 V AC ( IACI120/ IACO120)
220 V AC ( IACI 220/ IACO 220 )

4. Transistor-Transistor Logic ( TTL ) I/O Module:( signal range )

TTL interface level Low and High Level.
* Analog I/O Module : ( signal range )

1 to 5 Volt DC , 0 to 5 Volt DC, -5 to 5 Volt DC, - 10 to 10 Volt DC,

0 to 10 Volt DC 4 to 20 mA , 0 to 20 mA , -20 to 20 mA .

* Digital I/O Modules :

1. Binary Coded Decimal I/O Module.
2. Encoder/ Counter I/O Module.

* Intelligent I/O Modules :

1. Thermocouple Input Module.
2. Stepper Motor Output Module.
3. Control Loop Module.
Typical I/O with PLC
 INPUTS AND OUTPUTS

- Both inputs and outputs can be categorized into two basic types: logical or
continuous.
- Consider the example of a light bulb. If it can only be turned on or off, it is
logical control.
- If the light can be dimmed to different levels, it is continuous. Continuous
values seem more intuitive, but logical values are preferred because they
allow more certainty, and simplify control. As a result most controls
applications (and PLC) use logical inputs and outputs for most applications.
Hence, we will discuss logical I/O and leave continuous I/O.
- Outputs to actuators allow a PLC to cause something to happen in a process.
short list of popular actuators is given below in order of relative popularity.
- Solenoid Valves - logical outputs that can switch a hydraulic or pneumatic
flow.
- Lights - logical outputs that can often be powered directly from PLC output.
- Motor Starters - motors often draw a large amount of current when started.
- Typical examples of sensors are listed below in relative order of popularity.
- Proximity Switches - use inductance, capacitance or light to detect an object
logically.
- Switches - mechanical mechanisms will open or close electrical contacts for a
logical.
- LVDT (linear variable differential transformer) - measures linear displacement
continuously using magnetic coupling.
- Inputs for a PLC come in a few basic varieties, the simplest are AC and DC
inputs.
- Sourcing and sinking inputs are also popular. This output method dictates that a
device
- Sinking - When active the output allows current to flow to a common ground.
This is best selected when different voltages are supplied.
- Sourcing - When active, current flows from a supply, through the output device
and to ground. This method is best used when all devices use a single supply
voltage.
 Sketch of Input Module
- In smaller PLC the inputs are
normally built in and are specified
when purchasing the PLC. For larger
PLC the inputs are purchased as
modules, or cards, with 8 or 16 inputs
of the same type on each card. For
discussion purposes we will discuss
all inputs if they have been purchased
as cards. The list below shows typical
ranges for input voltages and is
roughly in order of popularity.

- 12-24 Vdc , 100-120 Vac , 10-60

Vdc ,12-24 Vac/dc
- 5 Vdc (TTL), 200-240 Vac ,48
Vdc ,24 Vac
 Sketch of Output Module
- Switch the power on or off for each output. Typical output voltages are
listed below, and roughly ordered by popularity.
120 Vac, 24 Vdc, 12-48 Vac, 12-48 Vdc ,5Vdc (TTL) ,230 Vac
- These cards typically have 8 to 16 outputs of the same type and can be
purchased
- Transistors or triacs. Relays are the most flexible output devices. They are
capable of switching both AC and DC outputs. But, they are slower (about
10ms switching is typical.
- Dry contacts - a separate relay is dedicated to each output.
- outputs to protect other outputs and the PLC. Response times are often
greater than 10ms. This method is the least sensitive to voltage variations
and spikes.
- Switched outputs - a voltage is supplied to the PLC card, and the card
switches it to different outputs using solid state circuitry (transistors, triacs,
etc.) Triacs are well suited to AC devices requiring less than 1A.
Transistor outputs use NPN or PNP transistors up to 1A typically. Their
response time is well under 1ms.
- Caution is required when
building a system with both
AC and DC outputs. If AC is
PLC outputs must convert the
5Vdc logic levels on the PLC
data bus to external voltage
levels.

- Basically the circuits use an

opto- coupler to switch
external circuitry. This
electrically isolates the
external electrical circuitry
from the internal circuitry.
Other circuit components are
used to guard against excess
or reversed voltage polarity.
Layout of All Modules of PLC
CASE STUDY :

Try the following case without looking at the solution

An electrical layout is needed for a hydraulic press. The press uses a 24Vdc
double actuated solenoid valve to advance and retract the press. This device
has a single common and two input wires. Putting 24Vdc on one wire will
cause the press to advance, putting 24Vdc on the second wire will cause it to
retract. The press is driven by a large hydraulic pump that requires 220Vac
rated at 20A, this should be running as long as the press is on. The press
outfitted with three push buttons, one is a NC stop button, the other is a NO
manual retract button, and the third is a NO start automatic cycle button.
There are limit switches at the top and bottom of the press travels that must
also be connected.

The input and output cards were both selected to be 24Vdc so that
they may share a single 24Vdc power supply. In this case the solenoid valve
was wired directly to the output card, while the hydraulic pump was
connected indirectly using a relay (only the coil is shown for simplicity).
This decision was
primarily made
because the hydraulic
pump requires more
current than any PLC
can handle, but a relay
would be relatively
easy to purchase and
install for that load.
All of the input
switches are connected
to the same supply
and to the inputs.
 Software ( INSTRUCTIONS ):
- For Programming of PLC , normally Ladder Programming is used . The
listed Instruction are as following.

1. Normally Open Contact : ----| |-----

2. Normally Closed Contact : ----|/ |----

3. Branch Start : |------

4. Branch End : -------|

[Link] Coil : -----( )-----

 Timers and Counters :

6. Time Delay Energized Coil ( ON ) : ----( TON )-----

7. Time Off Delay Coil ( TON ) : ----( TOF )-----

8. Retentive ON – Delay Timer Coil ( RTO) : ----( RTO )-----

9. Retentive Timer Reset Coil ( RTR) : ----( RTR )-----

10. Up-Counter ( CTU ) : ----( CTU )-----

11. Counter Reset ( CTR ) : ----( CTR )-----

12. Down-Counter ( CTD ) : ----( CTD )----

13. Latch Coil ( L ) : ----( L )----

14. Un Latch Coil ( L ) : ----( U )----

References :
1) Programmable Logic Controller :
T. A. Hhugs.
2) Industrial Manual of Siemens PLC

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