ELX305

PLC AND SCADA SYSTEMS

(Programmable logic controller

&
Supervisory control and data acquisition)

Lecturer: Preethy
Faculty of Engineering
What is PLC?

• PLC is a system used to perform logic functions

for the control and operation of manufacturing
process equipment and machinery.
• They are used in many industries such as oil
refineries, manufacturing lines, and conveyor
systems.
• PLC is dedicated to run one program that
monitors a series of different inputs and logically
manipulates the outputs as instructed.
 Advantages of a PLC Control System
Eliminates much of the hard wiring that was
associated with conventional relay control circuits.

The program takes

the place of much of
the external wiring
that would be required
for control of a process.
 Advantages of a PLC Control System
Increased Reliability:
Once a program has been written and tested
it can be downloaded to other PLCs.

Since all the

logic is contained
in the PLC’s
memory, there
is no chance
of making a
logic wiring
error.
 Advantages of a PLC Control System
More Flexibility:
Original equipment manufacturers (OEMs) can
provide system updates for a process by simply
sending out a new program.

It is easier to
create and change
a program in a PLC
than to wire and
rewire a circuit.
End-users can modify
the program in the
field.
 Advantages of a PLC Control System
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.

Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.
 Advantages of a PLC Control System
Communications Capability:
A PLC can communicate with other controllers
or computer equipment.

They can be networked

to perform such functions
as: supervisory control, data
gathering, monitoring
devices and process
parameters, and downloading
and uploading of programs.
 Advantages of a PLC Control System
Faster Response Time:
PLCs operate in real-time which means that an
event taking place in the field will result in an
operation or output taking place.

Machines that process

thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLC’s
quick response capability.
 Advantages of a PLC Control System
Easier To Troubleshoot:
PLCs have resident diagnostic and override
functions that allows users to easily trace and
correct software and hardware problems.

The control program

can be watched in
real-time as it
executes to find
and fix problems
 What is SCADA?
• SCADA stands for Supervisory Control And
Data Acquisition system.

• It generally refers to an industrial control

system: a computer system monitoring and
controlling a process
 Why SCADA?
• The term SCADA usually refers as a central
station for monitoring, gathering data and
managing the overall operation, even
supervising and overriding the PLC controls.
SCADA and PLC Systems
 PLC Architecture
Refers to the PLC hardware or software.
PLC System
 What does PLC consist of?

• Input and Output (I/O) Module.

• Central Processor Unit, (CPU) and Memory.

• Programming device with PLC program.

• Power supply.
 What is Input/Output Module?
• A connecting component between input and
output devices. It delivers input signals to the
PLC system and provides path to the output.

• Input devices are push buttons, limit switches,

proximity sensors, potentiometers and selector
switches.

• Output devices are magnetic contactors, motors,

solenoid valves, and indicator lights.
 I/O Configurations

Fixed I/O

• Is typical of small PLCs

• Comes in one package, with

no separate removable units.

• The processor and I/O are

packaged together.

• Lower in cost – but

lacks flexibility.
 I/O Configurations

Modular I/O

Is divided by compartments
into which separate modules
can be plugged.
This feature greatly
increases your options and
the unit’s flexibility. You can
choose from all the modules
available and mix them in
any way you desire.
 I/O Configurations

Modular I/O
When a module slides into the
rack, it makes an electrical
connection with a series of
contacts - called the backplane.
The backplane is located at the
rear of the rack.
 Discrete and Analog I/O Module
• Discrete and Analog are 2 types input and output
devices.

• Discrete I/O device gives output in ON/OFF or,

Open/Closed condition, e.g., limit switches, and
push buttons.

• Analog I/O device gives output that change in a

range of values, e.g., pressure sensors,
temperature probes, and potentiometers.
 What is Analog Signal?
• Analog signals are continuous electrical signals
that varies in amplitude or frequency with time in
response to change in sound, light, heat, position,
or pressure.
 What is Digital Signal?
• Digital signals are non-continuous, and they
consist of pulses or digits with discrete values,
such as 1 or 0, HIGH or LOW, TRUE or FALSE.
 I/O Section
Input Module

Forms the interface

by which input field
devices are connected
to the controller.

The terms “field” and “real world”are used to distinguish

actual external devices that exist and must be physically
wired into the system.
 I/O Section
Output Module

Forms the interface

by which output field
devices are connected
to the controller.
 Processor (CPU)
Is the “brain” of the PLC.
Consists of a microprocessor
for implementing the logic, and
controlling the communications
among the modules.
Designed so the desired circuit can be
entered in relay ladder logic form. Processor
Module
The processor accepts input data from
various sensing devices, executes the
stored user program, and sends
appropriate output commands
to control devices.
 Why PLC Memory?

• For the storage of PLC instruction.

• Memory for its operation storage (e.g. counters,

sequence, and timers) for controlling the process
machine.
 Why Programming Device?
• It is used to create, modify, and to deliver the
PLC instructions to the PLC memory.

• The program acts as the internal functions of the

PLC system, such as relays, timers, and
counters, that is physically non-exists.
What is Programming Device? PC with appropriate
software

A personal computer (PC) is the most commonly used programming device.

The computer monitor is used to display the logic on the screen.

The personal computer communicates with the PLC processor via a serial
or parallel data communications link.

The software allows users to create, edit, document, store and troubleshoot
programs.

If the programming unit is not in use, it may be unplugged and removed.

Removing the programming unit will not affect the operation of the user
program.
 Why Power Supply?
• Necessary to convert AC voltage to low voltage
DC for the PLC system and I/O modules.
• Usually consists step down transformer, full wave
rectifier, filter network and voltage regulator as
shown.
 Power Supply

Supplies DC power to other

modules that plug into the rack.

In large PLC systems, this power supply does not

normally supply power to the field devices.

In small and micro PLC systems, the power supply

is also used to power field devices.
How PLC system differs from computer?
• Designed for technical personnel with limited
knowledge of computer.
• PLC used Relay Ladder Logic language, that is
easy to access by most electricians.

• Designed to sustain industrial environment, e.g.,

withstands wide ranges of heat, vibration,
humidity, and electrical noise.
 PLCs Versus Personal Computers

Same basic architecture

PLC PC
-operates in the industrial -capable of executing several
environment programs simultaneously, in
-is programmed in relay any order
ladder logic -some manufacturers have
-has no keyboard, CD drive, software and interface cards
monitor, or disk drive available so that a PC can do
-has communications ports, the work of a PLC
and terminals for input and
output devices
 What is Relay Ladder Logic?
• ‘Relay’ is electrical switch that can open and
close, usually controlled by excitation of the
electromagnetic fields.

• PLC diagram resembles ladder, with two vertical

‘rails’ and horizontal ‘steps’ between them.
 What is Relay Ladder Logic?
• ‘Logic’ is defined as the study of how to evaluate
a decision making by arguments and reasons.

• ‘Logic’ languages used AND, OR, NOT, and IF..

THEN.
 SUMMARY

• Introduction to PLC and SCADA

Systems.