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PROGRAMMABLE
    LOGIC
  CONTROLLER
Control Systems Types



   Programmable Logic Controllers
   Distributed Control System
   PC- Based Controls
Programmable Logic Controllers

PLC
 Sequential logic solver
 PID Calculations.
 Advanced Subroutines
 BIT Operations.
 Data Transfer.
 Text Handling.
Programmable Logic Controllers

Applications :
   Machine controls, Packaging, Palletizing, Material handling, similar
    Sequential task as well as Process control
Advantages of PLC :
   They are fast and designed for the rugged industrial environment.
   They are attractive on Cost-Per-Point Basis.
   These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)
   These Systems are upgraded to add more Intelligence and Capabilities
    with dedicated PID and Ethernet Modules.
Disadvantages of PLC :
   PLC were Designed for Relay Logic Ladder and have Difficulty with
    some Smart Devices.
   To maximize PLC performance and Flexibility, a number of Optional
    Modules must be added
Programmable Logic Controllers

PLC Types
   Nano (Small)
   Micro (Medium)
   Large

Basic criteria for PLC Types
   Memory Capacity
   I/O Range
   Packaging and Cost per Point
Programmable Logic Controllers


Components
   Central Processing Unit (CPU)
   Input Output Modules
   Power Supply
   Bus system
Programmable Logic Controllers

Central Processing Unit
 It is a micro-controller based circuitary. The CPU consists
  of following blocks :
  Arithmatic Logic Unit (ALU), Program memory
   Process image memory (Internal memory of CPU)
   Internal timers and counters
  Flags
 CPU performs the task necessary to fulfill the PLC
  funtions. These tasks include Scanning, I/O bus traffic
  control, Program execution, Peripheral and External device
  communication, special functions or data handling
  execution and self diagnistics.
Programmable Logic Controllers

Input module
 These modules act as interface between real-time status of
  process variable and the CPU.
 Analog input module : Typical input to these modules is

   4-20 mA, 0-10 V
   Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
  (mV)
 Digital input module : Typical input to these modules is 24 V
  DC, 115 V AC, 230 V AC
   Ex. : Switches, Pushbuttons, Relays, pump valve on off
  status
Programmable Logic Controllers

Output module
 These modules act as link between the CPU and the output
  devices in the field.
 Analog output module : Typical output from these modules
  is 4-20 mA, 0-10 V
  Ex : Control Valve, Speed, Vibration
 Digital output module : Typical output from these modules
  is 24 V DC, 115 V AC, 230 V AC
  Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump
  valve on off control
Programmable Logic Controllers


Power Supply
 The power supply gives the voltage required for
  electronics module (I/O Logic signals, CPU, memory
  unit and peripheral devices) of the PLC from the line
  supply.
 The power supply provides isolation necessary to
  protect the solid state devices from most high voltage
  line spikes.
 As I/O is expanded, some PLC may require additional
  power supplies in order to maintain proper power
  levels.
Programmable Logic Controllers


Bus System
 It is path for the transmission of the signal . Bus system
  is responsible for the signal exchange between processor
  and I/O modules
 The bus system comprise of several single line ie wires /
  tracks
PLC Cycle


   Sense the Input
   Process the Logic
   Give Output

                        Programmable
                          controller



          Inputs                       Outputs

                          Machine
                            or
                          Process
PLC Signal Flow
          Input Module       Processor Memory          Output Modules


                           Input     Data Output
                         Image Table     Image Table
                            I:0/6        O:0/7
 I:0/6
                                                               O:0/7
                           I:1/4          O:1/5

Input Devices                                                          Output Devices
                              Ladder Program

                             I:0/6        O:0/7

                             I:1/4         O:1/5
  I:1/4                                                       O:1/5




                           Programming Terminal
PLC Architecture Evolution
x   Mid - 1970s : Discrete Machine Control


                           Programming
                             Terminal

                                     Connection is Point to Point



                                PLC
                                                          Programming Language :
           Connection is Point to Point
                                                           - Relay ladder logic
                                                           - Flexibility in altering
                                                             Control system operation
     I/O
PLC Architecture Evolution
x   Early - to - Mid 1980 : Discrete and Process Control

    MS - DOS
               Reasonable Computer
                   Running PLC
               Programming Software




                     PLC
                                      Programming Language :

                                       - Ladder Program
                                       - PID
                                       - Data Storage
     I/O
PLC Architecture Evolution


x   Late 1980’s to early 1990’s : Discrete and Process
    Control       Windows

                   PC running
            PLC Programming Software
                                Connection in networked allowing
                                 Multiple PLC


                      PLC                      PLC

                                       PLC became a part of the
                                       developing enterprise resource
      I/O                              system
PLC Architecture Evolution

 Today : Distributed I/O Modules
PL
C



                                Distributed I/O scanner




            Data Communication Bus




      Distributed I/O modules
PLC Architecture Evolution

            Today : Hot Redundant System




                                           TAPS
SPLITTERS
                                                     Remote
                                                  I/O Network

             FIBER OPTIC LINK




                                 Remote I/O
PLC Architecture Evolution
          Today : Ethernet Technology in PLCs




Workstation        Workstation           Workstation    Workstation




                    Switched Hub




                                                       Controller

                                   Controller
   Controller       Controller
PLC Architecture Evolution

           Today : Wireless communication
                                                PLC

              Wireless Modem




Remote
Platform


                               Wireless Modem

                    PLC



                                                HMI        PC
                                                 Display
PLC Systems of various vendors

Siemens
   S5 -110U, 115U, 135U
   S7 - 200, 300, 400
Allen Bradley
   Micrologix 1000, 1200, 1500
   SLC 5/01, 5/02, 5/03
   PLC 5/10, 5/25 and 5/40
Modicon
   Nano
   Micro
   Premium
   Quantum
Configuration of PLC : Modicon

                    Built in display for I/O      Programming Terminal PC Connection
                    (in-rack, AS-i) and Diag

8 Analog Inputs 1
Analog Output




                                                                              I/O Modules
Up/Down Fast
Counter




Up Counter                                               TSX37-22

         Unitelway Port for connection                   PCMCIA communications port
         of up to 5 Slaves
                                               PCMCIA memory expansion port
Configuration of PLC : Siemens




   CPU


                                            I/O Modules
External Power
Supply
Configuration of PLC : Allen Bradley




   CPU


                                             I/O Modules
Power Supply
Configuration of PLC : GE FANUC

                       I/O Modules   Back plane




CPU
PLC Programming Standards


             The open, manufacturer-independent programming
    standard for automation is IEC 61131-3. You can thus choose
    what configuration interface you wish to use when writing your
    application :

   Ladder Diagram
   Instruction List
   Function Block Diagram
   Sequential Function Chart
   Structured Text
PLC DCS Selection Criteria

   Cost of hardware, software, Integration Engineering,
    Design, Installation, Start-up and Commissioning,
    Validation documentation and Execution, Training, Spare
    parts, Maintenance, System service contract and system life
    cycle.
   Reliability, Flexibility, Scalability and Validatability.
   Ease of Database configuration, Graphics development,
    Interlocks and Batch processing.
   Integration of High-level Application.
   Control Philosophy for Centralized versus Remote
    Operator Console or both.
   Compliance with an Industry batch standard such as ISA
    SP88 and new Communication Protocol.

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Plc presentation

  • 1. PROGRAMMABLE LOGIC CONTROLLER
  • 2. Control Systems Types  Programmable Logic Controllers  Distributed Control System  PC- Based Controls
  • 3. Programmable Logic Controllers PLC  Sequential logic solver  PID Calculations.  Advanced Subroutines  BIT Operations.  Data Transfer.  Text Handling.
  • 4. Programmable Logic Controllers Applications :  Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control Advantages of PLC :  They are fast and designed for the rugged industrial environment.  They are attractive on Cost-Per-Point Basis.  These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)  These Systems are upgraded to add more Intelligence and Capabilities with dedicated PID and Ethernet Modules. Disadvantages of PLC :  PLC were Designed for Relay Logic Ladder and have Difficulty with some Smart Devices.  To maximize PLC performance and Flexibility, a number of Optional Modules must be added
  • 5. Programmable Logic Controllers PLC Types  Nano (Small)  Micro (Medium)  Large Basic criteria for PLC Types  Memory Capacity  I/O Range  Packaging and Cost per Point
  • 6. Programmable Logic Controllers Components  Central Processing Unit (CPU)  Input Output Modules  Power Supply  Bus system
  • 7. Programmable Logic Controllers Central Processing Unit  It is a micro-controller based circuitary. The CPU consists of following blocks : Arithmatic Logic Unit (ALU), Program memory Process image memory (Internal memory of CPU) Internal timers and counters Flags  CPU performs the task necessary to fulfill the PLC funtions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnistics.
  • 8. Programmable Logic Controllers Input module  These modules act as interface between real-time status of process variable and the CPU.  Analog input module : Typical input to these modules is 4-20 mA, 0-10 V Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)  Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Switches, Pushbuttons, Relays, pump valve on off status
  • 9. Programmable Logic Controllers Output module  These modules act as link between the CPU and the output devices in the field.  Analog output module : Typical output from these modules is 4-20 mA, 0-10 V Ex : Control Valve, Speed, Vibration  Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control
  • 10. Programmable Logic Controllers Power Supply  The power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.  The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes.  As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.
  • 11. Programmable Logic Controllers Bus System  It is path for the transmission of the signal . Bus system is responsible for the signal exchange between processor and I/O modules  The bus system comprise of several single line ie wires / tracks
  • 12. PLC Cycle  Sense the Input  Process the Logic  Give Output Programmable controller Inputs Outputs Machine or Process
  • 13. PLC Signal Flow Input Module Processor Memory Output Modules Input Data Output Image Table Image Table I:0/6 O:0/7 I:0/6 O:0/7 I:1/4 O:1/5 Input Devices Output Devices Ladder Program I:0/6 O:0/7 I:1/4 O:1/5 I:1/4 O:1/5 Programming Terminal
  • 14. PLC Architecture Evolution x Mid - 1970s : Discrete Machine Control Programming Terminal Connection is Point to Point PLC Programming Language : Connection is Point to Point - Relay ladder logic - Flexibility in altering Control system operation I/O
  • 15. PLC Architecture Evolution x Early - to - Mid 1980 : Discrete and Process Control MS - DOS Reasonable Computer Running PLC Programming Software PLC Programming Language : - Ladder Program - PID - Data Storage I/O
  • 16. PLC Architecture Evolution x Late 1980’s to early 1990’s : Discrete and Process Control Windows PC running PLC Programming Software Connection in networked allowing Multiple PLC PLC PLC PLC became a part of the developing enterprise resource I/O system
  • 17. PLC Architecture Evolution Today : Distributed I/O Modules PL C Distributed I/O scanner Data Communication Bus Distributed I/O modules
  • 18. PLC Architecture Evolution Today : Hot Redundant System TAPS SPLITTERS Remote I/O Network FIBER OPTIC LINK Remote I/O
  • 19. PLC Architecture Evolution Today : Ethernet Technology in PLCs Workstation Workstation Workstation Workstation Switched Hub Controller Controller Controller Controller
  • 20. PLC Architecture Evolution Today : Wireless communication PLC Wireless Modem Remote Platform Wireless Modem PLC HMI PC Display
  • 21. PLC Systems of various vendors Siemens  S5 -110U, 115U, 135U  S7 - 200, 300, 400 Allen Bradley  Micrologix 1000, 1200, 1500  SLC 5/01, 5/02, 5/03  PLC 5/10, 5/25 and 5/40 Modicon  Nano  Micro  Premium  Quantum
  • 22. Configuration of PLC : Modicon Built in display for I/O Programming Terminal PC Connection (in-rack, AS-i) and Diag 8 Analog Inputs 1 Analog Output I/O Modules Up/Down Fast Counter Up Counter TSX37-22 Unitelway Port for connection PCMCIA communications port of up to 5 Slaves PCMCIA memory expansion port
  • 23. Configuration of PLC : Siemens CPU I/O Modules External Power Supply
  • 24. Configuration of PLC : Allen Bradley CPU I/O Modules Power Supply
  • 25. Configuration of PLC : GE FANUC I/O Modules Back plane CPU
  • 26. PLC Programming Standards The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application :  Ladder Diagram  Instruction List  Function Block Diagram  Sequential Function Chart  Structured Text
  • 27. PLC DCS Selection Criteria  Cost of hardware, software, Integration Engineering, Design, Installation, Start-up and Commissioning, Validation documentation and Execution, Training, Spare parts, Maintenance, System service contract and system life cycle.  Reliability, Flexibility, Scalability and Validatability.  Ease of Database configuration, Graphics development, Interlocks and Batch processing.  Integration of High-level Application.  Control Philosophy for Centralized versus Remote Operator Console or both.  Compliance with an Industry batch standard such as ISA SP88 and new Communication Protocol.