Programmable Logic Controllers

( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

Programmable Logic Controller: Definition

Formerly:
Today: Function:

Definition: small computers, dedicated to automation tasks in an industrial environme

cabled relay control (hence 'logic'), analog (pneumatic, hydraulic) governo real-time (embedded) computer with extensive input/output Measure, Control, Protect

Distinguish Instrumentation flow meter, temperature, position,. but also actors (pump, ) Control programmable logic controllers with digital peripherals & field bus Visualization HMI* in PLCs (when it exists) is limited to service help and control of operator displays
*Human Machine Interface

PLC: functions
PLC = PMC: Protection, Measurement and Control

Measure Control (Command and Regulation) Protection Event Logging Communication Human interface

PLC: Characteristics
binary and analog Input/output with standard levels operate under harsh conditions, require robust construction, protection against dirt, water and mechanical threats, electro-magnetic noise, vibration, extreme temperature range (-30C..85C), sometimes directly located in the field. programming: either very primitive with hand-held terminals on the target machine itself, or with a lap-top able to down-load programs. network connection allows programming on workstations and connection to SCADA field bus connection for remote I/Os primitive Human-Machine-Interface for maintenance, either through LCD-display or connection of a laptop over serial lines (RS232) or wireless. economical - 1000.- .. 15'000.- for a full crate. the value is in the application software (licenses 20'000 ..50'000)

large number of peripherals: 20..100 I/O per CPU, high density of wiring, easy assem

PLC: Location in the control architecture

Engineer station Operator station Supervisor Station

Enterprise Network gateway

Control Bus (e.g. Ethernet)

large PLCs
Control Station with Field Bus
COM1 COM 2

PLC

CPU COM1 I/O I/O I/O I/O I/O

COM 2 I/O I/O I/O I/O

CPU I/O

PLC

CPU COM1

Field Bus
COM CPU I/O I/O I/O I/O COM I/O I/O I/O COM CPU

Field Bus
COM

gatewa y

direct I/O

Field Stations small PLC data concentrators, not programmable, Sensor Bus (e.g. but configurable ASI)

COM CPU

FB gateway Field Devices

PLC Size
- it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/Os and memories up to 32 Kbytes. 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant. 1. SMALL

Types of PLC
(1) Compact Monolithic construction Monoprocessor Fieldbus connection
Fixed casing Fixed number of I/O (most of them binary) No process computer capabilities (no MMC) Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7

(2)

Modular PLC Modular construction (backplane) One- or multiprocessor system Fieldbus and LAN connection
3U or 6U rack, sometimes DIN-rail Large variety of input/output boards Connection to serial bus Small MMC function possible

Typical products: SIMATIC S5-115, Hitachi H-Serie, ABB AC110

(3)

Soft-PLC Windows NT or CE-based automation products Direct use of CPU or co-processors

Compact PLC

Monolithic (one-piece) construction Fixed casing Fixed number of I/O (most of them binary) No process computer capabilities (no MMC) Can be extended and networked by an extension (field) bus Sometimes LAN connection (Ethernet, Arcnet) Monoprocessor

costs: 2000 Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7

Modular PLC
tailored to the needs of an application housed in a 19" (42 cm) rack (height 6U ( = 233 mm) or 3U (=100mm) high processing power (several CPU) large choice of I/O boards concentration of a large number of I/O interface boards to field busses requires marshalling of signals primitive or no HMI cost effective if the rack can be filled
CPU CPU Analog I/O Binary I/O fieldbus
courtesy ABB

RS232

developme nt environmen t

LAN backplane parallel bus fieldbus Power Supply

supply 115-230V~ , 24V= or 48V= (redundant) cost ~ 10000 for a filled crate

Small modular PLC

mounted on DIN-rail, 24V supply cheaper (5000) not water-proof, no ventilator extensible by a parallel bus (flat cable or rail)

INTRODUCTION TO PLCS
Advantages of PLCs

1. 2. 3. 4. 5.

Less wiring. Wiring between devices and relay contacts are done in the PLC program. Easier and faster to make changes. Trouble shooting aids make programming easier and reduce downtime. Reliable components make these likely to operate for years before failure.

Comparison between PC and PLC

The main difference from other computers is that PLCs are armored for severe conditions (dust, moisture, heat, cold, etc) and have the facility for extensive input/output (I/O) arrangements. Advantages over PC : 1. Cost effective for controlling complex systems. 2. Flexible and can be reapplied to control other systems quickly and easily. 3. Computational abilities allow more sophisticated control. 4. Trouble shooting aids make programming easier and reduce downtime. 5. Reliable components make these likely to operate for years before failure. Disadvantages over PC : 1. Too much work required in connecting wires. 2. Difficulty with changes or replacements. 3. Difficulty in finding errors; requiring skillful work force.

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Areas of Application
Manufacturing / Machining Food / Beverage Metals Power Mining Petrochemical / Chemical

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Block Diagram of PLC

POWER SUPPLY

From SENSORS Pushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

PROCESSOR CPU ALU Memory

O U T P U T

M O D U L E

PROGRAMMING DEVICE

To OUTPUT Solenoids , contactor s, alarms etc.

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