P1:

Describe the selection criteria and a

particular application for a unitary, a
modular and a rack mounted
programmable controller
 PLC selection criteria
In order to select a particular PLC for an application, there are many points/selection criteria
to be taken into account.
 Logical input and output: It is the number of inputs and outputs
that can be connected to PLC.
Memory: The size of the program and application decides the
memory requirement.
Number of I/O modules: The nature of application decides the
number and type of I/O modules.
Speed of operation/Scan time: The amount of time taken by PLC
to read input, process it and update the output is called scan time.
The length of program decides it. Typical values for this are 1
microsecond per simple ladder instruction.
Function: Depending on the application, a particular type of PLC
will be used that will be able to perform the job.
Safety: It should be a major concern. PLC must be safe to be
operate in a environment that includes reliability and back-up.
 Type of communication: Various Communication
standards like Serial and networked (DeviceNet,
ModBus, Profibus, Ethernet /IP) will be used
depending on the requirement. For big processes,
there may be need of data communication between
several PLCs then one has to select a particular
network protocol.
 Software/Maunfacturer’s support: The availability of
programming software and other tools is of great
importance for system development and debugging.
Also, whether there’s assistance/support available or
no.
 Cost: Depending on the application, the cost of the
control system will vary. However it must suit the
budget. Unitary PLC suits small applications and it is
cheaper as compared to Rack mounted PLC which is
used to control the entire industrial process.
Reliability: For certain high-end applications( like nuclear
power plant or oil and gas plant) its utmost important to have a
very reliable control system(even if a minor problem may create
a big loss/damage)

Environment: PLC must be suitable for the working

environment (like temperature, humidity/moisture,
interference(electric/magnetic), vibration)
HMI (Human Machine Interface): If the system needs operator
control or interaction. In order to convey information about
machine or process status, or to allow an operator to input data,
many applications require operator interfaces. Traditional
operator interfaces include pushbuttons, pilot lights and LED
numeric display. Electronic operator interface devices display
messages about machine status in descriptive text, display part
count and track alarms. Also, they can be used for data input.
 Points to be considered
 Is the application basic or complex ?
 How many input and output devices would be
required ?
 What are the types of input and output devices
to be used ?
 What are the voltage and power requirements ?
 What speed is required of the CPU?
 Will there be future expansion required ?
 Will the unit communicate with the other units
or computers ?
 What sort of communication will be used ?
 What kind of programming system will be used ?
 M1:
• Explain the benefits and limitations of a
programmable controller for a specific
applications.
 PLC Categories
• Depending upon size of PLC, input-out
numbers, memory requirement and
applications, there are four categories of PLC.
1. Micro PLC
2. Small PLC
3. Medium PLC
4. Large PLC
 Micro PLC
• Used for few numbers of discrete Inputs and
Outputs Applications
Features  Small Conveyer controls
 Up to 32 I/O  Monitoring of temperature
 16 bit processor  Activating an output
 Relay Replacer
 Memory up to 1K
 Digital I/O
 Built in I/Os in a compact unit
 Master Control Relays
 Timers and Counters
 Programmed with handheld
programmer
 Small PLC
 Single board controllers
 Mainly used for ON-OFF , timing and sequencing applications

Features Applications
 Up to 128 I/O
 16 bit processor  Small applications that require basic
 Relay Replacer math, control, network interface and
 Memory up to 2K data handling capacity
 Digital I/O
 Local I/O only
 Ladder or Boolean language only
 Master Control Relays
 Timers / counters / shift registers
 Dram timer or sequencers
 Programmed with handheld
programmer
 Medium PLC
 These controllers use range of modules that slot together
to make the complete system
The number of inputs and outputs can be expanded.
• Features
 Up to 1024 I/O  Master Control Relays
 16 or 32 bit processor  Timers / counters / shift registers
 Relay Replacer and analogue control  Dram timer or sequencers
 Memory up to 4K words  Jump
 Digital I/O  Math capabilities
 Analogue I/O  Limited data handling
 Local and remote I/O  Special function I/O modules
 Ladder or Boolean language  RS-232 communication port
 Function block/ high level language  Local area networks
 Support I/O bus networks
 Large PLC
Features
 Up to 4096 I/O
 16 or 32 bit processor
 Relay Replacer and analogue
control
 Memory up to 12K words
 Expandable to 128K
 Digital I/O
 Analogue I/O
 Local and remote I/O
 Ladder or Boolean language
 Function block/ high level
language
 Master Control Relays
 Timers / counters / shift
registers
 Dram timer or sequencers
 Jump
 Subroutines, interrupts
 Math capabilities
 Extended data handling
 Special function I/O
modules
 RS-232 communication port
 Local area networks
 Support I/O bus networks
 Large PLC Applications
• There's a need for data acquisition, data
manipulation with complex numerical
calculations
PLC category by size