PROGRAMMABLE

CONTROLLERS

Outline:
 Programmable Controllers Definition
 Components of a Programmable Controller
 Programming the Programmable Controllers
 Programmable controller functions
 Advantage of the Programmable Controllers
 Computers versus Programmable Controllers
PROGRAMMABLE CONTROLLERS
A digitally operating electronic apparatus
which uses a programmable memory for the
internal storage of instructions for

Prof. Nagaraj Raikar

implementing specific functions such as logic,
sequencing, timing, counting and arithmetic
to control various types of machines or
processes, through digital or analog
input/output modules.
Programmable controllers were first introduced around 1969
and are available today in wide variety of styles from a variety
of manufacturers.

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 Prof. Nagaraj Raikar
Fig.1.a series of programmable controllers models with CRT terminal 3
APPLICATIONS OF PROGRAMMABLE
CONTROLLERS

 Programmable Controllers have been used in

a wide variety of industrial applications,

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including:
1. Transfer machines
2. Flow line conveyer systems
3. Injection molding
4. grinding
5. welding
6. Cement processing
7. food processing
8. Energy management etc.
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COMPONENTS OF A PROGRAMMABLE
CONTROLLER
 The basic components of any programmable controller
are the following :

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 Input/output interfaces
 Processors
 Memory
 Programming Device
 Power Supply

This components will be contained in suitable housings and

cabinets to permit them to withstand the shop environment.

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 Power Supply

Programming memory Connection

Input/output
device interface to industrial
processor

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equipments

Fig.2 The configuration of the PC system

 The PCs are designed to be connected to industrial equipment

.This connection is accomplished by means of the input/output
interface.
 The input interface is designed to receive process and machine
signals and convert them into an acceptable form for the PC.
 The output interface converts PC control signals into a form
which can be used by the process equipment.
 The input interfaces are different from the output interfaces, 6
and both types are designed to be modular for flexibility .
 One I/O module might be designed foe up to 16 circuits.
 The external signals which must be interfaced with the PC through the I/O
modules might include:

 AC voltage, various levels

 DC voltage

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 BCD inputs and outputs
 Pulse data
 Low- level analog signals such as thermocouple millivolt signals

 The processor is the central component of the PC and it is sometimes

referred to as central processing unit (CPU). It executes the various logic
functions, performs the operation on inputs, and determines the
appropriate outputs.

 As microprocessor technology has developed, these devices have been

incorporated in the PC processor design to increase its mathematical and
decision-making capabilities. 7
 The PC memory is used to store the program which specifies the logic of the
input/output processing. Memory capacities of commercial PCs range from
less than 1K up to more than 48K.
 The program is loaded into the PC memory by means of a programming
device such as:
 CRT terminal

 Manual Keyboard device

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 CRT permits the programmer to use either a relay ladder diagram or other
programming language to input the control logic into memory.
 With Keyboards the control logic and other data are entered by means of
special function buttons and thumbwheels.
 Manual programming devices are less expensive and more portable, but
CRT is more convenient for programming.
 The power supply drives the PC and serves as a source of power for the
output signals. It is also used to help protect the PC against noise in the
electrical power lines.
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PROGRAMMING THE
PROGRAMMABLE CONTROLLER

 One of the attractive features of a PC is considered to be its ease of

programming.
Shop personnel who are familiar with relay ladder diagrams are not

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
required to learn a totally new language in order to use the
programmable controllers.

 The three basic types of PC programming languages are:

 Relay ladder diagrams

 Boolean-based languages
 Mnemonic languages similar to computer assembly languages

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 Prof. Nagaraj Raikar
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Fig.2. three basic types of programmable controller programming languages.
 Relay ladder diagrams are currently the most popular type, owing to
the fact that electricians, control engineers, and maintenance
personnel are familiar with them.
 The ladder diagrams consists of symbols representing normally open
and closed contacts and other components to control electrical
equipment.

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 Boolean based languages make use of logic statements to establish
relationships among PC inputs and outputs.
 These Boolean statements can include logical “AND” (represented by
a dot), “OR” (+), and equal (=). These symbols are shown in fig.3.
 The mnemonic language is quite similar to computer assembly
language.
 The language would include statements such as LOAD, AND, OR,
and STORE,, as illustrated in fig.
 The address attached to the statement would be used to identify a
particular input/output signal.
 Programming the PC by one of these mnemonic languages often
requires the assistance of a computer programmer since plant 11
personnel are usually unfamiliar with them.
PROGRAMMABLE CONTROLLER
FUNCTIONS
1 Control relay functions:
• These functions involve the generation of an output signal from
one or more input according to a particular logic rule contained in

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the PC memory.
• The figure is illustrative of the kind of the kind of logic rules used
in control relay functions.

2 Timing functions:
• Most programmable controllers allow the programming of timing
functions. This might be used to generate an output signal a
specified delay time after an input signal has been received.
• Another example would be to maintain an output signal for a
certain length of time and then shut off. 12
3 Counting functions:
• Counting functions are similar to timing functions.
• The counter adds up the number of input contact closures and
generates a programmed output when the some reaches a certain
counts. The counter would then be reset to repeat the cycle.

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4 Arithmetic functions:
• These involve mathematical functions such as addition, subtraction
and in certain cases multiplication and division.
• Hence it is possible to use the controller for more sophisticated
processes where complex calculations are required.

5 Analog control functions

• Analog control devises are used to accomplish proportional,
integral, and derivative control functions.
• The capability to perform these control functions is available on
some PCs, which permit it to be utilized to regulate analog devices 13
directly.
ADVANTAGES OF THE
PROGRAMMABLE CONTROLLERS

• Programming the PC is generally much easier than wiring the

conventional relay control panel.

Prof. Nagaraj Raikar

• The PC can be reprogrammed. Conventional controls must be
rewired to alter the control logic, and they are often scraped
instead because of the time and expense involved in rewiring.
• Programmable controllers often require less floor space than do
conventional relay controls.
• Maintenance of PC is easier, and reliability is better.
• The programmable controller can be interfaced with plant
computer systems more easily than relays can.

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 COMPUTERS VERSUS
PROGRAMMABLE CONTROLLERS
Programmable Controllers Computers

• Programmable controller is designed • Special arrangements have to be made

to be interfaced with industrial to link up with the process.
processes. The inputs and outputs of

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the PC can be wired directly to
production equipment in the plant
through the input/output modules.
• Computer cannot function in such
• The PC is designed to function in the environment.
environment which include vibration,
electrical noise, humidity, and a wide
range of temperature.

• A computer programmer is required to

• The PC uses programming language
run the computer.
which is familiar to shop personnel.
the system is modular and
diagnostics are therefore made
easier. 15
 Relay ladder diagram

Free format equivalent programmable controller diagram

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Boolean statement

Code or mnemonic language

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Fig.2. three basic types of programmable controller programming languages.