Programmable Controller Basics

Introduction
MicroLogix Packaged Controllers

Traditional PLC Concept

PLC performs relay equivalent functions PLC performs ON/OFF control Ladder diagram program representation Designed for industrial environment Designed for ease of use and maintenance

PLC Advantages

Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to change

Today's Higher Level Control Capability

Arithmetic

Data Comparison
Word Manipulation Master Control Relay Instructions Program Skip Capability Sequencing Matrix Data Manipulation Proportional, Integral, Differential (PID) Control

What Is A Programmable Controller?

A solid state device that controls output devices based on input status and a user developed program. Originally developed to directly replace relays used for discrete control.
Inputs Outputs

Programmable Controller
C R

Where do you Use a MicroPLC?

Conveyor control Printed circuit board handling equipment SCADA(Supervisory Control And Data Acquisition)
remote pump/lift station (water/wastewater) Flow monitoring for leak detection (oil&gas)

Strapping machinery / trash compactors Palletizers Compressor control Replace hard-wired relay panels or SBCs Many, many more

Other Types of Control

MicroPLCs vs. Relays
above 2/3 relays cost becomes a problem panel space, cost limited functions limited logic, no math, no application specific instructions timers and counters cost $ to add no communications
difficult to exchange data

maintenance/reliability mechanical devices wear out, create and are affected by vibration expensive to program time consuming, difficult to document, hard to pass on logic difficult to troubleshoot requires skilled technician race problems are common and difficult to deal with

Other Types of Control

MicroPLCs vs. Custom SBCs (single board computers)
High design costs
Contract or Staff with overhead and maintenance issues associated with each

Repair / Service nightmare for customers

Depending on markets served supplier must develop/support services

High level of technical expertise required by technicians

Specialized circuit boards require specialized equipment and technical staff

Not readily available through distribution (typically regional)

Suppliers sell the controller imbedded, replacement parts are not readily available even in emergency situations

Typically does not meet worldwide standards

Certifications cost money, typically a single controller does not warrant the investment. Volumes are not high enough and re-certification on each revision is unrealistic

Typically a Domestic product

Because of these issues many manufacturers limit themselves to a single market.

Input Devices
Pushbuttons Selector Switches Limit Switches Level Switches 120/230 VAC 24 VDC
Sourcing Sinking

Photoelectric Sensors
Proximity Sensors Motor Starter Contacts Relay Contacts Thumbwheel Switches

Output Devices
Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns Relays
120 VAC/VDC 240 VAC 24 VAC/VDC

Triac
120/230 VAC

Transistor MOSFET
24 VDC

Inside A PLC
Communications

I n p u t

C i r c u i t s

Central Processor

O u t p u t

C i r c u i t s

CR

High Voltage
Isolation Barrier

MEMORY
program
Low Voltage AC Power Supply 85-264 VAC, 50/60Hz

Isolation Barrier

High Voltage

data

or

External DC Power Supply

PLC Application Considerations

Inputs/Outputs
Type,
AC, DC, sourcing, sinking, etc.

Functions required
Instruction set
Messaging PID PTO, PWM

Number of
10, 16, 20, 32, 156

Memory
Type
Flash or Battery backed

Arithmetic Communications
DeviceNet, Ethernet Remote I/O, DH+

Size
1k, 6k, 12k, 16k, 64k

Report generation

PLCs Come in a Variety of Sizes...

Pico
Typically less than 20 I/O

Micro
Typically less than 32 I/O

Small
Typically less than 128 I/O

Medium
Typically less than 1024 I/O

Large
Typically greater than 1024 I/O

And a variety of shapes/configurations

Packaged
MicroLogix 1000,1200 and 1500

Packaged with expansion

MicroLogix 1200 and 1500

Modular (rack less)

MicroLogix 1200 and 1500

Modular (rack based)

SLC 500 and PLC5

Distributed
SLC 500 and PLC5

Packaged PLC
Power supply, inputs, outputs and communication port are enclosed in a single package. Input and output devices are wired individually to the packaged controller.

Packaged PLC With Expansion

Base is identical to the standard Packaged PLC, but it also has the ability to drive additional I/O. The most common form of expansion is a block of I/O that uses the same base, or makes use of different types of expansion modules.

Modular Rack-Less PLCs

Identical in functionality to rack based PLCs Typically not as robust (packaging) Typically found on smaller (small and medium) sized PLCs. Will likely become the prevalent form of packaging in the future.

+
Processor Base Unit

+
Compact I/O

Modular PLCs
Mix N Match Components
Processors, Power Supplies and I/O are plugged into a rack or chassis Available in Small, Medium, and Large platforms Flexibility results in higher costs when compared to packaged

Distributed
Rely on communications for EVERYTHING All I/O is connected to the processor through a High Speed data link. Typically found on larger (medium and large) PLCs. For certain applications this type of form factor is very advantageous. Usually higher cost for hardware, but much lower cost for system integration. RIO (Remote I/O), DeviceNet are examples of distributed control.

Why use a Micro PLC

Performance
Although small in size these products can perform the same tasks as much larger PLCs

Cost
The price range for the entire family: $200-$800 List

Reliability
Designed to meet existing industrial design standards
UL, CSA, CE Designed & manufactured in ISO9000 facilities

International Focus
Standard product available throughout the world

Typical PLC Application

Solenoid 1
Ingredient A

Motor

Solenoid 2
Ingredient B

Sensor 1

Sensor 2

Solenoid 3

Operation of Mixer
Solenoid 1
On = Sol 3 is off, and Motor is off, and Sensor 2 is off, and Auto Switch is on Off = Sol 3 is on, or Motor is on, or Sensor 2 is on

Solenoid 3
On = Sol 1 is off, and Sol 2 is off, and Motor has run for 30 sec. Off = Solenoid 3 has been on for 60 sec.
Solenoid 1
Ingredient A

Solenoid 2
On = Sol 3 is off, and Motor is off, and Sensor 2 is on Off = Sol 3 is on, or Motor is on, or Sensor 1 is on

Motor

Solenoid 2
Ingredient B

Sensor 1

Motor
On = Sensor 1 is on, and Solenoid 2 is off, and Solenoid 1 is off Off = Solenoid 3 on

Sensor 2

Solenoid 3

Input Wiring
Terminal Block Isolation Barrier

Input Devices

1 2 3 4 5 6 7 8

L1 L1

P L C

L2

10 COM

Output Wiring
Isolation Barrier Terminal Block

Output Devices L1 L2

CR

OUT 1 OUT 1 OUT 2 OUT 2 OUT 3 OUT 3

P L C

L1 L2

OUT 4
OUT 4 OUT 5 OUT 5 OUT 6 OUT 6

PLC Operating Cycle

START

Housekeeping
Internal checks on memory, speed and operation. Service any communication requests, etc.

Input Scan
The status of external inputs (terminal block voltage) is written to the Input image (Input file).

Output Scan
The Output Image data is transferred to the external output circuits, turning the output devices ON or OFF.

Program Scan
Each ladder rung is scanned using the data in the Input file. The resulting status (Logic being solved) is written to the Output file (Output Image).