PLCs

Module 4
Programmable Logic Controllers

Introduction

Automation Technician
 This Module:
Textbook
Software
Lab Projects AB SL5 / SL500 +
OJTEs Robots +
Factory Tours
Presentations

Automation Technician
 What is a
Programmable Logic Controller
(PLC) ?

Automation
Technician
 Agenda
History
PLC Overview
Hardware
Inputs/Outputs
Operation
Programming Software
Communication
What you need to know when specifying a PLC
Glossary

Automation Technician
 History of the PLC

First Programmable Logic Controllers were designed and

developed by Modicon as a relay replacer for GM and Landis.
These controllers eliminated the need for rewiring and adding
additional hardware for each new configuration of logic.
The new system drastically increased the functionality of the
controls while reducing the cabinet space that housed the logic.

The first PLC, model 084, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced

in 1973 which was designed by Michael Greenberg.

Automation Technician
 What is a PLC?

The Basic Block

CPU

Inputs Outputs

A PROGRAMMABLE LOGIC CONTROLLER is a solid state control system

that continuously monitors the status of devices connected as inputs.
Based upon a user written program, stored in memory, it controls the status
of devices connected as outputs.

Automation Technician
 What is a PLC with Distributed I/O?

Getting Complex
CPU

Inputs Outputs

Remote

Outputs

Inputs

Automation Technician
 What is a PLC with Distributed Control?

Getting Really Complex

CPU CPU

Inputs Outputs
Inputs Outputs

Remote

Outputs

Inputs

Automation Technician
 Inside a PLC

Communications
Port

C C
I i Central O i
n r u r
p c Processor t c
u u Unit p u
t i u i
t (CPU) t t CR
s s

High High
Voltage Isolation Voltage
Isolation MEMORY Barrier
Barrier
program data

Low Voltage

AC Power Supply or DC Power Supply

Automation Technician
 Inside a PLC
The CPU contains an Executive program that tells
the PLC how to:
Execute the control Instructions
Users Program
Communicate with other devices
Other PLCs, Programming devices, I/O devices, etc.
Perform Housekeeping activities
Diagnostics, etc

This program is stored in nonvolatile memory

Meaning that the program will not be lost if power is removed

Automation Technician
 What are Inputs?
Switches and Pushbuttons
Sensing Devices
Limit Switches
Photoelectric Sensors
Proximity Sensors
Condition Sensors
Pressure Switches
Level Switches
Temperature Switches
Vacuum Switches
Float Switches
Encoders

Automation Technician
 What are Outputs?
Valves
Motor Starters
Solenoids
Actuators
Control Relays
Horns & Alarms
Stack Lights
Fans
Counter/Totalizer
Pumps
Printers

Automation Technician
 PLC Operating Cycle
Four Steps in the PLC Operations
Input Scan START
Scan the state of the Inputs Housekeeping
Input
Program Scan Scan
Output
Processes the program logic Scan
Output Scan
Energize/de-energize the outputs
Program
Housekeeping Scan

This step includes communications, Internal

Diagnostics, etc.
The steps are continually repeated - processed in a loop

Automation Technician
 Programming the PLC

Types of Programming Software Languages

Ladder Logic (LL)

IEC Format
Function Block Diagram (FBD)
International
Structured Text (ST) Electrotechnical
Instruction List (IL) Commission
Ladder Diagram (LD)
Sequential Function Chart (SFC) - also known as Grafcet

Automation Technician
 Ladder Logic

Inputs Outputs

Read / Conditional Write / Control

Instructions Instructions
Start (Rung #1) || ()

|| || |/| ()

|| |/| ()

End (Rung #4) || |/| ()

||

Automation Technician
 IEC - Function Block Diagram (FBD)

Automation Technician
 IEC - Structured Text (ST)

Automation Technician
 IEC - Instruction List (IL)

Automation Technician
 IEC - Ladder Diagram (LD)

Automation Technician
 IEC - Sequential Function Chart (SFC)

Automation Technician
 Communication

Automation Technician
 Communication Basics
Protocols
A set of rules for data exchange (format and timing of data) in a
communications system
Stack / profile = selected set of protocols for a communication
application

Communication Relationships
Master / Slave - request / response & response only
Peer-to-Peer - client / server, publisher / subscriber

Communication Architectures
Star (point-to-point)
Bus, Ring, LAN (multidrop)

Automation Technician
 Communication Protocols

Ethernet CAN-Open
Modbus Plus ASi
Modbus Seriplex
S908 FIPIO/FIPway
LonWorks RIO
Interbus HART
Profi-bus DIO
DeviceNet ControlNet
Uni-Telway ASCII

Protocols are similar to languages -

Devices must support the same protocol to understand each other

Automation Technician
 What you need to know when specifying a PLC
Quantity, Type and Location of I/O
Number of Inputs and output points
AC or DC voltage
Analog or Discrete
Concentrated or spread out (distributed)

Communication Requirements
Protocol/Network used
Devices to communicate with (HMI, other PLCs, etc)

Speed of Application
Response time required (throughput) of the system
How fast does the process change

Automation Technician
 What you need to know when specifying a PLC
Control Architecture Philosophy
Centralized Control, Distributed Control or combination
Redundancy - CPUs, Power Supplies, etc

Programming Software
IEC vs. 984
Installed base / what is currently being used

User Logic
Size and complexity of Program
Feedback control used
etc.

Automation Technician
 Alphabet Soup

HMI / MMI Human Machine Interface / Man Machine Interface

I/O Input(s) and/or Output(s)
LSB / MSB Least Significant Bit / Most Significant Bit
MODICON MOdular DIgital CONtoller
PID Proportional Integral Derivative (feedback control)
RF Radio Frequency
RTU Remote Terminal Unit
SCADA Supervisory Control And Data Acquisition
TCP/IP Transmission Control Protocol / Internet Protocol

Automation Technician