Programmable Logic

Controllers (PLC)
PLC ADVANTAGES AND DISADVANTAGES
1.Flexibility: one plc can easily run many machines
2.Implementing changes and correcting errors : PLC
program can be changed from a keyboard sequence in a
matter of minutes. No rewiring is required for PLC controlled
system
3. Large quantities of contacts
4 .lower cost: PLC with numerous relays, timers and
counters, a sequencer and other function are available at
lower cost
5. Pilot running: PLC programmed circuit can be prerun and
evaluated in the office or lab. The program can be typed in,
tested, observed and modified if needed, saving valuable
factory time.
6. Speed operation :The operational time of the plc is
determine by scan time and is in milliseconds
7. Ladder or Boolean programming method: programmer
who works in digital or Boolean control system can easily
perform PLC programming
8.Reliability and maintainability: plc are made of solid state
components with high reliability reducing maintenance costs
9.Simplicity of ordering control system: PLC is one device
with one delivery date
10.Documentation: An immediate printout of the true plc
circuit at present time is available in minutes with no tracing
is needed for verification
11. Security: A plc program change cannot be made unless
the plc is properly unlocked and programmed
12.Ease of changes by reprogramming: PLC can be
programmed quickly, mixed production processing can be
accomplished
13. Newer technology: it is difficult to change the thinking of
some personnel from ladders and relays to the plc computer
concepts
14. Fixed program application: some application are single
function application
15. Environmental consideration:
16.Fail safe operation:
17. Fixed circuit operation
OVERALL PLC SYSTEM
•The Four major parts of PLC are
1. Central Processing Unit(CPU) 2. Programmer/Monitor
3. I/O Modules 4. Racks and chassis
1. Central Processing Unit(CPU): Brain of the system and
had three parts
a. Microprocessor: carries out mathematic and logic
operations
b. Memory: stores data and information. Holds system
software and user program
c. Power supply: converts Ac supply to DC supply
2. Programmer/Monitor: device used to communicate with
circuits of the plc example Hand-held terminals, industrial
terminals and personal computer
3. I/O Modules: input modules- has terminals into which
outside process electrical signals, generated by sensor or
transducer are entered
Output module- has terminals to which output signals are
sent to activate relays, solenoids, various solid state switching
devices, motors and displays
4. Racks and chassis: on which plc parts are mounted and
enclosed

Operational units often parts of the plc system are printer,

program recorder/player
 Solid- State Memory
• The four major types of solid-state memory used in PLC-CPU
•Programmable read only memory(PROM)
•Erasable programmable read only memory(EPROM)
•Electrical erasable programmable read only memory
(EEPROM)
 I/O MODULES (INTERFACES)
•The input module performs four tasks
•Senses the presence or absence of an input signal at each
of its input terminals
•Converts the input signals for high ,or on, to a DC level
usable by module’s electronic circuit
•Carries out electronic isolation by electronically isolating
the input module output from its input
•Electronic circuit produces an output via output logic to
be sensed by PLC CPU
•First block receives the input signal from the switch, sensor
and so on
•Converts consists of zener diode rectifiers to step the
voltage down to usable level
•The output of the converter is not directly connected to the
CPU
•The isolation block protects the CPU from input surge or
circuit malfunction
•The isolation block is usually accomplished by an
optoisolator
•When the input of the isolator is on, it sends a signal to the
CPU via the output logic block
•The output send by the isolator is sensed by the coded signal
from the CPU
•Each input and output module is assigned a coded signal
from the CPU
•Each terminal number of the module is assigned a number in
consecutive order
•The on-off status for each number is checked on each sweep
of the input scan
•The result on or off is placed in RAM memory
 OUTPUT MODULE
• Operates in the opposite manner from the input module
• A DC signal from the CPU is converted through each module
section (terminal) to usable output voltage either AC or DC
•A signal from the CPU is received by the output module logic,
once for each scan
•If the CPU signal code matches the assigned number of the
module, the module section is turned on
•The identification numbers of the module are determine by
the setting of the module SIP switches
•If no matching signal is received by a terminal during the
output scan the module terminal is not energized
•The matching CPU signal if received, goes through an
isolation stage
•Isolation stage provides protection against erratic voltage
surges from the output devices that can damage the CPU
•The isolator output is then transmitted to switching circuitry
or an output relay
•The output module can be DC OR AC output
•Input and output devices are connected to sinking or
sourcing circuit
•If a solid state device controls current from the load, it is
known as sinking device
•If a solid state device controls current to the load, it is known
as sourcing device
PLC INPUT/OUTPUT MODULE
• At the input end is an internal DC power supply that supplies
voltages for up to eight switches or sensors (terminals 0 to 7)
•When a switch or sensor is closed a current path is
completed through the LED of an optoisolator, a
phototransistor conducts as a result a signal is received by the
internal circuitry
•Output has 6 relays open or close when told to do so by the
internal circuitry
•Output terminals 200 to 202 share common return to the
load power
• terminals 203,204,205 are completely independent of each
other –has its own connection and power
 PROCESS SCANNING CONSIDERATIONS
•PLC function by scanning their operational programs
•Each PLC operational cycle is made up of three separate
parts
• Input scan- input terminals are read and the input status
is updated accordingly
•Program scan-data in the input status table is applied to
the user program ,the program is executed
•Output scan- data associated with the output status table
is transferred to output terminals
•The total time for one complete program scan is a function
of processor speed and length of user program
• The input , program and output scans are separate
independent function
• Anychanges in the status of the input devices during the
program or output scan are not recognized until the next
input scan
•Data changes in the output table are not transferred to the
output terminal during the input and program scans
•The transfer affecting the output devices takes place only
during the output scans
 PLC OPERATIONAL FAULTS
•PLC has error codes for identifying incorrect programming
and misoperation
•The codes appear on the monitor in code form in small
system and in user friendly language in larger system
•Example- In the figure the error code is displayed using one
to two digits in hexadecimal (0 to F)
•Each digit of the error code indicates a different set of
condition requiring attention as shown in charts below
•An error code 24 – requires attention to two condition
•“program check sum error” from first chart
•“memory pack replacement” from second chart
•In case of system misconnection or poor connection –
message such as “communication error ” is displayed
Diagnostic aids in the form of LED’S on the controller front
panel

•In the above example uses 5 LEDs to indicate the various

condition
 FACTORS TO CONSIDER IN SELECTING PLC
•Cost-cross over point-economically advantages to go with PLC as
opposed to another
•Overall cost – installation, maintenance and training costs
•Serviceability /support concerns
•Self diagnosis- correction with minimal effort and time , part
replacement in case failure
•Flexibility
•Expandability
•Memory
• I/O modules
•System expansion
•Communication infrastructure
•Training
•Documentation