Programmable Logic Controllers: Topic 2 - 2
Programmable Logic Controllers: Topic 2 - 2
Programmable Logic Controllers: Topic 2 - 2
2
BLOCK DIAGRAM OF PLC
3
BLOCK DIAGRAM OF PLC
8
CONTROL PANEL OF PLC
9
COMPONENTS OF PLC
10
COMPONENTS OF PLC
Central Processing Unit
It is a micro-controller based circuitry. The CPU consists
of following blocks :
• Arithmetic Logic Unit (ALU),
• Program memory
• Process image memory (Internal memory of CPU)
• Internal timers and counters
• Flags
CPU performs the task necessary to fulfill the PLC
functions. These tasks include Scanning, I/O bus traffic
control, Program execution, Peripheral and External
device communication, special functions or data
handling execution and self diagnostics. 11
COMPONENTS OF PLC
Input module
These modules act as interface between real-time status
of process variable and the CPU.
Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
(mV)
Digital input module : Typical input to these modules is
24 V DC, 115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off
status 12
COMPONENTS OF PLC
Output module
These modules act as link between the CPU and the
output devices in the field.
Analog output module : Typical output from these
modules is 4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration
Digital output module : Typical output from these
modules is 24 V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump
valve on off control
Remote I/O module
These modules are attached to computers which are
connected to network 13
COMPONENTS OF PLC
Power Supply
The power supply gives the voltage required for
electronics module (I/O Logic signals, CPU, memory
unit and peripheral devices) of the PLC from the line
supply.
The power supply provides isolation necessary to
protect the solid state devices from most high
voltage line spikes.
As I/O is expanded, some PLC may require additional
power supplies in order to maintain proper power
levels.
14
COMPONENTS OF PLC
Bus System
It is path for the transmission of the signal . Bus
system is responsible for the signal exchange
between processor and I/O modules
The bus system comprise of several single line i.e.
wires / tracks
15
PHYSICAL ADDRESSING IN PLC
16
PHYSICAL ADDRESSING IN PLC
• The address of a bit is:
• [type]:[word]/[bit]
• PLC uses the capital letter “I” to designate a
hardwired input & “O” for Output
• The typical address that references an output of a
PLC is O:0/0. i.e. (“O”: zero/zero)
• O:0/5 means that it is a physical output.
• O:0/5 means that it uses Slot 0
• O:0/5 means that it is the sixth output on the PLC.
17
PHYSICAL ADDRESSING IN PLC
18
PHYSICAL ADDRESSING IN PLC
• Internal Coil is a programmable bit used to simulate a
relay within the PLC.
• The internal coil has no connection to the outside
world. It does not connect to an output card.
• Internal coils are used to store information.
• The “contacts” of this “relay” can then be used
multiple times in other parts of the program.
• The “B3” (binary) file is commonly used for all the
internal coils.
• B3:0/0 means that it references an internal Binary file
19
PHYSICAL ADDRESSING IN PLC
20
MEMORY ORGANIZATION IN PLC
• Memory organization refers to how certain areas of
memory in a PLC are utilized.
• Physical addressing, discussed in a previous section,
is the ability to read data from a specific module
terminal or write information to a specific module
terminal.
• When information is read from a contact or input it is
stored in memory.
• A portion of memory, the input image map, is
designated to store this input information.
• Each input typically has, at a minimum, a single bit
designated to store its information. 21
MEMORY ORGANIZATION IN PLC
22
MEMORY ORGANIZATION IN PLC
23
MEMORY ALLOCATION IN PLC
• Each segment is assigned a specific function or assists
in the performance of a function. For instance, the
Timer file stores all information related to any timer
utilized by the PLC. This includes status, control, and
bit information. Timer information will not be stored
in the counter file.
• When referencing timers and counters, each will be
identified as T4:0 and C5:0, respectively.
• The T4 corresponds to the file location.
• The 0 identifies the specific timer instance.
24
MEMORY ALLOCATION IN PLC
25
SCAN CYCLE OF PLC
• The PLC’s CPU monitors the status of all inputs. It
takes these values and energizes or de-energizes the
outputs according to the ladder diagram/user
program. This is referred to as scanning.
• A scan does not consist of a PLC executing ladder
diagrams rung by rung.
• Instead the PLC performs an I/O and program scan.
• The I/O scan transfers data to and from the output
and input modules, respectively. The information is
transferred in the form of bits and stored in image
tables.
26
SCAN CYCLE OF PLC
27
SCAN CYCLE OF PLC
30
SCAN CYCLE OF PLC
31
SCAN CYCLE OF PLC
32
SCAN CYCLE OF PLC
Scanning Steps
• Transfer output map bits to the output module (I/O scan)
• Input module signals are frozen i.e. snapshot is taken (I/O
scan)
• Transfer input module bits to the input image map (I/O
scan)
• CPU reads all data bits currently in the input image map
(Program scan)
• CPU evaluates/performs ladder logic on current set of
data bits (Program scan)
• Results of evaluation transferred to the output image
map 33
LIST OF REMOTE DIGITAL AND ANALOG I/OS
34
LIST OF REMOTE DIGITAL AND ANALOG I/OS
Analog Inputs
• Typical analog signals come from temperature,
pressure, position, and motor speed.
• Analog input modules convert analog signals to digital
words.
• Typical Analog Inputs are
0 to 10 volts DC, -10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps , 0 to 20 milliamps,
-20 to +20 milliamps
35
LIST OF REMOTE DIGITAL AND ANALOG I/OS
Analog Output
• Typical Analog field devices are Variable Frequency
Drive (VFD), A Valve position actuator
• Typical Analog outputs are
0 to 10 volts DC
-10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps
0 to 20 milliamps
-20 to +20 milliamps 36
LIST OF REMOTE DIGITAL AND ANALOG I/OS
Discrete Input
• Discrete or digital input signals are two-state signals:
Input ON or OFF, 1 or 0
• Start / Stop Push buttons
37
LIST OF REMOTE DIGITAL AND ANALOG I/OS
Discrete Output
• Motor starter coils
• Pilot lights
• Solenoids
• Alarms
• Valves
• Fans
• Control relays
• Horns
• Start / stop signals to variable speed drives 38
LIST OF REMOTE DIGITAL AND ANALOG I/OS
41
COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS
42
COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS
Main advantages of a PLC over relays are:
• It is easier to develop complex logical expressions with
ladder logic software.
• PLC based systems are more reliable with long life
typically more than 10 years.
• It is easier and cheaper to modify or expand the control
system at a latter date.
• It has reduced design, installation and component costs.
43
COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS
44
HAPPY LEARNING!
Dr.Mahesh S. Narkhede
Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/ 45