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Programmable Logic

Controllers
Part-1

What is PLC?

Programmable logic
controllers, also called
programmable
controllers or PLCs, are
solid-state members of
the computer family,
using integrated circuits
instead of electromechanical
devices to implement control
functions.
PLCs can be thought of in
simple terms as industrial
computers with specially
designed architecture in
both their central units (the
PLC itself) and their
interfacing circuitry to field
devices (input/output
connections to the real
world).

Important PLC Models


SIMATI
C S7400

Honeywell
Allen
Bradley
(Rockwell
Mitsubishi

SIMATIC
S7-300
Siemens
SIMATIC
S7-200

ABB

Yokogawa

Siemens
Logo

Working Principle

The central processing


unit
The input/output interface
system
The central processing
unit (CPU) governs all PLC
activities.
The following three
components, form the
CPU:
The processor
The memory system
The system power supply

Process Cycle

During its operation, the


CPU completes three
processes:
(1) it reads, or accepts,
the input data from the
field devices via the input
interfaces,
(2) it executes, or
performs, the control
program stored in the
memory system, and
(3) it writes, or updates,
the output devices via the
output interfaces.

Programming Methods

Programming
device, usually a
personal computer
or a manufacturers
mini programmer
unit, is required to
enter the control
program into memory
The programming
device must be
connected to the
controller when
entering or
monitoring the control
program.

PLC Ranges
Micro PLCs
Small PLCs
Medium PLCs
Large PLCs
Very large
PLCs

LADDER DIAGRAMS AND THE PLC

The ladder diagram has


and continues to be
the traditional way of
representing electrical
sequences of operations.
+
These diagrams represent
the interconnection of
field devices in such a
way that the activation,
or turning ON, of one
device will turn ON
another device according
to a predetermined
sequence of events.

ADVANTAGES OF PLCS

PROCESSORS, THE POWER SUPPLY,


AND PROGRAMMING DEVICES

The CPU forms what can


be considered to be the
brain of the system. The
three components of the
CPU are:
The processor
The memory system
The power supply

PROCESSORS

Very small microprocessors (or


micros)integrated circuits
with tremendous computing
and control capabilityprovide
the intelligence of todays
programmable controllers.
The CPU of a PLC system may
contain more than one processor
(or micro) to execute the
systems duties and/or
communications, because extra
processors increase the speed of
these operations.
Standard word lengths are 8, 16,
and 32 bits. This word length
affects the speed at which the
processor performs most
operations.

PROCESSOR SCAN

The basic function of


a programmable
controller is to read
all of the field input
devices and then
execute the control
program, which
according to the logic
programmed, will turn
the field output
devices ON or OFF.

EXAMPLE

What occurs during


the scanning operation
of a programmable
controller if the
signal(s) from an input
field device behave as
shown
in Figures a and b?

PROCESSOR SCAN

The common scan


method of monitoring
the inputs at the end
of each scan may be
inadequate for
reading certain
extremely fast inputs.
Some PLCs provide
software instructions
that allow the
interruption of the
continuous program
scan to receive an
input or to update an
output immediately.

EXAMPLE

Referencing Figure
illustrate how, in one
scan, (a) an
immediate
instruction will
respond to an
interrupt input and (b)
the same input
instruction can update
an immediate output
field device, like a
solenoid

SOLUTION

The immediate instruction will


interrupt the control program
to read the input signal. It will
then evaluate the signal and
return to the control program,
where it will resume program
execution and update outputs.
Immediate update of an
output. As in part (a), the
immediate instruction
interrupts the control program
to read and evaluate the input
signal. However, the output is
updated before normal
program execution resumes

ERROR CHECKING AND


DIAGNOSTICS

The PLCs processor


constantly communicates
with local and remote
subsystems or racks as they
may also be called I/O
interfaces connect these
subsystems to field devices
located either close to the
main CPU or at remote
locations
Error-checking techniques
are also incorporated in the
continuous communication
between the processor and
its subsystems. These
techniques confirm the
validity of the data
transmitted and received..

ERROR CHECKING

The processor uses error-checking


techniques to monitor the
functional status of both the
memory and the communication
links between subsystems and
peripherals, as well as its own
operation. Common errorchecking techniques include
parity and checksum.
Parity or vertical redundancy
check (VRC).
Checksum
Cyclic redundancy check (CRC)
The most common error-detecting
and error-correcting code is the
Hamming code.

CPU DIAGNOSTICS

The processor is responsible for


detecting communication
failures, as well as other failures,
that may occur during system
operation.
Typical diagnostics include
memory OK, processor OK,
battery OK, and power supply
OK.

THE SYSTEM POWER


SUPPLY

The system power supply


plays a major role in the
total system operation. In
fact, it can be considered
the first-line manager of
system reliability and
integrity.
Require a 120 VAC or 220
VAC power source, while a
few controllers will accept
24 VDC.
Constant Voltage
Transformers

LOADING CONSIDERATIONS

Undercurrent conditions can


cause unpredictable
operation of the I/O system.
Undercurrent condition
sometimes arises in
applications where an
excessive number of special
purpose I/O modules are
used.
When power supply loading
limits have been exceeded
and overload occurs, the
normal remedy is to either
add an auxiliary power supply
or to obtain a supply with a
larger current capability.

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