Programmable logic
control
PLC a Process Control Computer System
Key Board Monitor
Data Processing
Light Pen Printer
Computer System
Mouse Plotter
Motion Sensor Motor
Sound Sensor Process Control Solenoid
Heat Sensor Computer System Heater
Light Sensor Light
Definition & Advantages
A PLC is user-friendly, microprocessor-based, specialized
computer that carries out control schemes of many types and levels of
complexity. It can be programmed, controlled and operated by person
unskilled in computers
rugged-noise
rugged-noiseimmune
immuneequipment
equipment
modular-easy
modular-easyinstallation/replacement
installation/replacement
standard
standardI/O
I/Oconnections
connections&&signal
signallevels
levels
simple
simpleprogramming.
programming.
compact
compactsizes.
sizes.
cost
costcompetitive
competitive
Comparison with Other Control Systems
C\Cs Relay systems Computers PLC systems
Price Per Function Fairly Low High Low
Physical Size Bulky Fairly Compact Very Compact
Operating Speed Slow Fairly Fast Fast
Noise Immunity Excellent Fairly Good Good
Installation Time Consuming in Time Consuming Easy in All
All Phases in Programming Phases
Complex Operation None Yes Yes
Ease of Changes Very Difficult Quite Simple Very Simple
Easy of Maintenance Poor-large No. Poor-several Good-few
Of Contacts Custom Boards Standard Cards
Structure
Programmable controller Process
Programming Program Input Input
panel memory circuits devices
Control
unit
Work Output Output
memory circuits devices
Power supply
Central Processing Unit
CPU(1)
The CPU controls and supervises all operation within PLC,
carrying out programmed instructions stored in the memory.
An internal communications highway or bus system carries
information to and from CPU, memory and I/O units, under
CPU control.
The CPU is supplied with a clock frequency by a quartz crystal
or RC oscillator with speed depending on the microprocessor
type.
The clock determines the operating speed of the PLC and
provides timing/synchronization of all system elements.
Central Processing Unit
CPU(2)
ROM with fixed operating
system program
Control unit ALU Registers
Control Section
Analysis
I/P scan Logic scan O/P scan Interface with
Peripherals
block program block other CPUs
I/P Modules O/P Modules
Central processing unit
CPU (3)
B
u
f Address Bus
f
e
r Control Bus
B C
a l
Optional tt
User Program p o System Data I/O
Program e
RAM CPU c ROM RAM Unit
Storage r k
y
Buffer Data Bus
System memory
Can be subdivided into two types :
Executive Memory and Scratchpad Memory.
Executive memory contains the executive operating system .Such
system is provided by PLC manufacturer and rarely changed, so it is
loaded on a PROM.
It provides the translation between the high level programming
language and the binary machine language,scans PLC to update
system status and reads inputs and updates outputs.
During administration of these functions, the executive often needs
an area of memory to store data temporarily: the memory is called
Scratchpad Memory, it is a RAM which is not accessible by the user
I/O Status Memory
It is a portion of RAM dedicated for storage of
current I/O status.
As the executive program requires I/O status update,
the I/O status memory can be considered as part of
system memory
Application Memory
It can be subdivided into two types :
Data memory & User memory.
Data memory holds generally the preset values (like
timers,).
User memory is the most accessible by the user where all
program sequence and specific functions are handled. It is
scanned by CPU for instructions when it is directed for
scan by the executive.
I/O scanning
Output Scan Input Scan
Program Scan
INPUT OUTPUT
T T
E E
R R
M Input User Input M
I status table program status table I
N N
A A
L L
S S
Input Scan Program Scan Output Scan
Output terminals are read During program scan data in I/P Data associated with O/P
and input status table is table is applied to user program, status table is transferred
updated accordingly. program is executed and O/P to O/P terminal.
table is updated accordingly.
Power Supply
PLCs internal circuitry operates at +/-5V DC.
Whether the available supply is AC or DC, a power supply
is required to condition, regulate, ... this supply to the
adequate need of the circuitry.
~ Rectifier Filter Regulator protection
Discrete Input
Opto-isolator
converter
Terminal 1
Input
(switch,
sensor,) CPU
common
Input module point
Discrete Output
Load
Terminal 1 Input logic Opto-isolator Converter
Trigger control
CPU
Output module point
Analog I/O
I/P signal transducer I/P module A/D converter CPU
1.1A 100% 10V 256
0A 0% 0V 0
Analog Input
CPU D/A converter O/P module transducer O/P signal
256 20mA 100% +50V
0 4mA 0% -50V
Analog Output
I/O Modules
PLCs operate at 5V DC to 15V DC, whilst process signals
can be much greater or of different levels.
The I/O units from the interface between the
microelectronics of PLC and the real world outside.
These units provide all necessary signal conditioning and
isolation functions.
I/O modules are available (Digital, analog) with all different
process signals which allow PLC to be directly connected to
process.
Special Modules
These modules are intelligent ones which perform certain
tasks independent of the CPU.
The use of such modules in process control is Known as
distributed processing.
Such modules are dedicated computers that perform preset
calculations on data received from detectors or other
devices connected to it.
PLC CPU is thus freed to handle larger control functions.
Housing
Small PLCs are build of individual printed circuit cards
within single compact unit
small PLCs are constructed modular basis with function
modules slotted into the back plane connectors of the
mounting rack
modular systems housing or mounting racks are equipped
with buses to exchange all information required to run the
system: data, control, address,.
Communication - Point to Point
Links: Links:
PLC w/ programming terminal. PLC w/ other PLC.
PLC w/ Man Machine Interface. PLC w/ any intelligent device.
Communication - Networking
Peer to Peer
Remote I/O
Master/slave
Programming Equipment
Allowing writing, editing and monitoring a program as well
as performing various diagnostic procedures.
Three types of programming tools are in common use:
1. Hand held programmer
2. Portable programming terminal
3. S/W to run on PC
the third type is commonly used and have larger capabilities.
