PLC AND SCADA

Subject code: 18MT61

Syllabus

 what is A PLC, Technical Definition of PLC, What

are its advantages,
 characteristics functions of A PLC, Chronological
Evolution of PLC, Types of
 PLC, Unitary PLC, Modular PLC, Small PLC, Medium
PLC, Large PLC, Block
 Diagram of PLC: Input/output (I/O) section,
Processor Section, Power supply,
 Memory central Processing Unit: Processor
Software / Executive Software, Multi
 asking, Languages, Ladder Language.
WHAT IS PLC
 PLC is a solid state/ computerised industrial controller
that performs discrete or sequential logic in a factory
environment.
 It was originally developed to replace mechanical
relays, timers and counters.
 Used to successfully execute complicated control
operations in a plant.
 A sequence of instructions is programmed by the user
to the PLC memory and when the programme is
executed the controller operates the system to correct
operating specifications.
 The PLC was introduced in late 1960s
 Today PLC is used as a stand alone control or a
part of a Complex Computer Integrated
Manufacturing System.
 PLC may also provide an interface between a
machine and robots or a machine and colour
graphics which are known as Human Machine
Interface (HMI).
 PLC is important in the world of industrial
automation.
Technical Defination Of
PLC
 Is currently defined by NEMA
(National Electrical Manufacturers
Association) as a
 “Digital electronic Device that uses a
programmable memory to store
instructions and to implement the
specific functions such as logic,
sequence, timing, counting and
arithmetic operations to control
machine and processes”.
History and Origin:
• •Developed to replace relays in the
late 1960s
• •PLC began in the 1970s, and has
become the most
• common choice manufacturing for
controls.
• •The PLC was invented in response
to the needs of
• the American automotive
manufacturing industry
• (primarily General motors).
• •Costs dropped and became popular
by 1980s
• • Now used in many industrial
designs
PLC Advantages
 Faster Scan time
 Intelligent I/O
 High speed Counters
 Supervised Control capability
 Reliability in operation
 Flexibility in programming and reprogramming in
a plant
 Cost effective for controlling complex systems
 Flexibility in Control techniques
 Minimum Maintainance
 Small physical size
 Superior computational capabilities to execute
complex control techniques
 ASCII message handling capablity
 Ability to communicate with computer systems in
a plant.
 Programmable troubleshooting aids which reduces
the downtime.
 PLC DISADVANTAGES
 There's too much work required in connecting wires.
 It is difficult to find errors.
 Skillful workers are required.
 There’s difficulty with replacements.
 PLC devices are proprietary, which means that parts
and software from one manufacturer can’t easily be
used in combination with parts of another
manufacturer, which limits the design and cost
 options.
PLC APPLICATIONS
• PLC’s are generally used in industries for
controlling heavy
machinery and processes like conveyor
system, CNC machines
etc.
• PLC usage can also be observed in day to
day life.
For eg : automatic washing machines, cars,
video cameras etc.
• PLC has it’s applications in almost every
automatic machine.
COMPONENTS OF PLC
1 . Processor.
2. Memory unit .
3. Power supply.
4. I/O Modules.
5. Programming device.
Characteristics of PLC
 PLC offers certain characteristic functions that
make it advantageous in an industrial
environment.
 It is superior in modern industrial control and
communication.
 Some of the major characteristic functions of
PLC are:
1. It is field programmable by the User: It
allows the user to modify the programs as per
the requirements of a plant without having it to
send the unit back to the manufacturer for this
purpose.
2. It contains the programmed functions:
PLCs contain at least logic, timing,
counting and memory functions that the
user can access through some kind of
control oriented programming language.
3. It scans memory, inputs and outputs
(I/O) in a predetermined manner.
4. It provides error checking and
diagnostics. A PLC will periodically carry
out internal tests of its memory,
processor and I/O systems through in built
program execution to ensure what it is
doing to the machine or system, against
what it was programmed to do.
5. A PLC can provide some form of
monitoring capabilities either through
indicating lamps that shows the status of
inputs and outputs or by an external
device that can display the program
execution status.
6. It is packaged in such a way that it can
withstand the temperature, humidity,
vibration and noise found in most factory
environments.
7. A PLC can be effectively designed for a
wide variety of control tasks, although it
can also be dedicated only for a particular
task.
TYPES OF PLC
 PLCs are of two types: 1. Unitary PLCs
2. Modular PLCs.
 1. Unitary PLC:
 Unitary PLC has a power supply, a CPU and
a limited number of inputs and outputs.
 It has 20 inputs- 12 outputs, 32 I/O
 It is sometimes called “shoebox type”.
 It is mainly used for the control of a small
system.
Unitary PLC
2. Modular PLC:
A modular PLC is one that it can be
constructed using separate modules of
power supply, CPU, inputs, outputs,
timers, counters, ADC, DAC, expansion
modules.
These modular PLCs are sometimes called
“rack mounted type PLC”.
Modular PLCs can be sub-divided into the
following types
a) Small PLC
b) Medium PLC
c) Large PLC
Modular PLC
a) Small PLC:
PLC having less than 100 inputs and outputs
are designated as small PLCs.
Out of the I/Os, 20 inputs and 12 outputs are
mounted locally within the processor.
Additional I/Os can be added through remote
I/O racks to accommodate the extra inputs
and outputs.
These PLCs generally have a memory from 2KB
to 10KB to store the users logic program.
b) Medium PLC:
These have extended instructions sets that
include mathematical functions, file
functions, PID process control etc.
These PLC can have between 4000 to 8000
inputs and outputs.
They are also made to support wide variety of
special modules such as ASCII communication
modules, BASIC programming modules, 16
bit multiplexing modules, analog input and
output modules (both voltage and current),
communication modules.
c) Large PLC
The purpose of introducing large PLC was to
provide enough memory space and I/O for
complete factory automation.
Major Disadvantage: Whole Factory may
collapse if the PLC starts malfunctioning.
Distributed Control: Introducing this enables to
use the LAN , where the small or medium PLCs
are connected together through an appropriate
network.
Entire factory is brought under the control of a
number of PLCs, but failure in one system will
not disturb any other system.
PLC SYSTEM
 Block Diagram of PLC
 PLC has three basic sections namely 1) I/O section
2)Processor Section 3) Program loader/monitor
section
 The input section converters convert the field signals to
logic level signals that the PLC’s processor can read
directly.
 The processor section reads these inputs, processes the
signals executing the program and prepare the output
signals.
 The output section converts the logic level output signals
coming from the processor section into high level signals
and releases the signals for various field devices.
 The program loader is to enter the user’s program into the
memory or change it and to monitor the execution of the
program.
 I/O section
 The input output section establish the
interfacing between the real world outside the
PLC and the digital arena inside the PLC.
 The signals from the machines or instruments
of a system are received through the input
section by a PLC.
 After processing the output signals are
transmitted to the machines or the
instruments for the desired control action
through the output section.
 The tasks of the I/O section can be classified as:
 1. Conditioning 2. Isolation 3) termination 4)
Indication
 The field signal is 220V or 440 V.
 PLC can support a voltage of 0-10 volts, the
field signal has to be conditioned before it is
applied to the PLC.
 To protect the PLC from any incoming surges
from the field, isolating devices such as
transformers or an opto-isolator are used.
 The I/O modules provides a proper terminal.
 It indicates the status of the I/O terminal, i.e
when the voltage is off the status indicator is
off.
Processor Section
 This section consists of four major elements.
 1.) Power supply 2.) Memory 3.) CPU 4.) I/O
interface
 1) Power Supply:
 Basic function of the power supply is to supply
conditioned power to the components of a PLC.
 The power supply is one of the most critical components of
the PLC for two reasons:
 1. It is typically non redundant. Hence failure of PLC
power supply can cause entire control system to fail.
 2. It contains high voltage components. Hence an
insulation failure can be a serious potential for injury or fire.
 The following guidelines should be followed
when choosing the power supply of a PLC:
 1) The power supply should be packed
properly, so that the heat generated by the
power supply can be dissipated in order to
prevent overheating. This increases reliability.
 The power supply should be tested for
temperature and electrical insulation by a
proper certification agency.
 The power supply should meet at least one
reputable standard for noise Immunity.
 Suitable redundancy will increase reliability.
2. Memory
 Two types of memory in a PLC: i) volatile
memory ii) non volatile memory.
 Non volatile memories: are generally used for
storing users programs so that they are
preserved during power cuts.
 The non volatile memory in a PLC uses some
form of error checking to ensure that memory
has not changed.
 To ensure to have a safe execution of the users
programs this error checking should also be done
while PLC is controlling a machine or a process.
 Different types of memory that are generally
used in a PLC are as follows.
 1. Battery backed up CMOS RAM : This is
the probably the most widely used type of
memory.
 CMOS variety consumes such a small amount of
power that a small battery will retain
memory during the power losses.
 The battery used vary from short life primary
cells (alkaline or Hg) which require periodic
replacement after 6 months to a year.
 To a long life battery which may last up to 10
years to rechargeable secondary cells.
 2. EPROM Memory:
 Electrically Programmable Read only
Memory is programmed using electrical
pulses.
 Can be erased by exposing the circuit to UV
light also called UV-EPROM.
 3. EEPROM Memory:
 Similar to EPROM Memory.
 It can also be erased using electrical pulses.
 In some PLC’s use of EEPROM only alleviates
the need of an UV light source.
 In other PLC’s the EEPROM is the only type of
memory used.
 This allows the flexibility of reprogramming.
 Four sections memory is subdivided: Executive
memory, internal RAM, user memory and I/O
image memory.
 The executive memory holds executive
software.
 User memory is meant for user program
storage
3. CPU
 The flexibility of a PLC is dependent on : i)
How CPU is constructed ii) Overall speed of
the PLC
 The speed is expressed in terms of how fst
the PLC will scan a given amount of
memory.
 This measure is called scan rate.
 It is expressed in milliseconds per thousand
words of memory.
 1. Processor:
 Processor is the central processing unit
(CPU) of the
 programmable controller, it executes the various
logic
 sequencing functions by operating on the PLC
inputs to determine
 the appropriate output signals.
 The CPU consists of one or more microprocessors
similar to that
 of PCs and other data processing equipment but
are designed to
 facilitate I/O transactions with different ranges
with corresponding
Consists of a microprocessor
for implementing the logic and
controlling the communications
among the modulus.
Designed, so the desired circuit
can be entered in relay ladder
logic form.
The processor accepts the input
data from various sensing devices,
executes the stored user program
and sends appropriate output
commands to control devices.
 2. Memory:
 Memory unit is connected to the CPU, which contains the
 programs of logic, sequencing and I/O operations .
 It also holds data files associated with these programs, Including
I/O stations bits, counter and timer constants, and other variable
and parameter values.
 This memory unit is referred to as the user or application memory
because its contents are entered by the user and also directs the
execution of control program and coordinates I/O operations with
the aid of system memory.
 3. Power Supply:
 A power supply of 120v alternating current(ac) is
typically
 used to drive the PLC (some units operate on 240 v ac).
 The power supply converts the 120v ac into direct current
(dc) voltages of ±5V.
 These low voltages are used to operate equipment that many
have much higher voltage and power ratings than the PLC
itself.
 The power supply often includes a battery backup that
switches in automatically in the event of an external power
source failure.
 Supplies DC power to other modules
 that plug into the rack.
 In large PLC systems, this power
 supply doe not normally supply power
 to the field devices.
 In small and micro PLC systems ,
 the power supply is also used to power field
devices.`
 4. I/O Modulus:
 The input/output module provides the
connections to the
 industrial equipment or process that is not to be
controlled.
 Inputs to the controller are signals from limit-
switches , pushbuttons,
 sensors , and other on/off devices.
 Outputs from the controller are on/off signals to
operate
 motors, valves, and other devices required to
actuate the process.
 Many PLCs are capable of accepting continuous
signals from
 Forms the interface by which input
 field devices are connected to the
 controller.
 The terms “field” and “real world”
 are used to distinguish actual
external
 devices that exist and must be
 physically wired into the system.
 Forms the interface by which
 output field devices are
connected
 to the controller.
 PLCs employ an optical isolator
 which uses light to electrically
 isolate the internal components
 from the input and output
terminals.
 5. Programming Device:
 The PLC is programmed by means of a programming device.
 The programming device is usually detachable from the PLC
cabinet
 so that it can be shared among different controllers.
 Different PLC manufacturers provide different devices , ranging
 from simple teach pendant type devices , similar to those
used in
 robotics, to special PLC programming keyboards and CRT displays.
 PCs and laptops now widely used for programming a much faster
 and a PC / laptop are also smaller now.
The software allows users to create ,
edit .document, store and
trouble shoot programs .
The personal computer communicates
with the plc processor via
serial or parallel data communications link
 Hand – held programming devices are sometimes used
to
 program small PLCs.
 They are compact, inexpensive and easily to use, but are
not able
 To display as much logic on screen as a computer
monitor.
 Hand-held units are often used on the factory floor for
trouble
 shooting, modifying programs and transferring programs
to multiple
 machines.
Languages
 Variables: These are the way in which the
language allows the user to access the I/O
internal data.
 On line s. OFF line: On line language is the
one that can be programmed interactively with
the PLC.
 OFF line: Requires that the program be
generated separately then downloaded to PLC.
 Flow Control: How easy to take decisions
and to control the program execution.
 Maintainability: How easy the language is to
debug, modify and teach to others.
 Functions: Some language provide minimum
set of logic, timing , counting and memory
functions.
 Speed: Some language takes a longer time
to execute than others.
 Choosing a slow but powerful language in
time critical applications can make
programming much more difficult than using
a fast but simple language.
 EFFECIENCY: This is the measure of how much
memory is required for a language to
implement a given function.
Ladder Language

 Electrical ladder diagram

 Relay logic
 Power flow through the ladder
diagram
 Program is fast
 Readable program for sequence
control
Multi Tasking
 Some PLC can execute multiple tasks within a
single processor.
 Two forms of multi tasking: Time driven and
Event Driven
 Time Driven: The user writes programs and assigns
a separate I/O for each task.
 The user may be then allowed to configure the
processor to run each task at periodic time intervals.
 Event Driven: In the Event driven multitasking user
defines a particular event that causes each task to
run.
 Some multitasking systems allows any task to access
any variable such as an I/O point.
 Configuration process typically consists of:
Assigning the I/O points to particular I/O
racks.
 Telling the processor how much memory I/O it
has.
 Assigning specific memory for tasks.
 Determining the fatal and non fatal faults.
 Assigning many other items interactively on a
program loader.
 Not all PLC can be configured, but the
processor can enhance the efficiency of the
PLC if it can be configured.