PLC (PROGRAMABLE LOGIC CONTROLER)

Definition-:
PLC stands for Programmable Logic Controllers. They are basically used to control automated
systems in industries. They are one of the most advanced and simplest forms of control systems
which are now replacing hard wired logic relays at a large scale. OR A
Programmable Logic Controller is simply a special computer device used for industrial control
systems. The basic units have a CPU (a computer processor) that is dedicated to run one
program that monitors a series of different inputs and logically manipulates the outputs for the
desired control. OR A programmable logic controller (PLC) is a small, modular computer with
customized instructions for performing a particular task. PLCs, which are used in industrial
control systems for a wide variety of industries, have largely replaced mechanical relays, drum
sequencers and cam timers.

PLCs are useful tools for repeatable processes because they have no mechanical parts and they
can gather information. Each central processor unit continually through an input scan, program
scan, output scan and housekeeping mode, repetitively performing a single task while monitoring
conditions. The information gathers can be used as feedback to guide needed changes and
improvements to processes, some of which can be performed automatically according to the
device’s coding.

PLCs take up less space, perform more complex tasks and are more customizable than the
mechanical technologies they have replaced. They are known for their ability to operate
continuously without maintenance and have had a great impact on digitizing a great many
industries, particularly manufacturing. The first PLC, for example, was invented by Dick Morley
in 1969 for General Motors and performed uninterrupted for 20 years before being retired.

Working Of PLC-:

 The input sources convert the real time analog electric signals to suitable digital electric
signals and these signals are applied to the PLC through the connector rails.

 These input signals are stored in the PLC external image memory in locations known as bits.
This is done by the CPU

 The control logic or the program instructions are written onto the programming device
through symbols or through mnemonics and stored in the user memory.

 The CPU fetches these instructions from the user memory and executes the input signals by
manipulating, computing, processing them to control the output devices
 Working Schematic Diagram

 The execution results are then stored in the external image memory which controls the output
drives.
 The CPU also keeps a check on the output signals and keeps updating the contents of the
input image memory according to the changes in the output memory.
 The CPU also performs internal programming functioning like setting and resetting of the
timer, checking the user memory.

Block Diagram of PLC-:

A simplified block diagram of a PLC shown in above. It has three major
units/sections.

 I/O (Input/Output) Modules.

 CPU (Central Processing Units).
 Programmer/Monitor.

The input section converts the field signals supplied by input

devices/sensors to logic-level signals that the PLC's CPU can read.

The Processor Section reads these inputs, Processes the signal, and
prepares the output signals.

The output section converts the logic level output signals coming from
processor section to high level signals and used to actuate various
output field devices.

The programmer/monitor is used to enter the user's program into

memory and to monitor the execution of the program.

1) I/O Section:- The I/O section establish the interfacing between

physical devices in the real world outside the PLC and the digital arena inside
the PLC.
The input module has bank of terminals for physically connecting input
devices, like push buttons, limit switches etc. to a PLC. the role of an input
module is to translate signals from input devices into a form that the PLC's
CPU can understand.
The Output module also has bank of terminals that physically connect output
devices like solenoids, motor starters, indicating lamps etc. to a PLC. The
role of an output module is to translate signals from the PLC's CPU into a
form that the output device can use.

The tasks of the I/O section can be classified as:

 Conditioning
 Isolation
 Termination
 Indication
2) CPU Section:- The Central Processing Unit, the brain of the system is
the control portion of the PLC. It has three Subparts.

 Memory System
 Processor
 Power Supply

Memory System:-

The memory is the area of the CPU in which data and information is stored
and retrieved .The total memory area can be subdivided into the following
four Sections.

 I/O Image Memory

The input image memory consists of memory locations used to hold

the ON or OFF states of each input field devices, in the input status
file.

The output status file consists of memory locations that stores the ON or
OFF states of hardware output devices in the field. Data is stored in the
output status file as a result of solving user program and is waiting to be
transferred to the output module's switching device.

 Data Memory

It is used to store numerical data required in math calculation, bar

code data etc.

 User Memory

It contains user's application program.

 Executive Memory

It is used to store an executive program or system software.

Processor:-

The processor, the heart of CPU is the computerized part of the CPU in the
form of Microprocessor / Micro controller chip. It supervises all operation in
the system and performs all tasks necessary to fulfill the PLC function.
  It reads the information i.e status of externally connected input
devices with input module.
 It stores this information in memory for later use.
 It carries out mathematical and logic operations as specified in
application program.
 After solving the user's program, it writes the result values in the
memory.
 It sends data out to external devices like output module, so as to
actuate field hardware.
 It performs peripheral and external device communication.
 It Performs self diagnostics.

Power Supply:-

The power supply provides power to memory system, processor and I/O
Modules.

 It converts the higher level AC line Voltage to various operational DC

values.
 for electronic circuitry.
 It filters and regulates the DC voltages to ensure proper computer
operations.

3) Programmer/Monitor:-

The Programmer/Monitor (PM) is a device used to communicate with the

circuits of the PLC.The programming unit allows the engineer/technicians to
enter the edit the program to be executed.

In its simplest form it can be hand-held device with membrane keypad for
program entry, and a display device (LED or LCD) for viewing program steps
of functions.

Advantage of PLC
The advantages of PLC are as follows:

1. Flexible in Nature: One model of PLC can be used for different operations as per
requirement.
2. Easy to install and trouble shooting: In hard wired relay based systems, installation
time is more as compared to the PLC based control panels.
 3. Availability of Large contacts: PLC programming tools contain internal large number
of contacts that can be used for any change induced in different applications.
4. Cost effective: Advanced technology and large production of PLC makes it cheaper than
the other controller or relay based systems.
5. Simulation feature: PLC programming software comes with the simulation features by
default.
6. Simple programming methods: PLC is provided with simple programming methods to
program the PLC like Ladder or Boolean type of programming.
7. Ease of maintenance: As compared with the control systems like relay based or micro-
controller based systems, maintenance cost of PLC is low.
8. Documentation: The programmer can program and print easily the programs of PLC for
future use.

Discrete I/O Modules-:

Discrete I/Os has only two states of operation ON/OFF. Process switches, pushbutton switches,
limit switches, and proximity switches are all examples of discrete sensing devices. The picture
below shows an discrete input connection:

Discrete input card

When the hand switch is turned ON, current passes through the circuit which turns ON a LED
light. The light is sensed by a photosensitive device such as a phototransistor inside the module,
which in turn activates a bit (a single element of digital data) inside the PLC’s memory. Each
input channel has its own optocoupler, writing to its own unique memory register bit inside the
PLC’s memory.

Using photosensitive devices in the switching action protects the PLC processor from an external
current circuit. It isolates the circuit from peak or excess current in the external circuitry.

Now lets look at the Discrete output module:

 Discrete output card

The output is given out from a PLC using a LED and when the light is emitted and there is a
photo sensing device at the other end. Which senses the light signal and turns ON the circuit.
Alternatively, small electromechanical relays may be used in lieu of opto-isolating
semiconductor switching elements such as transistors (DC) or TRIACs (AC).

Each output channel has its own optocoupler, driven by its own unique memory register bit
inside the PLC’s memory. Discrete output cards for PLCs also typically have 4, 8, 16, or 32
channels.

Analog I/O

Circuits of this type sense or drive analog signals.

Analog inputs come from devices, such as thermocouples, strain gages, or pressure sensors, that
provide a signal voltage or current that is derived from the process variable. Standard Analog
Input signals: 4-20mA; 0-10V.

Analog outputs can be used to drive devices such as voltmeters, X-Y recorders, servo motor
drives, and valves through the use of transducers. Standard Analog Output signals: 4-20mA; 0-
5V; 0-10V.
The analog input interface module contains the circuitry necessary to accept an analog voltage or
current signal from the level transmitter field device. This input is converted from an analog to a digital
value for use by the processor.

Analog I/O is commonly available for modular PLCs for many different analog signal types,
including:

• Voltage (0 to 10 volt, 0 to 5 volt)

• Current (0 to 20 mA, 4 to 20 mA)

• Thermocouple (millivoltage)

• RTD (Millivoltage)

• Strain gauge (millivoltage)

INSTALLATION OF PLC-:
There are many things to consider when installing a programmable logic controller (PLC).

First, the PLC will require a proper enclosure and output loads, such as room lights, should have their
own relay panel. The relay panel is installed above or below the PLC enclosure depending on the output
wiring of the PLC. Mount the PLC horizontally to provide proper ventilation. You cannot mount the PLC
vertically, upside down, or on a flat horizontal surface. Provide a minimum clearance of 40mm between
the PLC and all sides of the enclosure.

Remember to allow for other items, like a Lutron interface unit, to be mounted in the same PLC
enclosure. There should also be at least 80mm of clearance between the PLC and wiring that runs
parallel to the unit.

PLCs can be secured to an enclosure by using mounting rails. They are approximately 35mm high, with a
depth of 7mm. If you mount the PLC on a rail, do consider using end brackets on each side of the PLC.
The end bracket helps keep the PLC from sliding horizontally along the rail, reducing the possibility of
accidentally pulling the wiring loose.
The ground terminal on the PLC must be connected to a good common ground reference (Earth ground).
One method of providing an adequate common ground reference is connection to the incoming power
system ground. Most PLCs have no internal fuses for the input power circuits, so external circuit
protection is needed to ensure the safety of personnel and safe operation of the equipment itself. When
operating the PLC from 110/125 VAC, it is only necessary to fuse the line (L) lead; it is not necessary to
fuse the neutral (N) lead.

Most connections, indicators, and terminals on a PLC are located on its front panel. The communication
ports are located on front of the PLC as are the option card slots and the mode selector switch.

The PLC terminals are divided into two groups. Each group has its own terminal block. The outputs and
power wiring are on one block, and the input wiring is on the other. In some instances, it may be desirable
to remove the terminal block for easy wiring. The terminal block is designed for easy removal with just a
small screwdriver. Minimum wire sizes, color coding, and general safety practices should comply with
appropriate electrical codes and standards for your area. Each terminal connection of the PLC can accept
one 16 AWG wire or two 18 AWG size wire. Avoid running DC wiring close to AC wiring where possible.

The PLC systems are designed to be powered by 110/125 VAC. Electrical power in some areas where
the PLCs are installed is not always stable and storms can cause power surges. Due to this, powerline
filters are recommended for protecting the PLCs from power surges.

Evaluate any installations where the ambient temperature may approach the lower or upper limits of the
PLC specifications. If you suspect the ambient temperature will not be within the operating specification
for the PLC system, measures such as installing a cooling/heating source must be taken to get the
ambient temperature within the range of specifications.

TESTING OF PLC-:
 Checking that all cable connections between the PLC and the plant are complete, safe,
and to the required specification and meeting local standards.

 Checking that all the incoming power supply matches the voltage setting for which the
PLC is set.

 Checking that all protective devices are set to their appropriate trip settings.

 Checking that emergency stop button work.

 Checking that all input/output devices are connected to the correct input/output points
and giving the correct signals.

 Loading and testing the software.

Application of PLC-:

1. Traffic Light Signals

2. Control of barrier at Toll Tax booth
3. Switching of generator as per the availability of electricity
4. Airway Runway lighting control
5. Filling and packaging of products at food and beverages industry
6. Roller Coasters
7. Conveyor belts
8. Automatic doors
9. Elevator
10. Automatic car wash
11. Energy management in boiler control for maximum efficiency