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Good Morning

Control System
PB1 M1

LS1

INPUTS
M1

LOGIC

OUTPUTS

SOL M2R

What is a Programmable Controller? Processor

Interface

4 Basic PLC Parts


Processor I/O Interface Power Supply Programming Device

Processor
Central Processing Unit Memory

Program Panel

Input/Output Rack
Adapter Module Module Module Module Module Module Module Module

Power Supply

Output Devices
Solenoids Motor Starters Alarms Indicators D/A Logic BCD

Input Devices
Limit Switches Pres. Switches Prox. Switches Temp. Switches Push Buttons A/D Logic

BCD

Programmable Controllers
The most significant development in the industrial control field in this half-century

Programmable Controllers
The Control of the Future

PLC Advantages
Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to change

Higher Level Control Capability


Arithmetic Data Comparison Word Manipulation Master Control Relay Instructions Program Skip Capability Sequencing Matrix Data Manipulation Proportional, Integral, Differential (PID) Control

The Changing Face of Industrial Control

Historically:
Machines have been viewed as operational entities Processes have been viewed as functional entities

1978 1970

1967 1979

1958 1977

1975 1963 1940

1943

1971

1969

Evolution
Introduction into Automotive Industry
PLC performs relay-equivalent functions PLCs applied to:
Transfer lines Assembly machines Grinding machines Boring machines Materials handling equipment

Evolution
Proliferation into other industries
PLC performs relay-equivalent functions PLCs applied in
Manufacturing industries Food and beverage industries Power industry Process industries Metals industry Pulp and paper industries

Evolution
PLC usage proliferates into other industries

Evolution
Introduction of the intelligent Programmable Controller
PLC performs arithmetic and data manipulation functions Applications expand in all industries

Evolution
Introduction of mini Programmable Controllers
Intended for small scale dedicated applications

Evolution
Expansion of capabilities
Operator communication Analog control Positioning control Machine fault detection

Installations expand into minicomputer equivalent applications

Evolution
Installation of manufacturing lines controlled by PLC networks

Evolution
The year of PLC Downsizing
Microprocessor-based PLCs now cost effective in small-scale applications Space-efficient, high-density I/O

Evolution
The year of PLC Downsizing
Microprocessor-based PLCs now cost effective in small-scale applications Space-efficient, high-density I/O

Evolution
Introduction of fourth and future generations of PLCs providing continuing improvements in cost/performance effectiveness
Improved operator communication Expanded capabilities Extensive inter-control communication

Evolution
The advent of distributed control
Data Highways Peer-to-peer PLC networks Applications:
Material handling/tracking Decentralized process control

Evolution
Smart I/O, more distributed intelligence
Processing power in I/O interface Microprocessor CPUs increase functionality, at lower cost
PID control Graphic operator interfaces

Evolution
PLCs functionality expands into computer-like capability
Instruction sets expand to include floating point math, Boolean file manipulations Microprocessor-based I/O performs sophisticated closed loop control Use of Data Highways expand throughout industry

Traditional PLC Concept


PLC performs relay equivalent functions PLC performs ON/OFF control Ladder diagram program representation Designed for industrial environment Designed for ease of use and maintenance

What are Programmable Controller Applications?

Typical PLC Users


Manufacturing industries Power industry Metal industry Food and beverage Process industries Pulp and paper

PLC Application Considerations


Inputs/Outputs
Type, AC, DC, voltage, etc. Number

Functions required
Instruction set Arithmetic Remote I/O Computer communications Report generation

Memory
Type Size

Typical Process Applications

Power
Coal handling Burner control Flue control

Typical Process Applications

Metals
Heat treatment Ore unloading Pelletizing Fabrication

Typical Process Applications

Mining
Ore handling Ore loading Waste treatment Ore processing Water treatment Well (water) supply

Typical Process Applications

Food and Beverage


Process control Materials handling Palletizing Weighing Canning Packaging and filling Blending Bottling

Typical Process Applications

Chemical/Petrochemical
Waste treatment Water treatment Materials handling Batch process Weighing and blending

Typical Process Applications

Petroleum
Drilling Pipeline

Typical Process Applications

Pulp and Paper


Batch digester Water treatment Waste treatment Materials handling

Programmable Controllers

Processors

The Allen-Bradley Family Features:


Compatibility of Hardware Compatibility of Instruction Sets

Family of PLC-2 Programmable Controllers

Processor Comparison
Large
PLC2/30 PLC5/25 PLC5/15 PLC2/17 PLC2/16 PLC-2/02 PLC5/12 PLC-3 PLC-3/10

Memory

Medium

Small
SLC-150 SLC-100

I/O