Professional Documents
Culture Documents
Controllers (PLCs)
Definition
According to National Electrical Manufacturers Association
a PLC is:
A digital electronic device using a programmable memory
to store instructions and to implement specific functions
such as logic, sequence, counting, timing and arithmetic to
control machines and processes through digital or analog
input/output modules.
What is a PLC?
PLC History
In the late 1960's PLCs were first introduced
Bedford Associates (Bedford, MA) proposed something called
a Modular Digital Controller (MODICON) to a major US car
manufacturer
In the mid70's the dominant PLC technologies were sequencer statemachines and the bit-slice based CPU. The AMD 2901 and 2903 were
quite popular in Modicon and A-B PLCs
Communications abilities began to appear in approximately 1973.
The first such system was Modicon's Modbus. The PLC could now
talk to other PLCs and they could be far away from the actual
machine they were controlling
The 80's saw an attempt to standardize communications with General
Motor's manufacturing automation protocol(MAP
The 90's have seen a gradual reduction in the introduction of new protocols
PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring
by software programming.
It is consists of the
following modules:
Power supply module
CPU module
Digital input module
Digital output module
Analog input module
Analog output
PLC
COMPONENTS
1. Processor Microprocessor based, may allow
2. Memory
Measured in words.
ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electric Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only
Memory),
PLC COMPONENTS
3. I/O
Discrete I/O :
-AC Voltage I/O or
Discrete Input:
Selector switches,
Pushbuttons,
Photoelectric Eyes,
Limit switches,
Circuit breakers,
proximity switches,
Level switch,
Pressure switch,
Temperature switches,
Motor starter contacts,
Relays contacts and
Thumbwheel switch
Normally
open
Multiple
through
SPDT
locking
Normally closed
Multiple
pole
DPST
RELAYS
A switch whose operation is activated by an electromagnet is called
a "relay" . Coil circuit controls many contact points
contact
Relay coil
R1
coil
input
R1
R1
in p u t c o il
O R
n o r m a lly
c lo s e d
n o r m a lly
open
O R
relay logic
input B
(normally open)
input A
(normally closed)
output C
(normally open)
C
ladder logic
power
supply
+24V
com.
PLC
inputs
ladder
logic
outputs
115Vac
AC power
neut.
light
Discrete Output
Alarms,
Control relays,
Fans, Lights, Horns,
Valves,
motor starters, and
Solenoids
Analog I/O
Analog inputs:
-Flow sensor,
Pressure sensors,
Potentiometers,
Humidity sensors,
Temperature sensors,
load cell transducers
Analog outputs:
Analog meters
Analog valves
Actuators
Chart recorders
DC and AC motor drives
Some Special
Thermocouple
I/O input
LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means
of graphically representing the logic required in a relay
logic system.
Rail
Rung
start
PB1
emergency stop
PB2
R1
R1
R1
A
LADDER DIAGRAM
The left vertical line of a ladder
logic diagram represents the
power or energized conductor.
The output element or instruction
represents the neutral or return
path of the circuit.
The right vertical line, which
represents the return path on a
hard-wired control line diagram,
is omitted. Ladder logic diagrams
are read from left-to-right, topto-bottom. Rungs are sometimes
referred to as networks.
A network may have several
control elements, but only one
output coil.
NEUTRAL
A
INPUTS
OUTPUTS
Statement list
A statement list (STL) provides another view of a set of instructions. The
operation, what is to be done, is shown on the left. The operand, the
item to be operated on by the operation, is shown on the right. The set
of instructions in this statement list perform the same task as the ladder
diagram.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
2
3
4
5
6
7
8
LD N
LD
A N D
LD
LD
A N D
O R
ST
EN D
A
B
t h e m n e m o n ic c o d e is e q u iv a le n t t o
t h e la d d e r lo g ic b e lo w
C
D
X
A
EN D
N o t e : T h e n o t a t io n s h o w n a b o v e is
n o t s t a n d a r d A lle n - B r a d le y
n o t a t io n . T h e p r o g r a m t o t h e
r ig h t w o u ld b e t h e A - B e q u iv a
le n t .
SO R
BST
X IC A
X IO B
N X B
X IO C
X IO D
BN D
O TE X
EO R
EN D
PLC Scan
The PLC program is executed as part of a repetitive process referred
to as a scan. A PLC scan starts with the CPU reading the status of
inputs. The application program is executed using the status of the
inputs. Once the program is completed, the CPU performs internal
diagnostics and communication tasks.
The scan cycle ends by updating the outputs, then starts over. The
cycle time depends on the size of the program, the number of I/Os,
and the amount of communication required.
Software
Software is any information in a form that a
computer or PLC can use. Software includes the
instructions or programs that direct hardware.
Hardware
Hardware is the actual equipment. The PLC, the programming device,
and the connecting cable are examples of hardware.
Basic Requirements
In order to create or change a program, the following items are
needed:
PLC
Programming Device
Programming Software
Connector Cable
Programming Devices
The program is created in a programming device (PG) and then
transferred to the PLC. The program for the S7-200 can be
created using a dedicated Siemens SIMATIC S7 programming
device, such as a PG 720 (not shown) or PG 740, if STEP 7
Micro/WIN software is installed.
Software
A software program is required in order to tell the PLC what instructions it
must follow. Programming software is typically PLC specific. A software
package for one PLC, or one family of PLCs, such as the S7 family, would
not be useful on other PLCs. The S7-200 uses a Windows based software
program called STEP 7-Micro/WIN32. The PG 720 and PG 740 have STEP
7 software pre-installed. Micro/WIN32 is installed on a personal computer
in a similar manner to any other computer software.
S7-200 Models
There are five S7-200 CPU types: CPU 221, CPU 222, CPU 224,
CPU 224XP, and CPU 226 and two power supply configurations
for each type.
S7-200 Features
The S7-200 family includes a wide variety of CPUs and features. This
variety provides a range of features to aid in designing a cost-effective
automation solution. The following table provides a summary of the
major features, many of which will be covered in this course.
Optional Cartridge
The S7-200 supports an optional memory cartridge that provides a
portable EEPROM storage for your program. The cartridge can be
used to copy a program from one S7-200 PLC to a like S7-200 PLC.
Expansion Modules
The S7-200 PLCs are expandable. Expansion modules contain additional
inputs and outputs. These are connected to the base unit using a ribbon
connector.
The ribbon connector is protected by a cover on the base unit. Sideby-side mounting completely encloses and protects the ribbon
connector.
The ribbon connector is protected by a cover on the base unit. Sideby-side mounting completely encloses and protects the ribbon
connector.
I/O Numbering
S7-200 inputs and outputs are labeled at the wiring terminations and
next to the status indicators. These alphanumeric symbols identify
the I/O address to which a device is connected. This address is used
by the CPU to determine which input is present and which output
needs to be turned on or off. I designates a discrete input and Q
designates a discrete output. The first number identifies the byte, the
second number identifies the bit. Input I0.0, for example, is byte 0,
bit 0.
Inputs
Outputs
Freeport Mode
The programming port has a mode
called freeport mode.
Freeport mode allows connectivity to
various intelligent sensing devices
such as a bar code reader.
Printer
Interconnection
Symbols
Contacts
Coils
Coils represent relays that are energized when power flows to them.
When a coil is energized, it causes a corresponding output to turn on
by changing the state of the status bit controlling that output to 1.
That same output status bit may be used to control normally open and
normally closed contacts elsewhere in the program.
Boxes
Entering Elements
An AND Operation
Input
01
Output
PLC
01
02
20
11
12
02
20
03
20
11
External
switches
Stored program
PLC
Programming Device
Programming Software
Connector Cable
H ot
P L C In p u t C a rd
24V A C
00
01
02
N e u t.
03
04
n o r m a lly o p e n
t e m p e r a t u r e s w it c h
05
06
07
C O M
P u s h b u t t o n ( b o b :3 :I . D a t a . 1 )
it is in r a c k " b o b "
s lo t 3
T e m p s e n s o r ( b o b :3 :I . D a t a . 3 )
N o t e : in p u t s a r e n o r m a lly h ig h im p e d a n c e . T h is m e a n s t h a t t h e y w ill
u s e v e r y lit t le c u r r e n t .
120 V A C
P ow er
S u p p ly
00
N e u t.
01
R e la y
02
03
M o to r
04
05
24 V L am p
06
07
C O M
ra c k "s u e "
s lo t 2
+24 V D C
P ow er
S u p p ly
C O M
M o t o r ( s u e :2 . O . D a t a . 3 )
L a m p ( s u e :2 . O . D a t a . 3 )
24 V D C
P ow er
S u p p ly
00
01
02
03
R e la y
04
05
06
07
in r a c k 0 1
I/O g ro u p 2
M o to r
2 4 V la m p
120 V A C
P ow er
S u p p ly
Relays
010
s to p
s ta rt
C R1
M C R
020
C R1
030
040
L1
C R1
I :0 / 0
PB1
I :0 / 1
LS1
I :0 / 2
050
060
PB2
070
PLC
N
O :0 / 0
O :0 / 1
O :0 / 2
I :0 / 3
O :0 / 3
9 0 -1
1 0 0 -1
1 1 0 -1
090
100
S1
1 2 0 -1
120
C R2
C R1
090
9 0 -1
035
100
1 0 0 -1
050
110
1 1 0 -1
060
1 2 0 -1
070
120
130
C R2
L2
G
11 0
ac com
080
L1
R
D r ill S t a t io n
L1
N
Wiring Symbols
disconnect
(3 phase AC)
normally open
limit switch
normally open
push-button
circuit interrupter
(3 phase AC)
normally closed
limit switch
normally closed
push-button
double pole
push-button
mushroom head
push-button
Input
Connections
AC
AC input module allows
interfacing of input
devices which provide
AC output. Converter is
used to covert incoming
AC voltage to a DC logic
signal to be used by the
processor
DC
The Dc input module
allows interfacing of
input devices which
provide a DC output
voltage. The range of
input voltage for DC
input module varies
between 5 VDC and 30
VDC
TTL
TTL input interfaces allow the
controller to accept signals
from TTL compatible devices
including solid state controls
and sensing instrumentation.
TTL inputs are used for
interfacing with some 5 VDC
level control devices and
several types of photoelectric
sensors
Output Connections
AC
AC output module
allows interfacing of
output devices which
provide AC input.
DC
DC output module
interface is used to
control DC loads by
switching On and Off.
TTL
The TTL output
interface allows
the controller to
drive output
devices that are
TTL compatible
such as seven
segment LED
display
DC Inputs
The difference between the two types is whether the load (in our
case, the plc is the load) is switched to ground or positive voltage.
An NPN type sensor has the load switched to ground whereas a
PNP device has the load switched to positive voltage.
DC Inputs
Inside the sensor, the transistor is just acting as a switch. The sensors
internal circuit tells the output transistor to turn on when a target is
present. The transistor then closes the circuit between the 2 connections
shown above. (V+ and plc input).
AC Inputs
AC input modules are less common these days than dc input modules
sensors typically have transistor outputs
Relay Outputs
Transistor Outputs
The shown
diagram is a
typical PLC
with input
and output
module to
control
pneumatic
actuator
Advantages of PLCs:
Increase flexibility,
Faster implementation of changes and
correction,
Lower cost,
Increased visual observations,
Increased operation speed,
Increased reliability and maintainability,
Increased security,
Reprogramming capability,
Elimination of wiring.
Summary
This sequence covered the following
topics
1-PLCS definition
2-PLCs Components
3-PLCS advantages
5-PLCS I/O connections