Programmable Logic

Controllers
PLCs
An Overview, Use in HVAC and Web
Technologies
By Sleepy Wombat

Overview
What is a PLC ?
History
Overview of Technology
PLC Configuration and Selection
Programming PLCs
PLCs in HVAC
Web Technologies

What is a PLC ?
PLC (Programmable Logic Controller)
A PLC works by looking at its inputs
and depending on their state, and the
user entered program, turns on/off
outputs.
A PLC can be thought of as:
Industrial Computers with specially
designed architecture in both their
central units (the PLC itself) and their
interfacing circuitry to field devices
(input / output connections to the real
world).

History 1/4
Early control systems consisted of huge control boards
consisting of hundreds to thousands of electromechanical
relays.
An Engineer would design the system logic.
Electricians would receive a schematic outline of logic then
implement the logic with relays.
The schematic was commonly called Ladder Schematic
The Ladder displayed all switches, sensors, motors,
valves, relays etc in the system.
Problems: Long commissioning time, Mechanical Reliance,
Any system logic design change required the power to the
control board to be isolated stopping production.

History 2/4
General Motors was among the first to recognise a
need to replace the systems wired control board
Hydramatic Division of GM specified the design
criteria for the programmable controller in 1968.
Goal Eliminate the high cost associated with
inflexible, relay controlled systems.

History 3/4
New Controller Specifications:

Solid State System

Computer Flexibility
Operate in Industrial Environment (vibrations, heat,
dust etc.)
Capability of being reprogrammed
Easily programmed and maintained by electricians
and technicians.

History 4/4
In 1969 Gould Modicon developed the first PLC.
Strength Programmed with Ladder Logic
Initially called Programmable Controllers PCs
Now - PLCs, Programmable Logic Controllers

PLCs have evolved from simple on/off control to

being able to communicate with other control
systems, provide production reports, schedule
production, diagnose machine and process
faults.

Overview of Technology

Basic PLC Schema

CPU
Power Supply
Memory
Input Blocks
Output Blocks
Communications
Expansion
Connections

CPU Module
The Central Processing Unit (CPU)
Module is the brain of the PLC.
Primary role to read inputs, execute
the control program, update outputs.
The CPU consists of the arithmetic
logic unit (ALU), timing/control
circuitry, accumulator, scratch pad
memory, program counter, address
stack and instruction register.
A PLC works by continually scanning
a program

Scan
Inputs

Self
Check
PLC Program
SCAN

Update
Outputs

Execute
Code

Memory
The memory includes pre-programmed ROM memory
containing the PLCs operating system, driver
programs and application programs and the RAM
memory.
PLC manufacturer offer various types of retentive
memory to save user-programs and data while power
is removed, so that the PLC can resume execution of
the user-written control program as soon as power is
restored.

Memory contd
Many PLCs also offer removable memory modules,
which are plugged into the CPU module.
Memory can be classified into two basic categories:
volatile and non-volatile.
- Volatile memory is that which loses state (the
stored information) when power is removed.
- Nonvolatile memory, on the other hand, maintains
the information in memory even if the power is
interrupted.

Memory contd
Some types of memory used in a PLC include:
ROM (Read-Only Memory)
RAM (Random Access Memory)
PROM (Programmable Read-Only Memory)
EPROM (Erasable Programmable Read-Only Memory)
EEPROM (Electronically Erasable Programmable ReadOnly Memory)
FLASH Memory
Compact Flash Can store complete program
information, read & write text files

I/O Modules
Input and output (I/O) modules connect
the PLC to sensors and actuators.
Provide isolation for the low-voltage, lowcurrent signals that the PLC uses
internally from the higher-power
electrical circuits required by most
sensors and actuators.
Wide range of I/O modules available
including: digital (logical) I/O modules
and analog (continuous) I/O modules.

Inputs Modules
Inputs come from sensors that translate physical or
chemical phenomena into electrical signals.
The simplest form of inputs are digital/discrete in AC/DC.
In smaller PLCs the inputs are normally built in and are
specified when purchasing the PLC.
For larger PLCs the inputs are purchased as modules, or
cards, with 8,16, 32, 64, 96 inputs of the same type on
each card.

Inputs Modules

The list below shows typical ranges for input

voltages.

5 Vdc

12 Vdc
24 Vdc
48 Vdc
12 Vac
24 Vac
120 Vac
240 Vac

Example of Input Card

Outputs Modules
Output modules rarely supply any power, but instead act as
switches.
External power supplies are connected to the output card
and the card will switch the power on or off for each output.
A common choice when purchasing output cards is relays,
transistors or triacs.
Relay are the most flexible output devices. They are
capable of switching both AC and DC outputs. But, they
are slower, cost more, and they will wear out after millions
of cycles.

Relays
The most important consideration
when selecting relays, or relay
outputs on a PLC, is the rated
current and voltage.
For transistor outputs or higher
density output cards relay terminal
blocks are available.
Advantage of individual standard
replaceable relays

Outputs

Typical output voltages are listed below,

5 Vdc
12 Vdc
24 Vdc
48 Vdc
24 Vac
120 Vac
240 Vac

WARNING: Always check rated voltages and currents for

PLCs and never exceed.

Example of Output Card

Analogue Cards
Typical Analogue Input
signals are:
Flow sensors
Humidity sensors
Load Cells
Potentiometers

Analogue Output signals

control:

Pressure sensors
Temperature sensors
Vibration

Analogue Valves
Actuators
Chart Resorders
Variable Speed Drives
Analogue Meters

Typical Analogue Signal

Levels

4-20mA
1-5 Vdc
0-10 Vdc
-10 10Vdc

Analogue Inputs/Outputs
Analogue input cards convert continuous signals via a
A/D converter into discrete values for the PLC
Analogue output cards convert digital values in then PLC
to continuous signals via a D/A converter.
Resolution can be important in choosing an applicable
card
Example, for a temperature input of 0 to 100 degrees C
For 8 bit resolution the value in the PLC is 0 to 255
For 12 bit resolution the value in the PLC is 0 to 4095
For 12.5 bit resolution the value in the PLC is 0 to 6000
For 13 bit resolution the value in the PLC is 0 to 8192
For 16 bit resolution the value in the PLC is 0 to 32768

Special Modules
RF ID
Voice
Gas Flow Calculation
Weigh Cell
Hydraulic Servo
ASCII
Fuzzy Logic
Temperature Sensor
Temperature Control
Heat/Cool Control
Field Bus Cards
DeviceNet, Profibus etc
Lonworks, BACNet

Fast Response (Interrupt)

PID
Loop Controller
BASIC Cards
RS232 Comms
Modbus ASCII/RTU
Ethernet Comms
High Speed Counters
Position Control Cards
Per to Per Comms

Controller Link
DH+
Modbus Plus

Available Instructions
Sequence

Input
Output
Control

Logic
Timer and Counters
Comparison
Range Comparison
Data Movement
Data Shift
Step / Step Next
Serial Communications
Text String Processing
File Manipulation

Increment/Decrement
Conversion
ASCII
Number Systems

Math
Floating Point Math
Statistics
Scaling
PID
PID with Auto tune
Clock / Date
Block Processing
IF,THEN,ELSE,LOOP

Table Processing
LIFO, FIFO

Networks
ASI
Devicenet
Interbus-S
Profibus
Interbus
Fieldbus

Ethernet I/P
Smart Distributed System
(SDS)
Seriplex
CANopen
Lonworks
BACNet

Gateways enable communications between

different network topologies

PLC Configuration

RACK

SHOE BOX

MINI

MICRO

The Configuration of PLC

The configuration of PLC refers to the packaging of the

components.
Typical configurations are listed below from largest to
smallest.
Rack Type : A rack can often be as large as 18 by 30 by 10
Mini: These are similar in function to PLC racks, but about the
half size. Dedicated Backplanes can be used to support the
cards OR DIN rail mountable with incorporated I/O bus in
module.
Shoebox: A compact, all-in-one unit that has limited expansion
capabilities. Lower cost and compactness make these ideal for
small applications. DIN rail mountable.
Micro: These units can be as small as a deck of cards. They
tend to have fixed quantities of I/O and limited abilities, but costs
will be lowest. DIN rail mountable.

Sizing of PLC
Micro PLCs: I/O up to 32 points
Small PLC: I/O up to 128 points
Medium PLC: I/O up to 1024 points
Large PLC: I/O up to 4096 points
Very Large: I/O up to 8192 points

Selecting a PLC

Criteria

Number of logical inputs and outputs

Memory
Number of special I/O modules
Expansion Capabilities
Scan Time
Communication
Software
Support
Dollars

Selecting a
PLC

Example of PLC Specifications

Example of PLC Specifications

Manufactures
Major Brands
OMRON
Allen Bradley
Schneider (Modicon, Telemecanique, Square D)
GE Fanuc
Siemens
Keyence
Automation Direct (Koyo)
Festo
Toshiba
Eberle
Texas Instruments
Mitsubishi
April
Hitachi

Programming PLCs

Programming PLCs
Ladder Logic remains the most common
technique for programming PLCs

PLC Standardization
Open Controller
IEC 61131

Based on IEC 1131 (1992) standard, developed to be

a common and open framework for PLC architecture.

IEC 61131-1 Overview

IEC 61131-2 Requirements & Test Procedures
IEC 61131-3 Data Types & Programming
IEC 61131-4 User Guidelines
IEC 61131-5 Communications
IEC 61131-7 Fuzzy Control
IEC 61131-7 Guidelines for the application and
implementation of programming languages

IEC 61131-3
IL (Instruction List) mnemonic programming
LD (Ladder Diagram) Relay logic
ST (Structured Text) A BASIC like programming
language
FDB (Functional Block Diagram) Graphical dataflow
programming language
SFC (Sequential Flow Chart) Graphical method for
structured programs

IEC 61131-3 Examples

Ladder

Instruction List

Structured Text

Function Block
Sequential Flow Chart

PLCs in HVAC control

PLCs in HVAC control

Despite the versatility of todays PLCs,
many controls professionals are skeptical of
applying PLCs to new applications such as
HVAC control.
Reasons included :
Lack of knowledge of these systems
Requirement for programming
Lack of initial capability of technology
Premium first up cost

Advantages
PLCs remain a predominate piece of equipment
on the factory floor and will probably remain so for
some time to come.
The advantages they offer are:
Cost effective for controlling complex systems
Flexible and can be reapplied to control other systems
quickly and easily
Computational abilities allow more sophisticated control
Trouble shooting aids make programming easier and
reduce downtime
Reliable components (high MTBF) ensure operation for
years

Advantages continued.
Variety of I/O interfaces
Small size
Growing with technology, faster scan times, capability
etc
Quick I/O disconnects that aids in field servicing
Modularity in hardware architecture
Modularity in software design (programmer
dependant)
Software Timers/Counter, Relays
Clean failure mode
On-line programming
Self inspecting for operation code during execution
Availability of programmers/trouble
shooters/integrators
Availability of replacement parts

Benefits
The benefits achieved with programmable
controllers will grow with the individual using
them:
The more you learn about PLCs, the more you
will be able to solve other control problems.

Examples
Southgate Melbourne
Millennium Dome London
Woolworths Britain

ST Microelectronics France
Einstein III Building - Munich

Web Technologies

Web Enabled Automation...?

Is it just more Internet hype or is there
some benefit behind the idea.
Is it possible to connect all of these
systems by their PLCs to the Internet ?
Is it practical ?
Is it profitable ?

Short Answers
Internet access can provide compelling
competitive advantages linking customers,
suppliers, subcontractors, front line management.
Improve fault reporting and response time
Enhance flexibility
Optimise process control

Proven affordable technologies are readily

available to connect any PLC, Process Controller
or I/O to the Internet and Intranet.
Process to Internet access has the potential to
become a standard utility.

What is Web Enabling

Web enabling gives real time access to data and
control, virtually anytime, anywhere.
It uses communication with any manufactures
PLC or I/O to send information via the Internet to
anywhere in the world.
Web enabled automation drives real-time
accessibility Vertically Down to the control
device level.

What can we do with it ?

Check real time process data without waiting for
end of shift reports
Track equipment run time and initiate
maintenance requests
Automatically notify a technician via email or
GSM phone etc of faults and allow rectification
Collect process data on a server PC and
analyse with statistics and control (SPC)
Use HTML help files including graphics
Monitor and control remote operations reducing
field staffing and unnecessary travel

What pieces and parts are required ?

Interface
Web Server
Data Service
Browser

Interface
An interface to the equipment to be monitored
and controlled via the web (network) connection

Ethernet Line
Modem / Phone line
ISDN
Wireless Modem (eg 802.11b Ethernet)

Type of connection is typically determined by the

thin server and the existing network
infrastructure or lack thereof

Web Server
Web Server (or thin server data service) to
enable the remote browser to view the desired
displays and web pages.
Typical installation requires a connection to an
existing PLC or proprietary controller.
Most PLCs support at least a serial connection using
the vendor supplied protocol to communicate.
Use an Open network controller (interface)
Some PLCs have Web Servers built into their
Ethernet Units.

Data Service
A data service or interface to handle exchanging
data between the local equipment/ process
(server) and the remote system (client)

A common language, protocol is required..

XML (Extended Markup Language)
Benefit of XML is its independence from senders and
receivers hardware, OS, and application.

Browser Interface
Use the thin servers assigned IP address to
access the remote system.
Simple browsing requires standard browser
interface found on a desktop computer, PDA,
WAP, or Thin Client
For application information sharing (SPC,
Enterprise Software), if the thin server and
remote application software support a common
interface such as OPC, setting up the data
exchange can be accomplished in a couple of
minutes

New term OPC

OLE for Process Control
Object Linking and Embedding
One of industries most popular standards
Maintained by OPC foundation
OPC standard is non proprietary technical
specification based on Microsoft's
OLE/DCOM technology.
www.opc.org

Web Servers
Computer Based Displays
SCADA Supervisory Control and Data Acquisition
Citect, Wonderware, Fix, Iconics, Genius
Ethernet, Serial, OPC (OLE for Process Control), Dedicated
Computer Boards for Propriety Buses

Dedicated Packages for BMS

Citect SCADA Facilities

Embedded Web Servers

Open Network Controller Interface Gateway
Embedded Web Servers in PLCs Ethernet cards
New Dedicated HMI Screens some have embedded Web
Servers
Example of Web Technology visit www.WebHMI.com

Thank you.
Questions ?