Programmable Logic Controllers (PLCs)

NHPC

PLC
A PLC: an industrial computer that monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine. Interface with sensors and actuators Work in industrial environment

Basic PLC Operation

PLCs consist of input modules or points, accepts and converts signals from sensors into a logic signal a Central Processing Unit (CPU) executes control instructions output modules or points. convert control instructions a signal that can be used by actuators Additional Optional PLC Components A programming device An operator interface device displays process information allows new control parameters to be entered.

Basic PLC Operation (cont.)

Programming PLCs
The purpose of plc programme is to control the state of PLC output based on the current condition of the PLC input. Different PLCs support different languages, but the most popular plc language is known as the LADDER LOGIC PLC ladder logic purposly resembles relay logic.

PLC vs Hard-Wired Control

Hard-Wired Control Circuit diagrams had to be designed, Electrical components must be specified and installed, and wiring diagrams and lists must be created. A change in function or system expansion required extensive component changes and rewiring. PLCs Smaller physical size than hard-wire solutions Easier and faster to make changes PLCs have integrated diagnostics and override functions Diagnostics are centrally available Applications can be immediately documented Applications can be duplicated faster and less expensively

Integrated PLCs
contains all of those components in a single case, so the I/O capabilities of an integrated PLC are decided by the manufacturer, not by the user. Expandable via expansion sockets

Modular PLCs
must contain (in forms of components purchased separately) a CPU module, a power supply, and I/O modules They may all plug together or they may all be plugged into the same rack.

Classes of PLCs
Modular PLCs come in a variety of sizes and are traditionally classed as small, medium, or large. The classification is based in part on the capabilities of the CPU module, the amount of memory input and output image data

The CPU Module

The CPU module contains the central processor and its memory. The memory ROM OS, driver programs, and application programs, and RAM containing: user-programs and working data

The Rack or Bus

a bus, a set of parallel conductors to connect CPU module I/O modules normally in a backplane circuit card in a rack, and all PLC modules are plugged into slots in the rack. For data, control and power

The Power Supply

A power supply module converts available power to dc power at the level(s) required by the CPU and I/O module internal circuitry. Some but not all power supplies include power conversion circuitry that outputs 24 V dc via screw terminals on the power supply module. enough power to drive a few of the sensors and actuators that are connected to I/O modules.

I/O Modules
isolate the low-voltage, low-current signals that the PLC uses internally from the higher-power electrical circuits required by most sensors and actuators. buffers holding output state

Digital I/O Modules (cont.)

Digital OutputModules transistors Transistor output modules can be either current sinking NPN transistors or current sourcing PNP transistors slightly more expensive and less abuse tolerant than NPN transistors, or both triac-controlled output circuit allows current to flow in either direction.

Programming Units
for program and data entry to monitor the execution of a program and the contents of working data memory as the PLC runs. various types a pendant simplest type only a few special-purpose keys and a small display for a few lines of text or for one simple ladder logic rung. difficult to program and monitor a sophisticated PLC proprietary programming units programming software

Basics of Control Components

Control Loads and Control Devices

The control load is an electrical device that uses electrical power. E.g. Pilot lights, relays, and Contactors. Control devices are used to activate the control load. E.g. Pushbuttons and switches.

Electrical Symbols
Contact Switch Pushbutton Coil Overload Relay Pilot Light etc

Contact
used to indicate an open or closed path of current flow. require an action to change their state. can be Normally Open (NO) or Normally Closed (NC).

Switch
also used to indicate an open or closed path of current flow. require another device or action to change their state. can be Normally Open (NO) or Normally Closed (NC).

Selector Switch
Two-position Three-position Etc.

Switch (cont.)
Variations of this symbol are used to represent limit switches,

level switches,
selector switches.

Pushbutton
2 basic types of pushbuttons: momentary maintained (latches in place when the button is pressed.) can be Normally Open (NO) or Normally Closed (NC).

Pilot Lights

Pilot Light
a small electric light used to indicate a specific condition of a circuit. E.g., a red light might be used to indicate a motor is running. The letter in the center of the pilot light symbol indicates the color of the light.

Control Relays

Coil
used in electromagnetic starters, contactors, and relays. The purpose of contactors and relays is to open and close associated contacts. A letter is used to designate the coil; the associated contacts have the same identifying letter.

Coil (cont.)
Associated contacts can be Normally Open (NO) or Normally Closed (NC).

Two-Wire Control
A two-wire control circuit provides lowvoltage release but not low-voltage protection. low-voltage release In the event of a power loss the contactor will deenergize, stopping the motor. However, when power is restored, the motor will restart without warning if the control device is still closed.

Two-Wire Control (cont.)

This type of control scheme is used for remote or inaccessible installations such as watertreatment plants or pumping stations. In these applications it is desirable to have an immediate return to service when power is restored.

Holding Circuit Three-Wire Control

low-voltage protection. If an overload causes the OL contacts in the control circuit to open, the M coil is deenergized and the motor shut down. When the overload is cleared, the motor will not suddenly restart on its own. An operator must depress the Start button to restart the motor

Limit Switches

Output Configurations
Two-wire relay output or dry contact Three-wire, DC proximity sensor can either be PNP (sourcing) or NPN(sinking). This refers to the type of transistor used in the output switching of the transistor. Outputs are considered (NO) or (NC) based on the condition of the transistor when a target is absent/present.

PNP Sensor
The load is connected between the output (A) and the negative side of the power supply (L-). A PNP transistor switches the load to the positive side of the power supply (L+).

NPN Sensor
The load is connected between the output (A) and the positive side of the power supply (L+).

Photoelectric Sensors

Theory of Operation
The control consists of an emitter (light source), a receiver to detect the emitted light, and associated electronics that evaluate and amplify the detected signal causing the photoelectrics output switch to change state.

Sensor Applications

Proximity Switches Ultrasonic Sensors Photoelectric Sensors

Proximity Switches

Ultrasonic Sensors

Photoelectric Sensors

Basic PLC advantages

Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to chage