PLC

[Programmable logic
controller]
 [Programmable logic controller]

INDEX
 Introduction
1. What is PLC?
2. Why use PLC?
3. Applications of PLC
 Plc components
1. Overview
 Plc Topics
1. Features
2. System scale
3. User interface
4. Communication
 Conclusion

1. Introduction
 A programmable logic controller (PLC) or programmable controller is a computer
used for automation of electromechanical processes, such as control of machinery on
factory assembly, amusement rides, or lighting fixtures. PLCs are used in many industries
and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs
and output arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. Programs to control machine operation are typically
stored in battery-backed or non-volatile memory. A PLC is an example of a hard real
time system since output results must be produced in response to input conditions within a
bounded time, otherwise unintended operation will result.
1.1 What is plc?
A programmable logic controller (PLC) is an electronic device that controls machines
and processes. It uses a programmable memory to store instructions and execute specific
functions that include ON/OFF control, timing, counting, sequencing, arithmetic and
data handling.
PLCs development began in 1968 in response to the request from hydromantic division
of general motors. At the time, gm frequently spent days or weeks replacing inflexible
relay-based control systems whenever it changed car models or made line
modifications. To reduce the high cost of rewiring, control specifications called for a
solid state system that had the flexibility of a computer yet could be programmed and
maintained by plant engineers and technicians. It also had to withstand the dirty air,
vibration, electrical noise, humidity and temperature extremes found in the industrial
environment.
The first PLCs were installed in 1969 and quickly became a success. Functioning as
relay replacements; even the early PLCs were more reliable than relay-based systems,
largely due to the ruggedness of their solid-state components compared with the moving
parts in electrochemical relays. PLCs provided material, installation; troubleshooting
and labor cost savings by reducing wiring and associated wiring errors. They took up
less space than the counters, timers and other control components they replaced. And
their ability to be reprogrammed dramatically increased flexibility when changing
control schemes.
Perhaps the biggest key to industrial acceptance of the PLCs was based on the ladder
diagrams and electrical symbols commonly used by electricians. Most plant personnel
were already trained in ladder logic, and they easily adopted it for PLCs. In fact, ladder
 logic still plays an integral role in programming and troubleshooting; even though more
programming languages have been developed.
1.2 Why use plc?
During the 1970s and early ‘80s, many engineers, manufacturing managers and
control system designers spent considerable time debating this issue, trying to evaluate
cost effectiveness.
Today, one generally accepted rule is that PLCs become economically viable in control
system that requires three to four or more relays. Given that micro PLCs cost only a few
hundred dollars, coupled with the emphasis manufacturers place on productivity and
quality, the cost debate becomes also immaterial. In addition of cost savings, PLCs
provide many value added benefits:
1.2.1 RELIABILITY 
Once a program has been written and debugged. It can be easily transferred and
download to other PLCs. This reduces programming time, minimizes debugging, and
increases reliability. With all the logic existing in the PLCs memory, there is no chance
of making a logic wiring error. The only wiring required is for power and inputs and
outputs.
1.2.2 FLEXIBILITY 
Program modifications can be made with just a few key strokes. Advanced functions
PLCs can perform a wide variety of control tasks, from a single, repetitive action to
complex data manipulation. Standardizing on PLCs opens many doors for designers,
and simplifies the job for maintenance department personnel.
1.2.3 COMMUNICATIONS 
Communicating with operator interfaces, other PLCs or computers facilities data
collection and information exchange.
1.2.4 SPEED 
Some automated machines process thousands of items per minute and objects spend
only a fraction of a second in front of a sensor, hence many automation applications
require the PLCs quick response capability.
1.2.5 DIAGNOSTICS 
The troubleshooting capability of programming devices and the diagnostics resident in
the PLCs allow users to easily trace and correct software and hardware problems.
 1.3 APPLICATIONS OF PLC

No matter what the application, the use of PLCs helps increase competitiveness. Process
using PLCs include: packaging, bottling and canning, material handling, machining,
power generation building control systems, automated assembly, paint lines, and water
treatment. PLCs are applied in variety of industries including food and beverages,
automotive, chemical, plastics, pulp and paper, pharmaceuticals and metals. Virtually
any application that requires electrical control can use PLCs.

2. Plc components.
2.1 Overview.

The main components of PLCs are as follows:

1. Inputs
2. Outputs
3. CPU
4. Memory for program and data storage
2.1. INPUTS 
The input screw terminals on a PLC from the interface by which field devices are
connected to the PLC. Inputs include the items such as tool buttons, thumbwheels, limit
switches, selector switches, proximity sensors and photoelectric sensors. These are all
discrete devices that provide an ON/OFF status to the PLC. While larger PLCs can
directly accept analog values (variable voltage or current signals). Such as from
temperature or pressure sensors, micro PLCs do not typically possess this capability.
The electrical signals that field devices send to the PLC are typically unfiltered 120v
a.c. or 24v D.C. The inputs circuitry on PLC takes this field voltage . It too is usable by
the PLC. Conditioning is necessary because the internal components of PLC operate on
5v D.C. and this minimizes the possibility if damage by shielding them from voltage
spikes. To electrically isolate internal components from the input terminals, PLCs
employ an optical isolator, which uses light to couple signals from one electrical device
to another.
2.1.2 OUTPUTS 
Connectors tot the o/p terminals of the PLC are devices such as solenoids, relays,
contractors, motor starters, indicator lights, valve and alarms. Output circuits
operate in a manner similar to i/p circuits: signals from the CPU pass through an
isolation barrier before energizing o/p circuits.
PLC use a variety of o/p circuits to energies their o/p terminals: relays, transistors
and triac.

 Relays are for either ac or dc power. Traditional PLC, electromagnetic relay

typically handle current up to a few amps. Relays can better withstand voltage
spikes, and they have an air gap between their contacts, which eliminates the
possibility of current leakage. However they are comparatively slow and subject to
wear overtime.
 Transistors switch dc power are silent and have no moving parts to wear out
transistors are fast and can reduce response time, but only carry loads of 0.5amps
or less. Special types of transistors, such as FET (field effect transistors) can
handle more power, typically up to 1amp.
Triac strictly switch ac power. Like transistors trial o/p are silent, have no moving parts
to wear, are fast and carry loads of 0.5 amps or less.
2.1.3 CENTRAL PROCESSING UNIT- CPU 
The CPU made up of a microprocessor and a memory system, forms the primary
component of the PLC. The CPU reads the inputs, executes logics as dictated by the
application program, performs calculations and controls the output.
PLC users works with two areas of the CPU: program files and data files. Program files
stores the user application program, subordinate files and the error files. Data files store
data associated with the program such as input, counter/timer preset and accumulates
the valves. Together, these two areas are called application memo0ry or user memory.
Also the CPU carries an executing program or a system memory that directs and
performs .operation activities such as executing the user program and co-ordination
scans and output updates. The user cannot access system 
2.1. 4 DATA, MEMORY AND ADDRESSING 
Memory is a physical space, data is and information stored in that space. The
CPU operates just like a computer; it manipulates data using binary digits, or bits. Thus
the data is a patter of electrical charges that represents the numerical values. CPU
processes the stored data in 16 bit groups also known as ‘words’.
Each word of data has a specific physical location in the CPU called an address or a
register. When assigned address to input in a program, note that address is related to the
terminal where input and output are connected.
3. Plc topics.

3.1Features

The main difference from other computers is that PLCs are armored for severe
conditions (such as dust, moisture, heat, cold) and have the facility for
extensive input/output (I/O) arrangements. These connect the PLC
to sensors and actuators. PLCs read limit switches, analog process variables (such as
temperature and pressure), and the positions of complex positioning systems. Some
use machine vision. On the actuator side, PLCs operate electric motors, pneumatic or
hydraulic cylinders, magnetic relays, solenoids, or analog outputs. The input/output
arrangements may be built into a simple PLC, or the PLC may have external I/O
modules attached to a computer network that plugs into the PLC.
3.2 System scale
A small PLC will have a fixed number of connections built in for inputs and outputs.
Typically, expansions are available if the base model has insufficient I/O.
Modular PLCs have a chassis (also called a rack) into which are placed modules with
different functions. The processor and selection of I/O modules is customised for the
particular application. Several racks can be administered by a single processor, and may
have thousands of inputs and outputs. A special high speed serial I/O link is used so that
racks can be distributed away from the processor, reducing the wiring costs for large
plants.
3.3 User interface
PLCs may need to interact with people for the purpose of configuration, alarm reporting
or everyday control.
A Human-Machine Interface (HMI) is employed for this purpose. HMIs are also
referred to as MMIs (Man Machine Interface) and GUIs (Graphical User Interface).
A simple system may use buttons and lights to interact with the user. Text displays are
available as well as graphical touch screens. More complex systems use programming
and monitoring software installed on a computer, with the PLC connected via a
communication interface.
3.4 Communications
PLCs have built in communications ports, usually 9-pin RS-232, but optionally EIA-
485 or Ethernet. Modbus, BACnet or DF1 is usually included as one of
the communications protocols. Other options include various field buses such as Device
Net or Prefabs. Other communications protocols that may be used are listed in the List
of automation protocols.
Most modern PLCs can communicate over a network to some other system, such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or
web browser.
PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between
processors. This allows separate parts of a complex process to have individual control
while allowing the subsystems to co-ordinate over the communication link. These
communication links are also often used for HMI devices such as keypads or PC-type
workstations.
4 conclusions
This report has explored the opportunities for coordinated implementation of PLC
technology in U.S.

Army WWTPs and concludes that the decision to use PLCs in military environmental
engineering systems should be based on the following requirements and
considerations:

1. PLC applications should be designed to complement rather than to replace the

existing workforce.

2. All PLC applications should be accompanied by an intensive training effort to

familiarize . the associated workforce in handling and using PLC hardware and
software.

3. The control hardware, instrumentation, etc. Of PLC systems should be designed for
simplicity.

4. The design engineer should incorporate an uninterrupted power supply for any
controlled system. whose long-term failure or (down-state) will constitute a critical
or unsafe condition.

5. The design engineer should consider initial installation of a parallel manual

backup for the controlled system.

6. Any employed PLC system should always be provided with a full set of
replacement parts/modules. (NOTE: PLC parts and modules are inexpensive and
should be available for prompt.(replacement of failed hardware.)

7. PLC applications will likely evolve on a trial-and-error basis over an extended

period of time.(PLCs will not become an overnight panacea.)

8. Effective PLC implementation will require an ongoing quality control effort to

clarify situations. Promote facility confidence in successful applications (i.e., past
errors, as well as success stories, should be addressed during the inherent
"learning" curve)