Programmable Logic Controllers PLCs

History 101
Prior to PLCs, systems consisted of relay control panels and wiring and required engineers to design the logic and electricians to hardwire the devices. Electricians based wiring on a blueprint of the logic or ladder schematic. Disadvantages of hardwiring - hard to correct errors by engineer or electrician - defective/worn parts or troubleshooting required system down time - system changes required down time idling all associated workers

Figure 1. Power plant control room (approximately 1980) plus a behind the scene view of a hardwired panel and wiring closet.

PLCs -

gained in popularity since they: improved quality increased productivity provided flexibility provided quick change to fluid environment cost effective for controlling simple and complex systems

Figure 2. Power plant control room (updated late 1990s), associated control devices and the updated wiring closet.

GM, which utilized large assembly lines, recognized the need to replace electromechanical systems as a means of staying competitive. In 1968, GM wrote the design criteria for the first PLC. The requirements included: 1. be price competitive with relay system to replace 2. be electronic not mechanical device 3. facilitate easy replacement of input and output devices 4. provide flexibility of a computer (perform logic ops & decisions) 5. withstand heat, vibration, dirt, etc. of industrial area 6. be modular to facilitate easy repair and replacement (reduce hardwiring) 7. reprogrammable (reusable) 8. easily programmed by electrician/technician First PLCs were available by 1969 that met some of the above criteria. - initial versions were simple on off devices based on input from switches, etc. - todays PLCs control complex processes and are faster and easier to program (even though tasking complexity increased) Originally called programmable controllers but changed to PLC to avoid confusion with personal computers or the PC

PLC Parts

Figure 3. Break out of PLC parts.

I. Central Processing Unit CPU - brain of PLC which controls logical decisions and communication with other system components - processor similar to that in a PC except PLC geared initially for ladder logic (structured text, function block for current usage) - CPU hardened to resist factory floor electrical noises (fluorescent lights, motor starters, etc.) II. Memory - ROM holds the operating system, high level programming code and cannot be changed - programming code translates the ladder diagrams into machine language (language understood by microprocessor) - RAM stores the user program, I/O, counter, and timer variables A. Older PLCs partition RAM into blocks with specific functions. These blocks are referred to as files and they store status information for functions such as inputs, outputs, timers, counters, etc. B. More recent technology allows PLCs to utilize memory similar to the technique of a personal computer harddrive III. Power Supply - PLC is powered by DC voltage (typically 24VDC) - supply may be housed in CPU unit or a separate module - external devices are typically powered by their own source (some low powered devices may utilize PLC power supply)

IV. I/O (Input/Output) - provides means for communicating and receiving information A. PLCs are grouped based on fixed or modular I/O 1. fixed I/O is typical of smaller PLCs that come in a single, inexpensive package - inexpensive but has limited expansion flexibility - if portion of unit fails typically must replace entire unit
Common Power Bus

Input Interface Processor Output Interface MicroLogix 1000 PLC

Common Return Bus Figure 4. Fixed Package PLC MicroLogix 1000 PLC.

2. modular I/O is divided by compartments into pluggable modules (similar to plug and play for PC) - expensive but highly flexible (mix and match modules available from manufacturer) - modules sit in a rack and establish electrical connection to PLC through backplane (series of contacts)

Power supply

Processor Module

Input Module

Output Module

Module slides in/out of rack

Figure 5. Modular Package PLC ControlLogix PLC.

B. Input/Output Interface equivalent of eyes, ears, and mouth to the brain of a PLC: the CPU - provides an interface between the hard-wired field devices and the CPU 1. Input Module Accepts signals from the machine or process device and converts them into signals that are used by the PLC

- devices that provide input include sensors (motion detector, temperature sensors, etc.), switches, and even other PLCs - input devices are typically interchangeable to meet the various needs facing a PLC - protects CPU from outside world by isolating any input signal through optical isolation circuitry a. An input signal is converted to a light that shines on a photosensitive diode. The diode, when activated by the light, supplies an input signal of 5 volts to the CPU. The CPU translates the 5 volts to a true or high input

Figure 6. Optical isolation of PLC internal circuitry.

2. Output Module Provides a means for the PLC to communicate with output devices by converting controller signals into external signals to control a machine or process - devices that could be connected include motor starters, lights, etc. (commonly referred to as field devices) - protects CPU from outside world through optical isolation - PLC outputs 5 volts which turns on an LED that shines on a photosensitive diode. The diode, when activated by the light, supplies an output signal to a field device Examples of input and output devices are listed in the following figure.

Figure 7. Sample input and output devices for a PLC.

C. I/O Details A modular PLC is flexible in that multiple I/O modules may be plugged into slots in the rack. The only limitation is the number of slots available. ControlLogix racks are available with 4, 7, 10, and 17 slot options. (The equipment in lab has a 10 slot rack.) 1. Modules perform different functions. Samples of these include: Analog Input/Output (2 slots) DC Input/Output (2 slots) Control Net Ethernet Communications Relay Output Modules

POWER SUPPLY

0 Processor Module

Slot

I/O modules

Figure 8. ControlLogix I/O & Networking modules.

2. The location of a module within a rack (commonly known as a slot) and the terminal number of the module to which an input or output device is connected determines the devices specific address. This address is used by the PLC to monitor or control the device and is referred to as the physical address. 3a. Physical Address components for SLC 500 - Type (Input or Output represented by an I or O, respectively) - File Number (identifies block of memory to store status bits) - Slot (location of module in the rack) - Word/Bit (module terminal to which the device is wired)

Inputs Address Type I I Slot 0 0 Word 0 0 Bit 5 0

Outputs Address Type Slot 0 0 Word 0 0 Bit 4 0

O
O

Micrologix 1000 Processor Input/Output Module

Real-world address

1 : 3 . 0 / 01
Terminal number For terminals above #15 Slot number File Number

Module type Figure 9. Allen-Bradley SLC 500 addressing format.

Examples:

O 0:4.0/15 I 1:3.0/08 O 0:6.0 I 1:5.0

Output module in slot 4, terminal 15 Input module in slot 3, terminal 08 Output module , slot 6 Input module , slot 5

3b. Physical Address components for ControlLogix 5550 - Chassis Reference (Defines whether the addressed module resides in the local PLC or a remote PLC cabinet) - Slot Location (Location of module in PLC rack) - Type (Input or Output represented by an I or O, respectively) - Data (Bit type) - Terminal (module terminal to which the device is wired)
I for Input O for Output Terminal

Local : 2 : I . Data . 0
Slot Location Bit Type: Data

Chassis Reference Figure 10. Allen-Bradley ControlLogix addressing format.

V. Programming Devices A. Methods to program a PLC 1. Hand Held/Field Device or Dumb Terminals 2. Dedicated Terminals 3. Microcomputers with graphical interfaces or DOS based system

Figure 11. Hand held Device and DOS based PLC programming software screen

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Figure 12. Windows based PLC programming software

PLC Applications
PLCs may be deployed in different configurations I. Single-Ended A. single PLC controlling one process II. Multitask A. single PLC controlling several processes II. Control Management A. single PLC controlling several other PLCs B. PLC downloads programs telling other PLCs what to do

Modes of Operation
PLCs typically have 3 modes of operation Run, Prog, and Rem. I. Run - places controller in run mode - controller actively controlling a process/machine - programs may not be edited through on-line or operator interfaces II. Prog - places controller in program mode - prevents execution of ladder programs - allows new programs to be entered or existing programs to be changed - prevents operator interface from changing PLC mode III. Rem places controller in remote mode allows mode to be changed from operator interface into Remote Run, Remote Program, Remote Test

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Remote Run Mode is identical to Run Remote Program Mode allows online program editing to be performed Remote Test Mode allows code to execute with limited editing operations available The mode may be changed through software or by moving the key switch position. The Micrologix 1000 utilizes software to change its mode. The ControlLogix utilizes both software and the key switch. NOTE: The ControlLogix key switch should remain in the remote position at all times. Changing the key switch position could result in operational errors. The time taken to correct these errors may result in the operator running out of time to complete the lab.

Figure 13. Front view of ControlLogix with key switch in REM Mode.

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