Intro to PLC

8/3/2019 Intro to PLC

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Good MorningGood Morning


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Control SystemControl System

PB1

LS1

INPUTSM1

M2R

LOGIC OUTPUTS

M1

SOL


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What is a ProgrammableWhat is a Programmable

Controller?Controller? ProcessorProcessor

InterfaceInterface


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4 Basic PLC Parts4 Basic PLC Parts

ProcessorProcessor

I/O InterfaceI/O Interface

Power SupplyPower Supply

Programming DeviceProgramming Device


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ProcessorCentral Processing Unit

Memory

Input/Output Rack

A d a p t e r

M o d u l e

M o d u l e

M o d u l e

M o d u l e

M o d u l e

M o d u l e

M o d u l e

M o d u l e

Output Devices

SolenoidsMotor Starters

AlarmsIndicators

D/ALogic

BCD

Input Devices

Limit SwitchesPres. SwitchesProx. Switches

Temp. SwitchesPush Buttons

A/DLogic

BCD

Program Panel

Power Supply


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ProgrammableProgrammable

ControllersControllers

The most significantThe most significant

development in the industrialdevelopment in the industrialcontrol field in this half-centurycontrol field in this half-century


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ProgrammableProgrammable


The Control of the FutureThe Control of the Future


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PLC AdvantagesPLC Advantages Ease of programmingEase of programming

Ease of maintenanceEase of maintenance

Designed for industrial environmentDesigned for industrial environment Quick installationQuick installation

Adaptable to change Adaptable to change


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Higher Level ControlHigher Level Control

CapabilityCapability Arithmetic Arithmetic Data ComparisonData Comparison

Word ManipulationWord Manipulation Master Control Relay InstructionsMaster Control Relay Instructions Program Skip CapabilityProgram Skip Capability

SequencingSequencing Matrix Data ManipulationMatrix Data Manipulation Proportional, Integral, Differential (PID)Proportional, Integral, Differential (PID)

ControlControl


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The Changing Face of The Changing Face of

Industrial ControlIndustrial Control


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Historically:Historically: Machines have been viewed asMachines have been viewed as

operational entitiesoperational entities

Processes have been viewed asProcesses have been viewed asfunctional entitiesfunctional entities

1978

1943

1967

1971

1958

1969

1975

1963

1970 1979 1977 1940


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EvolutionEvolution Introduction into AutomotiveIntroduction into Automotive

IndustryIndustry PLC performs relay-equivalentPLC performs relay-equivalent

functionsfunctions PLCs applied to:PLCs applied to:

Transfer linesTransfer lines

Assembly machines Assembly machines Grinding machinesGrinding machines Boring machinesBoring machines Materials handling equipmentMaterials handling equipment


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EvolutionEvolution Proliferation into other industriesProliferation into other industries

PLC performs relay-equivalentPLC performs relay-equivalentfunctionsfunctions

PLCs applied inPLCs applied in Manufacturing industriesManufacturing industries Food and beverage industriesFood and beverage industries

Power industryPower industry Process industriesProcess industries Metals industryMetals industry Pulp and paper industriesPulp and paper industries


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EvolutionEvolution PLC usage proliferates into other PLC usage proliferates into other

industriesindustries


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EvolutionEvolution Introduction of the intelligentIntroduction of the intelligent

Programmable Controller Programmable Controller PLC performs arithmetic and dataPLC performs arithmetic and data

manipulation functionsmanipulation functions Applications expand in all industries Applications expand in all industries


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EvolutionEvolution Introduction of miniIntroduction of mini

Programmable ControllersProgrammable Controllers Intended for small scale dedicatedIntended for small scale dedicated

applicationsapplications


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EvolutionEvolution Expansion of capabilitiesExpansion of capabilities

Operator communicationOperator communication Analog control Analog control Positioning controlPositioning control Machine fault detectionMachine fault detection

Installations expand intoInstallations expand intominicomputer equivalentminicomputer equivalentapplicationsapplications


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EvolutionEvolution Installation of manufacturingInstallation of manufacturing

lines controlled by PLClines controlled by PLCnetworksnetworks


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EvolutionEvolution The year of PLC DownsizingThe year of PLC Downsizing

Microprocessor-based PLCs nowMicroprocessor-based PLCs nowcost effective in small-scalecost effective in small-scaleapplicationsapplications

Space-efficient, high-density I/OSpace-efficient, high-density I/O


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EvolutionEvolution The year of PLC DownsizingThe year of PLC Downsizing

Microprocessor-based PLCs nowMicroprocessor-based PLCs nowcost effective in small-scalecost effective in small-scaleapplicationsapplications

Space-efficient, high-density I/OSpace-efficient, high-density I/O


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EvolutionEvolution Introduction of fourth and futureIntroduction of fourth and future

generations of PLCs providinggenerations of PLCs providingcontinuing improvements incontinuing improvements incost/performance effectivenesscost/performance effectiveness Improved operator communicationImproved operator communication Expanded capabilitiesExpanded capabilities

Extensive inter-controlExtensive inter-controlcommunicationcommunication


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EvolutionEvolution The advent of distributed controlThe advent of distributed control

Data HighwaysData Highways Peer-to-peer PLC networksPeer-to-peer PLC networks Applications: Applications:

Material handling/trackingMaterial handling/tracking Decentralized process controlDecentralized process control


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EvolutionEvolution Smart I/O, more distributedSmart I/O, more distributed

intelligenceintelligence Processing power in I/O interfaceProcessing power in I/O interface Microprocessor CPUs increaseMicroprocessor CPUs increase

functionality, at lower costfunctionality, at lower cost PID controlPID control

Graphic operator interfacesGraphic operator interfaces


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EvolutionEvolution PLCs functionality expands intoPLCs functionality expands into

computer-like capabilitycomputer-like capability Instruction sets expand to includeInstruction sets expand to include

floating point math, Boolean filefloating point math, Boolean filemanipulationsmanipulations

Microprocessor-based I/O performsMicroprocessor-based I/O performssophisticated closed loop controlsophisticated closed loop control

Use of Data Highways expandUse of Data Highways expandthroughout industrythroughout industry


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Traditional PLC ConceptTraditional PLC Concept PLC performs relay equivalentPLC performs relay equivalent

functionsfunctions

PLC performs ON/OFF controlPLC performs ON/OFF control Ladder diagram programLadder diagram program

representationrepresentation

Designed for industrial environmentDesigned for industrial environment Designed for ease of use andDesigned for ease of use and

maintenancemaintenance


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What areWhat areProgrammableProgrammableControllerControllerApplications?Applications?


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Typical PLC UsersTypical PLC Users Manufacturing industriesManufacturing industries

Power industryPower industry

Metal industryMetal industry Food and beverageFood and beverage

Process industriesProcess industries

Pulp and paper Pulp and paper


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PLC ApplicationPLC Application

ConsiderationsConsiderations Inputs/OutputsInputs/Outputs Type, AC, DC,Type, AC, DC,

voltage, etc.voltage, etc.

Number Number MemoryMemory

TypeType SizeSize

Functions requiredFunctions required Instruction setInstruction set Arithmetic Arithmetic

Remote I/ORemote I/O Computer Computer

communicationscommunications Report generationReport generation


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PowerPower Coal handlingCoal handling

Burner controlBurner control

Flue controlFlue control

Typical Process Application Typical Process Applications


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MetalsMetals Heat treatmentHeat treatment

Ore unloadingOre unloading

PelletizingPelletizing FabricationFabrication



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MiningMining Ore handlingOre handling

Ore loadingOre loading

Waste treatmentWaste treatment Ore processingOre processing

Water treatmentWater treatment

Well (water) supplyWell (water) supply



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Food and BeverageFood and Beverage Process controlProcess control

Materials handlingMaterials handling

PalletizingPalletizing WeighingWeighing

CanningCanning

Packaging and fillingPackaging and filling

BlendingBlending

BottlingBottling



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Chemical/PetrochemicalChemical/Petrochemical Waste treatmentWaste treatment


Materials handlingMaterials handling Batch processBatch process

Weighing and blendingWeighing and blending



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PetroleumPetroleum DrillingDrilling

PipelinePipeline



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Pulp and PaperPulp and Paper Batch digester Batch digester


Waste treatmentWaste treatment Materials handlingMaterials handling



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Programmable ControllersProgrammable Controllers

ProcessorsProcessors


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The Allen-Bradley FamilyThe Allen-Bradley Family

Features:Features: Compatibility of HardwareCompatibility of Hardware Compatibility of Instruction SetsCompatibility of Instruction Sets


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Family of PLC-2Family of PLC-2ProgrammableProgrammable



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Processor ComparisonProcessor Comparison

M e m o r y

M e m o r y

I/OI/O

SLC-100SLC-100

SLC-150SLC-150

PLC-2/02PLC-2/02

PLC-PLC-2/162/16

PLC-PLC-2/172/17

PLC-PLC-5/125/12

PLC-PLC-5/155/15

PLC-PLC-5/255/25

PLC-PLC-

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PLC-3/10PLC-3/10

PLC-3PLC-3LargeLarge

MediumMedium

SmallSmall

Documents

Intro to PLC