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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
ControllersControllers
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
Typical Process Application Typical Process Applications
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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
Typical Process Application Typical Process Applications
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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
Typical Process Application Typical Process Applications
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Chemical/PetrochemicalChemical/Petrochemical Waste treatmentWaste treatment
Water treatmentWater treatment
Materials handlingMaterials handling Batch processBatch process
Weighing and blendingWeighing and blending
Typical Process Application Typical Process Applications
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PetroleumPetroleum DrillingDrilling
PipelinePipeline
Typical Process Application Typical Process Applications
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Pulp and PaperPulp and Paper Batch digester Batch digester
Water treatmentWater treatment
Waste treatmentWaste treatment Materials handlingMaterials handling
Typical Process Application Typical Process Applications
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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
ControllersControllers
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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-
2/302/30
PLC-3/10PLC-3/10
PLC-3PLC-3LargeLarge
MediumMedium
SmallSmall