Relay and PLC

(P.T.O)
(P.T.O)
 Advantages of PLC Control
Systems
• Flexible
• Faster response time
• Less and simpler wiring
• Solid-state - no moving parts
• Modular design - easy to repair and expand
• Handles much more complicated systems
• Sophisticated instruction sets available
• Allows for diagnostics “easy to troubleshoot”
• Less expensive

Lecture – Introduction to PLC's MME 486 – Fall 2006 5 of 47

 Advantages of a PLC Control System
Eliminates much of the hard wiring that was associated
with conventional relay control circuits.

The program takes

the place of much of
the external wiring
that would be required
for control of a process.

Lecture – Introduction to PLC's MME 486 – Fall 2006 6 of 47

 Advantages of a PLC Control System
Increased Reliability:
Once a program has been written and tested it can be downloaded to
other PLCs.

Since all the logic is

contained in the PLC’s
memory, there is no
chance of making a
logic wiring error.

Conversely ......

Lecture – Introduction to PLC's MME 486 – Fall 2006 7 of 47

 Advantages of a PLC Control System
More Flexibility:
Original equipment manufacturers (OEMs) can provide system updates
for a process by simply sending out a new program.

It is easier to create
and change a program
in a PLC than to wire
and rewire a circuit.
End-users can modify
the program in the
field.

Lecture – Introduction to PLC's MME 486 – Fall 2006 8 of 47

 Advantages of a PLC Control System
Lower Costs:
Originally PLCs were designed to replace relay control logic. The cost
savings using PLCs have been so significant that relay control is
becoming obsolete, except for power applications.

Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.

Lecture – Introduction to PLC's MME 486 – Fall 2006 9 of 47

 Advantages of a PLC Control System
Communications Capability:
A PLC can communicate with other controllers or computer equipment.

They can be networked to

perform such functions as:
supervisory control, data
gathering, monitoring
devices and process
parameters, and downloading
and uploading of programs.

Lecture – Introduction to PLC's MME 486 – Fall 2006 10 of 47

 Advantages of a PLC Control System
Faster Response Time:
PLCs operate in real-time which means that an event taking place in the
field will result in an operation or output taking place.

Machines that process

thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLC’s
quick response capability.

Lecture – Introduction to PLC's MME 486 – Fall 2006 11 of 47

 Advantages of a PLC Control System
Easier To Troubleshoot:
PLCs have resident diagnostic and override functions allowing users to
easily trace and correct software and hardware problems.

The control program

can be watched in
real-time as it
executes to find
and fix problems

Lecture – Introduction to PLC's MME 486 – Fall 2006 12 of 47

 PLC System

Lecture – Introduction to PLC's MME 486 – Fall 2006 14 of 47

 PLC Architecture
• An open architecture design allows the system to be
connected easily to devices and programs made by
other manufacturers.

• A closed architecture or proprietary system, is one

whose design makes it more difficult to connect devices
and programs made by other manufacturers.

NOTE: When working with PLC systems that are

proprietary in nature you must be sure that any generic
hardware or software you use is compatible with your
particular PLC.

Lecture – Introduction to PLC's MME 486 – Fall 2006 15 of 47

 I/O Configurations
Fixed I/O

• Is typical of small PLCs

• Comes in one package, with

no separate removable units.

• The processor and I/O are

packaged together.

• Lower in cost – but

lacks flexibility.
Lecture – Introduction to PLC's MME 486 – Fall 2006 16 of 47
 I/O Configurations

Modular I/O

Is divided by compartments
into which separate modules
can be plugged.

This feature greatly increases

your options and the unit’s
flexibility. You can choose
from all the modules available
and mix them in any way you
desire.

Lecture – Introduction to PLC's MME 486 – Fall 2006 17 of 47

 I/O Configurations

Modular I/O

When a module slides into the rack,

it makes an electrical connection with a series of
contacts - called the backplane. The backplane
is located at the rear of the rack.

Lecture – Introduction to PLC's MME 486 – Fall 2006 18 of 47

 Power Supply

• Supplies DC power to other

modules that plug into the rack.

• In large PLC systems, this

power supply does not
normally supply power to the
field devices.

• In small and micro PLC systems, the power supply

is also used to power field devices.

Lecture – Introduction to PLC's MME 486 – Fall 2006 19 of 47

 Processor (CPU)
• Is the “brain” of the PLC.
• Consists of a microprocessor
for implementing the logic, and
controlling the communications
among the modules.
• Designed so the desired circuit can be
entered in relay ladder logic form. Processor
Module
• The processor accepts input data from
various sensing devices, executes the
stored user program, and sends
appropriate output commands to
control devices.

Lecture – Introduction to PLC's MME 486 – Fall 2006 20 of 47

 I/O Section

Consists of:
• Input modules
• Output modules.

Lecture – Introduction to PLC's MME 486 – Fall 2006 21 of 47

 I/O Section

Input Module

• Forms the interface

by which input field
devices are connected
to the controller.

• The terms “field” and

“real world”are used to
distinguish actual external
devices that exist and must
be physically wired into the system.

Lecture – Introduction to PLC's MME 486 – Fall 2006 22 of 47

 I/O Section
Output Module

• Forms the interface

by which output field
devices are connected
to the controller.

• PLCs employ an
optical isolator which
uses light to electrical-
ly isolate the internal
components from the
input and output
terminals.
Lecture – Introduction to PLC's MME 486 – Fall 2006 23 of 47
 Programming Device

PC with appropriate
software

• A personal computer (PC) is the most commonly used

programming device
• The software allows users to create, edit, document,
store and troubleshoot programs
• The personal computer communicates with the PLC
processor via a serial or parallel data communications link
Lecture – Introduction to PLC's MME 486 – Fall 2006 24 of 47
 Programming Device

Hand-held unit
with display

• Hand-held programming devices are sometimes used to

program small PLCs

• They are compact, inexpensive, and easy to use, but

are not able to display as much logic on screen as a
computer monitor

Lecture – Introduction to PLC's MME 486 – Fall 2006 25 of 47

 Programming Device

Hand-held unit
with display

• Hand-held units are often used on the factory floor

for troubleshooting, modifying programs, and
transferring programs to multiple machines.

Lecture – Introduction to PLC's MME 486 – Fall 2006 26 of 47