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Basic PLC 1 Basic PLC Description This training introduces the basic hardware and software components of a Programmable Controller (PLC). It details the architecture and basic instruction set common to all PLC’s. Basic programming techniques and logic designs are covered. This training describes the operating features of the PLC, the advantages of the PLC over hard-wired control systems, practical applications, troubleshooting and maintenance of PLC’s. 2 Basic PLC Objectives At the end of the training the participants should be able to: Describe the major components of a common PLC.  Interpret PLC specifications.

 Apply troubleshooting techniques.  Convert conventional relay logic to a PLC language.

 Operate and program a PLC for a given application.  3 Basic PLC Course Contents History of Programmable Controllers  Relay Ladder Logic  Central Processing Unit  Input/Output System  Programming and Peripheral Devices  Programming Concepts  Applications  Troubleshooting and Maintenance  4 Basic PLC INTRODUCTION TO PLCS Advantages of PLCs • Less wiring. • Wiring between devices and relay contacts are done in the PLC program. • Easier and faster to make changes. • Trouble shooting aids make programming easier and reduce downtime. • Reliable components make these likely to operate for years before failure.

Basic PLC PLC Origin •- Developed to replace relays in the late 1960s •- Costs dropped and became popular by 1980s •- Now used in many industrial designs Basic PLC Historical Background The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968 Their primary goal To eliminate the high costs associated with inflexible, relay-controlled systems. 7 Basic PLC Historical Background • The controller had to be designed in modular form, so that sub-assemblies could be removed easily for replacement or repair.

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• The control system needed the capability to pass data collection to a central system. • The system had to be reusable. • The method used to program the controller had to be simple, so that it could be easily understood by plant personnel. 8 Basic PLC Programmable Controller Development 1968 1969 1974 1976 1977  Programmable concept developed  Hardware CPU controller, with logic instructions, 1 K of memory and 128 I/O points  Use of several (multi) processors within a PLC - timers and counters; arithmetic operations; 12 K of memory and 1024 I/O points  Remote input/output systems introduced  Microprocessors - based PLC introduced 9 Basic PLC Programmable Controller Development  Intelligent I/O modules developed Enhanced communications facilities Enhanced software features (e.g. Documentation) Use of personal microcomputers as programming aids 1983  Low - cost small PLC’s introduced 1985 on  Networking of all levels of PLC, computer and machine using SCADA software.

1980 10 Basic PLC Programmable Logic Controllers ( Definition according to NEMA standard ICS3-1978) A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process. 11 Basic PLC Leading Brands Of PLC AMERICAN 1. Allen Bradley Gould Modicon Texas Instruments General Electric Westinghouse Cutter Hammer Square D EUROPEAN 1.

Siemens Klockner & Mouller Festo Telemechanique 12 Basic PLC Leading Brands Of PLC JAPANESE 1. Toshiba Omron Fanuc Mitsubishi 13 Basic PLC Areas of Application  Manufacturing / Machining  Food / Beverage  Metals  Power  Mining  Petrochemical / Chemical 14 Basic PLC PLC Size - it covers units with up to 128 I/O’s and memories up to 2 Kbytes. - these PLC’s are capable of providing simple to advance levels or machine controls. MEDIUM - have up to 2048 I/O’s and memories up to 32 Kbytes. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/O’s and memories up to 750 Kbytes.

- can control individual production processes or entire plant. SMALL 15 Basic PLC Tank Used to Mix Two Liquids MOTOR A FLOAT SWITCH FS SOLENOIDS B SOLENOID C TIMER 1 -MINUTE 16 Basic PLC Tank Used to Mix Two Liquids A tank is used to mix two liquids. The control circuit operates as follows: 1.

When the start button is pressed, solenoids A and B energize. This permits the two liquids to begin filling the tank. When the tank is filled, the float switch trips. This deenergizes solenoids A and B and starts the motor used to mix the liquids together. The motor is permitted to run for one minute. After one minute has elapsed, the motor turns off and solenoid C energizes to drain the tank. 17 Basic PLC Tank Used to Mix Two Liquids 4.