Presentation

On PLC
Sofcon Systems India Pvt. Ltd.
C-87, Sector 88, NOIDA.
Uttar Pradesh.
E-mail: sales@sofcononline.com

INTRODUCTION TO
PROGRAMMABLE LOGIC
CONTROLLERS

INDUSTRIAL CONTROL
SYSTEM (ICSs)
Encompasses several types of control
systems used in industrial production, including
SCADA, DCS, and PLCs.
ICSs are typically used in industries such as
electrical, water, oil, gas and data.

INDUSTRIAL CONTROL
SYSTEM (ICSs)
Industrial Control enables:
Mass production of continuous processes
such as oil refining, paper manufacturing,
chemicals, power plants and many other
industries.
Automation, with which a small staff of
operating personnel can operate a complex
process from a central control room.

TYPES OF INDUSTRIAL
CONTROL SYSTEMS
Process control systems can be characterized as
one or more of the following forms:
Discrete
Continuous
Batch

DISCRETE PROCESS
Found in many
manufacturing, motion
and packaging
applications. Robotic
assembly, such as that
found in automotive
production.
Most discrete
manufacturing involves
the production of
discrete pieces of
product, such as metal
stamping.

CONTINUOUS PROCESS
Equipment operates in a single,
constant state and performs one
dedicated function.
The process rarely shuts down.
The goal is to produce a
consistent product, no matter
how long the process operates.
Examples of Continuous Processes:
Float Glass Line
Cement Kiln
Combustion Control
Water or Wastewater Treatment
Plant

BATCH PROCESS
Consists of a sequence of one or more steps
in a defined order.
Finite quantities of raw materials
processed by the equipment to
produce finite quantities of finished
products.
If more product is to be created, the
process must be repeated.
The goal is to produce a consistent product
through repeatability, batch to batch.
Examples of Batch Processes:
Production of beer, ice
cream, and other food products.

HARD WIRED RELAY

BASED SYSTEMS
The contactor and Relays together with
hardware timers and counters were used in
achieving the desired level of automation.
DRAWBACKS:
Relays had limitations as control devices:
Controlled on/off type of operations, while
manufacturing and process equipment were
becoming more sophisticated
Hardwired - changes in industrial and
manufacturing operations required
equipment modifications and rewiring
Took up space - bulky

COMPARISON
MICROPROCESSOR MICROCONTROLLER
A multipurpose,
Microcontroller has
programmable device
a microprocessor,
that accepts digital
in addition with a
data as input,
fixed amount of
processes it
RAM, ROM and
according to
other peripherals
instructions stored in
all embedded on a
its memory, and
single chip.
provides results as
A microcontroller is
output.
a specialized form
It is only one
of microprocessor
component of an
that is designed to
electronic device and
be self-sufficient
requires additional
and cost-effective.
circuits, memory and
firmware or software
before it can
function.

PLC

A PLC is a special
microcontroller
designed for
industrial use, that
is for controlling
machinery or
processes.

A PLC is a system
that uses a
microprocessor or
microcontroller as
one of the
components

PROGRAMMABLE LOGIC
CONTROLLER
A PLC is a microprocessor based, mini-computer
specifically tailored specifically for certain control
tasks.
It uses programmable memory to store
instructions and specific functions that include
On/Off control, timing, counting, sequencing,
arithmetic and data handling to control machines
and processes.

PROGRAMMABLE LOGIC
CONTROLLER
Extensive use of PLCs because of:
Flexible
Faster Response time

Less and simpler wiring

Modular design easy to repair and troubleshoot
Rugged can withstand harsh industrial
surroundings

HISTORY OF PLC
The first PLC systems evolved from conventional
computers in the late 1960s and early 1970s.
Programmable logic controllers were initially
adopted by the automotive industry where
software revision replaced the re-wiring of hardwired control panels when production models
changed.
The plants had to be shutdown for up to a
month at model changeover time but the early
PLCs when used along with other new automation
techniques shortened the changeover time.

HISTORY OF PLC
The earliest PLCs were developed to offer the
same functionality as the existing relay logic
systems.
The PLCs:
Could start in seconds
Could bear tough plant environment
Had battery backup

GENERAL FEATURES OF
A PLC
General characteristics of a programmable
controller include:
Withstands rugged industrial environment,
such as temperature and humidity
Easily installed and maintained
Reusable (i.e., can be moved and
reprogrammed)
Modular (i.e., parts can be replaced easily
for maintenance or repair)
Easy transition for people who worked with
relays

COMPONENTS OF
PROGRAMMABLE
LOGIC CONTROLLERS

COMPONENTS OF PLC

COMPONENTS OF PLC
CPU module compresses of the processor and the
memory.
PLC takes information from inputs and makes
decisions to energize or de-energize outputs.

- A wide variety of types are available

The PLC power supply converts AC power into DC
power to support those components of the PLC.
The Rack enables data exchange with I/O modules.

APPLICATIONS OF PLC

TYPICAL PLC APPLICATION

Here we can see an example of a typical PLC
(Programmable Logic Controller) application. This
application could be production of any liquid product,
such as the brewing of a batch of beer. What we see
are several devices that can detect information about
the beer. The sensors are an example of this-- they
can detect whether the tank is filled too much, or too
little. We call these devices Input Devices.

TYPICAL PLC APPLICATION

We can also see devices that can create actions to the
batch of beer, such as the motor, that can turn on and
mix the beer, or the valves that can open or close, to
either allow beer ingredients to fill the tank, or to allow
the batch of beer out of the tank to the next stage of
the system. We call these devices Output Devices.

TYPICAL PLC APPLICATION

The instructions that tell the output devices what to
do based on the conditions returned by the input
devices are written in programs that are stored and
run by the PLC (Programmable Logic Controller).

ADVANTAGES OF PLCs
FLEXIBILITY
It is easier to create and
change a program in a
PLC than to wire and
rewire a circuit.
The program can be
modified by the end-user
on field.
Moreover, one model of a
PLC can be used to run
numerous machines with
distinct program for each
machine.

ADVANTAGES OF PLCs
LOWER COST
With day-by-day
improving
technology, it is
possible to get
more functions
(relays, timers,
counters,
sequencers ) into
smaller and less
expensive
packages.

ADVANTAGES OF PLCs
CAPABILITY OF
COMMUNICATION
PLCs can be
communicated to
perform functions such
as: supervisory
control, data
gathering, monitoring
devices and process
parameters, and
downloading and
uploading of programs.

ADVANTAGES OF PLCs
QUICK RESPONSE TIME
PLCs have real-time
operation which implies
that they react
immediately on the input
they obtain.
Real-time operation is a
relative concept that
means any task is
guaranteed to be handled
within a certain time.

COMPONENTS OF PLC
There are five basic components in a PLC system:
The PLC processor, or controller
I/O (Input /Output) modules
Chassis or backplane
Power supply
Programming software that runs in a PC
In addition to these 5, most PLCs also have:
A network interface

PROCESSOR, CONTROLLER,
OR CPU
Stores the control program and
data in its memory
Reads the status of connected
input devices
Executes the control program
Commands connected outputs
to change state based on
program execution
For example: Turn a light on,
start a fan, adjust a speed, or
temperature
Comes in various physical forms

PROCESSOR, CONTROLLER,
OR CPU
Comes in various physical forms:

I/O MODULES

Physically connect to field devices

Input modules convert electrical signals coming
in from input field devices such as pushbuttons,
to electrical signals that the PLC can understand.
Output modules take information coming from
the PLC and convert it to electrical signals the
output field devices can understand, such as a
motor starter, or a hydraulic solenoid valve.
I/O modules form the interface by which input
field devices are connected to the controller.

I/O MODULES
I/O comes in various forms:

TYPES OF I/O MODULES

The following table illustrates four different I/O
module types and their specific functions:

I/O CONFIGURATION:
TYPES
Local, Extended-local, and Remote I/O
are terms used for different types of I/O
configurations. I/O configurations are
differentiated by the following:
The number and type of modules present in
the chassis
The distance of each chassis and module
from the processor
The required speed of communications

LOCAL I/O
Local I/O: I/O
modules connected
to a processor
across a backplane,
thus limiting their
distance from the
processor.
Resident I/O
Chassis: Chassis
that houses the
processor.

LOCAL I/O
Local I/O configuration:
I/O modules and the processor reside in
the same chassis.
I/O modules are connected to the processor
across the backplane.

EXTENDED-LOCAL I/O

Extended-Local I/O: I/O modules connected to

a processor across a parallel link, thus limiting
the distance from the processor.
Parallel Link: A communication link that allows
information to transfer simultaneously.
Adapter Module: A module in an I/O chassis
that provides a communication interface between
the I/O modules in that I/O chassis and the
processor.

EXTENDED-LOCAL I/O
Extended-local I/O configuration:
I/O modules reside in a separate chassis
from the processor.
An extended-local I/O adapter module and
a multi-conductor cable are needed to
communicate.
The chassis is generally located closer to
the processor than with remote I/O
configuration.
The parallel link to the processor provides a
faster data transfer than a serial link.

REMOTE I/O
Remote I/O: I/O modules connected to a
processor across a serial link.
Serial Link: A communication link that allows
information to transfer sequentially.

REMOTE I/O
Remote I/O configuration:
I/O modules reside in separate chassis
from the processor.
A remote I/O adapter module is needed to
communicate.
The chassis generally can be located farther
from the processor than with extendedlocal configuration.
Serial link gives a slightly slower data
transfer than extended-local configuration.
The distance from the processor (cable
length) depends on the type of
programmable controller and the
communication rate.

CHASSIS/BACKPLANE
All PLCs need some method of communicating
between the controller, I/O and communications
modules.
A chassis provides the following:
Communication pathways between I/O modules
and processor (or other communications adapter)
via a circuit board called the backplane
Power supply connections

CHASSIS AND BACKPLANE

EXAMPLES

POWER SUPPLY
A power supply is needed to provide power to the
PLC and any other modules.
The Power Supply also furnishes the following:
Conditions voltage and current so that they are
compatible with processor and I/O components
Provides over and under voltage protection
Provides over current protection

FORMS OF POWER SUPPLIES

Power supplies come in various forms:

Power supply modules that fit into one of the slots in

a chassis

External power supplies that mount to the outside of

a chassis

Stand alone power supplies that connect to the PLC

or I/O through a power cable

Embedded power supplies that come as part of the

PLC block.

INTRODUCTION TO FIELD
DEVICES & TYPE OF I/Os

I/O SYSTEMS

I/O systems are often referred to as local or

distributed.
Local I/O refers to the I/O being attached
directly to the Controller or on the same
backplane as the Controller
Distributed I/O refers to I/O which is not on
the same backplane as the Controller.
Distributed I/O is connected using a network.

The distributed input module sends the inputs across the

backplane to the adapter.
The adapter sends them over the I/O network to the PLC
(Controller).

LOCAL vs. DISTRIBUTED I/O

SYSTEM

Why use Local I/O?

Faster than distributed I/O
Easy to install - add a module to the chassis
Less expensive than adding distributed

Why use Distributed I/O?

Field devices distributed around the machine too much wiring to take back to one chassis
Out of local I/O
local I/O limited by number of slots in the
backplane or fixed I/O attached to the
processor
Local I/O does not meet your needs
module type, current capability, etc.

INPUT MODULES
Input modules interface directly to devices such
as switches and temperature sensors.
Input modules convert many different types of
electrical signals such as 120VAC, 24VDC, or 420mA, to signals which the controller can
understand.

INPUT MODULES
Input modules convert real world voltage and
currents to signals the PLC can understand.
Since there are different types of input devices,
there is a wide variety of input modules available,
including both digital and analog modules.

DISCRETE vs. ANALOG

MODULES
Discrete Modules (Digital Modules)
Devices that are either on or off, such as a
pushbutton, get wired to discrete modules.
Discrete modules come in a variety of types, such
as 24VDC or 120VAC, and allow you to typically
connect anywhere from 2 to 32 devices, with the
most popular being 16 devices.
Since it takes only 1 bit to represent the state of
a device, a 16 point discrete module only
requires 16 bits of memory in the controller to
store the states of all the points on the module.

DISCRETE vs. ANALOG

MODULES Analog Modules
Devices that have a number associated with them, such
as a temperature sensor, get wired to analog
modules.
Analog modules come in a variety of types, such as 4 to
20 mA or 0 to 10 VDC, and allow you to connect
anywhere from 2 to 16 devices.
Since it takes 1 word to represent a number, a 16 point
analog module requires 16 words of memory in the
controller to store the value of all the numbers on the
module. Each word in a PLC takes 16 or 32 bits
(depending on the PLC), therefore it takes 16 or 32
times the amount of PLC memory to store analog points
vs. digital points.

OUTPUT MODULES
Output modules interface directly to devices such
as motor starters and lights
Output modules take digital signals from the PLC
and convert them to electrical signals such as
24VDC and 4 mA that field devices can
understand.

OUTPUT MODULES

Output modules take a signal from a PLC and

convert it to a signal that a field device needs to
operate.
Since there are different types of output devices,
there is a wide variety of output cards available,
including both digital and analog cards.

ACTUAL WIRING OF
DEVICES TO PLC

WIRING OF PLC
One of the many advantages to using a PLC/PAC is
the simplicity of the I/O wiring.
I/O devices are wired to I/O points on a fixed I/O
unit and to I/O modules in a modular unit.
Input devices such as switches, pushbuttons and
sensors are wired to input module points and
output devices such as indicator lights, solenoids
and motor starter coils are wired to output
module points.

DEFINITIONS
Sinking and Sourcing:
Sinking and sourcing are
terms to describe a
current flow relationship
between field input and
output devices in a control
system and their power
supply.
Sourcing I/O circuits
supply current to sinking
field devices.
Sinking I/O circuits
receive current from
sourcing field devices.

SINK SOURCE
CONNECTIONS

Sink Connections: A sink I/O device or I/O

module will always have a connection to the
negative side of the DC power supply. The
negative side of the DC power supply is referred
to by any one of or either of the terms: ground,
common, DC common, return, DC return, etc. All
these terms refer to the same electrical point;
the negative side of the DC power supply. Sink is
designated NPN.
Source Connections: A source I/O device or I/O
module will always have a connection to the
positive side of DC power supply. The positive
side of the DC power supply is referred to as
VDC+, positive, etc. Source is designated PNP.

WIRING OF PLC SINK &

SOURCE

It is method of connecting two different polarity signal

to a common terminal. It may be of two types
1. Input wiring
a. sinking configuration
b. sourcing configuration
2. Output wiring
a. sinking configuration
b. sourcing configuration

SINK SOURCE
CONNECTIONS
Source & Sinking is used exclusively with
Digital DC circuits. If the common pin is +
polarity, its called a sourcing circuit. If its
polarity, its called a sinking circuit.

Advantages: No moving parts, so lifespan is long

Disadvantages: No AC support. Cant handle
significant current.

SCAN CYCLE OF PLC

SCAN CYCLE OF PLC PLC

OPERATION
A PLC works by continually scanning a program.
We can think of this scan cycle as consisting of 3
important steps.

The Scan Time, the time required for one full

cycle, provides a measure of the speed of
response of the PLC.

BASIC TERMINOLOGY

Scan Time: The time required for the controller to

read all inputs, execute the program, and update all
outputs.
Program Scan Time: The time required for the
controller to execute the instructions in the program.
I/O Scan Time: The time required for the processor
to scan all I/O modules, writing output data and
reading input data.
The following graphic shows both the program and I/O
scan time:

PROCESSOR SCANNING
1. Input Scan: The state of the inputs is recorded in
the input image table.
The PLC records this data into its memory to be
used during the next step.
This makes the PLC operation faster, and avoids
cases where an input changes from the start to the
end of the program (e.g., an emergency stop).
2. Program Scan:
The input image data table is examined & the
program logic is executed.
The data is changed in accordance with the
program and output image table is prepared.
The information does not go to actual outputs.

PROCESSOR SCANNING
3. Output Scan:
The output table is copied from memory to the
outputs. These then drive the output devices by
providing 0 or 1 logic.
In this way, the information stored in the output
image table is used to switch output devices.

SYNCHRONOUS &
ASYNCHRONOUS SCAN
Synchronous and asynchronous scan is one
example of a variation among I/O and
communication interfaces.
A synchronous interface begins the I/Odevice update only when the processor
communicates with the interface.
An asynchronous interface, on the other
hand, scans the I/O devices on a
continuous basis - independent of
processor communication with the interface
board.

CONTINUOUS
SCAN

PERIODIC
SCAN

Executes each program

top to bottom and then
restarts
Operates at the lowest
priority on the controller
Uses all CPU time left
after other tasks
execute
Interrupted by operating
system to perform
processor and
communications
overhead
Traditional PLC Scan

Triggered automatically
at a preset time interval
Interrupts lower priority
tasks and can be
interrupted by higher
priority tasks (15 Levels)
Will share time (on a
1ms basis) with other
same priority level tasks
Captures fault for task
overlap
Similar to PLC/SLC
Selectable Timed
Interrupt (STI)

CONTINUOUS
SCAN

PERIODIC
SCAN

INTERRUPTS
Interrupt function. It is an event that interrupts
the scan to process a special routine that you have
written.
In simpler terms, this means that as soon as the
input turns on, regardless of where the scan
currently is, the PLC immediately stops what its
doing and executes an interrupt routine.
A routine can be thought of as a mini program
outside of the main program.
An interrupt must be configured and enabled to
execute.
After its done executing the interrupt routine, it
goes back to the point it left off at and continues
on with the normal scan process.

INTERRUPT PRIORITY

When there are more than one interrupt occurred at the same
time, only the interrupt with highest priority can be executed.
All the other interrupt routines need to wait until it became the
highest priority among the pending interrupts.
Consequently, a response delay of hundreds of microseconds,
or even few milliseconds, may be caused. Hence, in a multiple
interrupt inputs structure, an interrupt priority is given to each
interrupt in accordance with its importance.

INTERRUPT PRIORITY
If another interrupt request is made when the
PLC is carrying out a higher priority interrupt
service routine than the new interrupt request, the
CPU will wait until the execution of the subroutine
is completed before accepting the new interrupt
request.
However, if the priority of the new interrupt
request is higher than the one being executed, the
CPU will stop the running of the current interrupt
service routine immediately to execute the
interrupt service routine with a higher priority.
After completing the execution, the CPU will return
to the previously interrupted service routine with a
lower priority to continue the incomplete work.

REDUNDANCY
CONCEPTS

REDUNDANCY
In engineering, redundancy is the duplication of
critical components or functions of a system with
the intention of increasing reliability of the
system, usually in the case of a backup or failsafe.
Redundancy: Many PLCs are capable of being
configured for redundant operation in which one
processor backs up another.
This arrangement often requires the addition of a
redundancy module, which provides status
confirmation and control assertion between the
processors. In addition, signal wiring to
redundant racks is an option.

REDUNDANCY OBJECTIVE
To improve the amount of up-time of a
machine or process by ensuring
consistent availability of that machine.
This also reduces costs associated
with equipment failure
To guard against system shutdown, a
redundant system must provide:
equipment with exceptional reliability
automatic fault isolation
minimal disturbance of the process
when switching from the primary
to the secondary system

IMPORTANT TERMS IN A
REDUNDANT SYSTEM

TYPES OF REDUNDANCY

Redundancy in PLCs can be of two types:

Hardware, and/or
Software Redundancy.
Hardware redundancy Refers to
secondary controllers, secondary chassis,
redundant power supplies, I/O s, present to
take control of primary hardware in times
of failure.
Software redundancy- Refers to
secondary programming software,
communication software present to take
control in times of software failure.

LEVELS OF
REDUNDANCY

Redundancy at the I/O, controller and

communication levels is available as options,
affording maximum flexibility.

LEVELS OF
REDUNDANCY
Redundancy solutions are available at all levels
including; power supply, communication interfaces
and I/O circuits.

INDUSTRIAL NETWORKS

INDUSTRIAL NETWORKS

What is a Network?
A network provides a means of connecting
multiple devices together for the purposes
of exchanging information.

A common example of a network is an

organization where the computers are
connected together using an Ethernet
network for the purpose of sending emails
or printing documents on a networked
printer.

REASONS TO USE A
NETWORK

There are many reasons to use a network. Some

examples are:
Data Acquisition from the Control System
Control devices in a remote location
Data Sharing Between PLC Controllers
The ability to program devices from a remote
location
The ability to troubleshoot problems from a
remote location
The ability to integrate manufacturing systems
with business system
Examples of networks used in industrial automation
today are
EtherNet/IP, ControlNet, DeviceNet, DH+, Remote
I/O, Foundation Fieldbus, Profibus DP, Modbus.

TYPES OF NETWORKS

Fieldbus
A generic term covering all industrial networks.
Note that there is also a specific network known
as Foundation Fieldbus that is often referred to as
just Fieldbus.
Information Network
Typical devices are computers.
In an industrial environment, typically PLCs are on
the network with computers.
Common uses are data collection, data
monitoring, file transfers, and email.
Control Network
Typical devices are PLCs, HMI terminals, and I/O
chassis.
Common use is for control of plant floor devices
such as I/O chassis, robots and other intelligent
devices.

TYPES OF NETWORKS
Device Network
Typical devices are field devices such as
buttons, lights, valves, and drives. Also
small blocks of I/O.
Common use is for direct connection to field
devices.
Sensor
Typical devices are very simple field devices
such as sensors, and lights.
Common use is for direct connection to field
devices

NETWORK FUNCTIONS

NETWORK FUNCTIONS
Rockwell Automation connects to a number of networks
to support control, configure, and collect activities
ControlNet
DeviceNet
Ethernet/IP
Remote I/O (RIO)
DH+
DH-485
Other competitive
Also serial communications using DF1 protocol
For Process applications to interface to instrumentation
Foundation Fieldbus
HART

FUNCTIONS THEY PROVIDE

DF1
A serial protocol for RS-232
Typically point-to-point, two nodes (full
duplex)
Designed for A-B PLCs to communicate
over modems.

RIO (Remote I/O)

An I/O control network, used by PLCs.
Optimized for scanning a known amount of

I/O in a very predictable fashion

Deterministic
Media: PVC Twinaxial cable (w/shield)
Blue hose
Daisy-chain between nodes
Data Rates: 57.6k, 115.2k, 230.4k baud
Max Distance: 10,000 ft. (30 miles via fiber
optic repeaters)
Topology: Master/Slave
Max Nodes: 32

DH+ (DATA HIGHWAY PLUS)

A messaging network for PLCs.
Allows access to PLC data table info via read or
write messages (PCCC)
Protocol: a token passing Peer to Peer bus
network.
Number of Stations: 64 stations maximum
15 or less recommended.
Cable System: Twin axial Baseband (Blue Hose)
Provides online programming capability
57.6 Kbaud ---->
115.2 Kbaud ---->
230.4 Kbaud ---->

10,000 ft.
5,000 ft.
2,500 ft.

DH485
An information network primarily designed for
SLC500, 5/02, 5/03
A token passing Peer to Peer bus network up to
19.2 Kbaud
Number of stations: 32 maximum / 15 or less
recommended
Often requires more hardware to support network
connections (i.e.. AIC Link Coupler) vs. DH+
Message passing network only, not deterministic.
Supports a respond only mode for low level devices
Remote programming support
Based on RS-485 electrical signal specification

CONTROLNET

High-speed (5 Mbits/sec) control and I/O network

Improved I/O and improved peer-to-peer
performance
Ability to accommodate I/O (time critical) and
programming (non-time critical on the same network
Industrial Hardened Physical Media
High noise immunity (coaxial and fiber optic cabling)
Intrinsically safe media and products (Flex Ex, fiber
optic repeaters)
Sealed (IP67) media
Media redundancy
Advanced network capabilities
Deterministic - know when data will be transmitted
Repeatable - transmit times are constant, even as
devices enter and leave the network
Producer/Consumer model: Multimaster,
multicast inputs, and peer-to-peer

DEVICENET
Lower Acquisition and Installation Cost
Reduction in plant wiring (eliminates hardwiring of I/O)
Lower installation, start-up, and maintenance times
Network Attributes
Data flow is governed by the Producer/Consumer model
Ability to link smart factory floor devices together and
bridge to higher level networks
Superior device level diagnostics
Device Plug and Play capabilities - add or remove nodes
on the fly
64 devices per network and data rates of 125, 250, and
500KB
Media Options
Passive bus media: nodes can enter and leave without
affecting the network
Sealed (IP67) and unsealed (IP65) media
Low cost flat media

ETHERNET/IP
Ethernet is a high speed network designed
originally for communications between
computers and peripheral devices.
Is the name of the Ethernet network that uses
the Common Industrial Protocol.

ETHERNET/IP
Connectivity to all computer manufacturers and software
Standard network management software: SNMP
Highly efficient data transfer
Increased baud rates (10Mb, 100Mb), use of switches
(instead of hubs), full duplex data transmission to
minimize effect of message collisions, and isolation
from the office Ethernet network
Use of commercial off the shelf products and technology
Common set of installation and support tools
Well established network standard, Can take
advantage of web browsing services in the products
Media Options
Active bus media: supports star network topologies
High noise immunity (fiber optic cabling)
Extend bus length with multiple switches (copper
and fiber)

HOW THESE NETWORKS

DIFFER

FOUNDATION FIELDBUS H1
Digital network designed specifically to support
the demands of devices used in a process
application.
Device communication is scheduled at specific
intervals
Control, such as loop functions, can be
distributed among the devices. Devices have
embedded function blocks.
Devices are capable of transferring large
amounts of analog data, in addition to digital
data.
Foundation Fieldbus H1 is an open protocol
developed in the 1990s.

HART
Digital signals encoded on the analog signal
providing additional diagnostic data from the
transmitter
Can be used in traditional 4-20mA applications and
is backward compatible with existing installations.
HART was the first open protocol to connect analog
devices together
Millions of devices installed worldwide
80% of all Instruments sold today have HART
connectivity
Many customers dont use it, but device
manufacturers build it in to almost all devices
rather than making HART and non-HART devices.

PROTOCOL CONVERTER
It is a device used to convert standard
protocol of one device to the protocol suitable for
the other device or tools to achieve the
interoperability.
Protocols are software installed on the routers
which convert the data formats, data rate and
protocols of one network into the protocols of
the network in which data is navigating.

GENERAL ARCHITECTURE
OF A PROTOCOL
CONVERTER

It includes an:
internal master protocol - communicating to the
external slave devices and the data collected is
used to update the internal database of the
converter.
When the external master requests for data, the
internal slave collects the same from the
database and send it to the external master.
There will be different schemes for handling the
spontaneous reporting of events and commands.

PROTOCOL CONVERTER

Protocol Converters are generally used for

transforming data and commands from one device or
application to another.
This necessarily involves transformation of data,
commands, their representation, encoding and
framing to achieve the conversion.
The simplest and most commonly used conversion is
protocol conversion between Modbus RTU and
Modbus TCP.

WIRELESS
COMMUNICATION

WIRELESS TECHNOLOGY
Industrial Wireless Technologies
Technology Based on Spread Spectrum
Introduction to Spread Spectrum
Spread Spectrum vs. Narrow Band
Technology
Frequency Hopping Spread Spectrum
Direct Sequence/OFDM
RF Bands - 900 MHz, 2.4 GHz, 5 GHz
Future Technology

BASIC INDUSTRIAL
WIRELESS TECHNOLOGY
RADIO TYPES

Analog vs. Digital

Some video/voice use analog

Spread spectrum radios such

as RadioLinx are digital

Receiver

Receives signal - does not

intentionally transmit a signal
Like FM or XM music receiver

Transmitter
Transmits signal only

Generally lower cost part of a

radio

Separate transmitter /
receiver systems
Communication is single
direction
Common for telemetry of a
analog or digital signal
Low cost transmitters on
remotes, fewer receivers
Transceiver (RadioLinx)
Single radio sends and
receives signals
Receiver can ask or request to
resend message

BASIC INDUSTRIAL
WIRELESS
TECHNOLOGIES

UHF / VHF Licensed radios (Narrow Band)

220 MHz, 450 MHz & 900MHz
Unlicensed ISM band (FHSS, DSSS, OFDM)
Spread spectrum
900 MHz (902MHz to 928MHz 26 MHz of Bandwidth)
2.4 GHz (2.4GHz to 2.4835GHz 83.5 MHz of Bandwidth)
5.8 GHz
IEEE 802.11 (WiFi)
IEEE 802.11a, b, g and n
2.4 GHz (b/g), 5.8 GHz (a)
802.15 short range
Bluetooth
Zigbee
802.16 (WiMax)
GSM / GPRS cellular
Satellite ( GEO, LEO, MEO)

MOST POPULAR AND

EMERGING TECHNOLOGIES

WIRELESS TECHNOLOGIES
RECOMMENDED
APPLICATIONS*

TECHNOLOGY BASED ON
SPREAD SPECTRUM
INTRODUCTION TO SPREAD
SPECTRUM
Spread spectrum
a class of modulation techniques that spreads a signals
power over a wider band of frequencies than is necessary
for the information being transmitted
Spreads the RF energy across the RF spectrum
Benefits of spreading the signal:
Signal is more immune to unwanted noise / interference
Simultaneous transmission of multiple signals within the
same frequency band
Provides inherent data encryption / security
Supports fast data rates

NARROWBAND VS.
SPREAD SPECTRUM
Narrow band (VHF)

Spread Spectrum

License required

License free

Long range

Long range in some

Line-of-sight not

required
Slow data rates

situations
Line-of-sight critical
High speed capable

INDUSTRIAL WIRELESS
TECHNOLOGIES
SHORT RANGE (802.15.4
ZIGBEE)
Designed for Controls and
Sensors
Low Cost, Low Power
Wireless Mesh Networking
Standard
250 kbps in the ISM 2.4 GHz
band
20 kbps in the 868 MHz band
(Europe)
40 kbps in the 915 MHz band
(North America & Australia)

INDUSTRIAL WIRELESS
TECHNOLOGIES SHORT RANGE
(802.15.1 BLUETOOTH)
802.15 Wireless Personal Area
Network (WPAN)
2.4 GHz FHSS fast hopping
(1600 hops/s)
Class 3 1 mW ~ 10m
Class 2 - 2.5 mW ~ 20m
Class 1 - 100 mW ~ 100m
720 kbits/s (less w/ Forward
Error Correction FEC)

FUTURE INDUSTRIAL
WIRELESS TECHNOLOGIES
WIMAX (802.16 STANDARD
75MBPS TO 10 KM)

Fixed WiMax - 2.5GHz and 3.5 GHz Requires License

Fixed WiMax 5.8 GHz license free

Information gathered from

//www.wimax.com/education

FUTURE INDUSTRIAL
WIRELESS TECHNOLOGIES
CELLULAR (GSM & CDMA)
1G, 2G and 3G Cellular refers to generation of wireless
Monthly Charges depending on the frequency of data
Coverage Depends on the Carrier (Verizon, AT&T, etc.)

INTRODUCTION TO PLC
PROGRAMMING

PLC PROGRAMMING
Every PLC has associated programming software that
allows the user to enter a program into the PLC.
Software used today is Windows based, and can
be run on any PC.
Different products may require different
software: PLC5, SLC, and ControlLogix each
require their own programming software.

Example of PLC programming software

PLC PROGRAMMING
Before a PLC can perform any control task, it must
be programmed to do so.
Ladder Logic is the most popular language used
to program a PLC

Example of a ladder logic program

PLC PROGRAMMING
LADDER LOGIC

Each line of code is known as a rung. In this example

there are 4 rungs, numbered 0, 1 and 2, and the end rung
marking the end of the program.
The PLC executes the program 1 rung at a time, starting
with the first rung and then working down.
Ladder logic rungs are basically IF-THEN statements. Each
individual rung is executed from the left to the right

OTHER PROGRAMMING
LANGUAGES
While ladder logic is the oldest and most popular
language used in PLCs today, many other languages
are widely in use. Examples are:

Sequential Function Chart (SFC)

Function Block

Structured Text

Higher level languages such as C.

CONTROLLER & PROGRAM

SCOPE DATA
Controller-scoped tags
Accessible by all programs and routines within
the controller
Certain tags must reside at controller level
Input / Output Module tags
Produced/Consumed Tags
Message Tags
Motion group and Axis tags
Program-scoped tags
Limited access to routines within a single
Program
Provides isolation between programs
Separate name space prevents name collisions
when a tag name is used multiple times

PRODUCED / CONSUMED
TAGS

Multiple Logix controllers in the same backplane

or connected via Ethernet/IP or ControlNet may
share tag data values
No code or message instructions required to
pass values
Consumed tag can be used to trigger an
Event Task in a controller
Data may be scheduled between processors
similar to I/O operation
Simple configuration of tag settings
Mark a tag as a produced and point consumed
tags in remote controllers to it
Select the requested packet interval or
broadcast rate as fast as 1msec

VARIABLE TAGS AND DATA

TYPES
Allen Bradley uses the terminology tags to describe

variables, status, and input/output (I/O) values for the

controller.
Controller Tags include status values and I/O definitions.
These are scoped, meaning that they can be global and
used by all programs on the PLC.
These can also be local, limiting their use to a program that
owns it.
Variable tags can be an alias for another tags, or be given a
data type. Some of the common tag types are listed below.

BASIC INSTRUCTIONS
One organizes ladder logic as rungs on a ladder
and put instructions on each rung. There are two
basic types of instructions:
Input instruction: An instruction that checks,
compares, or examines specific conditions in the
machine or process.
Output instruction: An instruction that takes
some action, such as turn on a device, turn off a
device, copy data, or calculate a value.

BASIC INSTRUCTIONS

REALIZATION OF BASIC
GATES USING BASIC PLC
INSTRUCTIONS

The logical AND function is constructed by series

combinations of digital (discrete) inputs
Two (or more) series components
The logical OR function is constructed by parallel
combinations of digital (discrete) inputs
Two (or more) parallel components
The logical NOT function is constructed by referencing the
input signal with a normally closed contact (XIO
instruction)
More complex Boolean expressions can be formulated with
various serial-parallel combinations of XIC and XIO
instructions
NAND, NOR, XOR, XNOR

EQUIVALENT LADDER LOGIC

DIAGRAM

TIMERS
TON Timer On Delay
Count time base intervals when
the instruction is true.
TOF Timer Off Delay
Counts time base intervals
when the instruction is false.
RTO Retentive Timer
Counts time base intervals
when the instruction is true
and retains the accumulated
value when the instruction
goes false or when power cycle
occurs.

COUNTERS

CTU Count UP
Increments the accumulated value
at each false to true transition and
retains the accumulated value
when the instruction goes false or
when power cycle occurs.
CTD Count Down
Decrements the accumulate value
at each false to true transition and
retains the accumulated value
when the instruction goes false or
when power cycle occurs.
RES Reset
Resets the accumulated value and
status bit of a timer or counter.

FILE INSTRUCTIONS
1. FFL - First In, First Out (FIFO) Load
On a false-to-true rung
transition, the First in First out Load
(FFL) instruction loads words
or long words into a
user-created file called
a FIFO stack.
2. FFU First In, First Out (FIFO)
Unload
On a false-to-true rung transition,
the FFU instruction unloads words
Or long words from a user created
file called a FIFO stack.

FILE INSTRUCTIONS
3. LFL - Last In, First Out (LIFO) Load
On a false-to-true rung
transition, the LFL instruction
loads words or long words
into a user-created file called
a LIFO stack.
4. LFU Last In, First Out (LIFO) Unload
LIFO unload (LFU), is
paired with a given LFL
instruction to remove
elements from the LIFO
stack.

COMPARISON
INSTRUCTIONS

1. EQU Instruction
When source A and source B are
equal, the instruction is logically
true. If these values are not
equal, the instruction is logically
false.
2. NEQ Instruction
When source A and source B are not
equal, the instruction is logically
true.
Here, Source A must be an address.
Source B can be either a
program constant or an address.

COMPARISON
INSTRUCTIONS

3. LES Instruction
When source A is less than the
value at source B, the
instruction is logically true.
4. LEQ Instruction
When the value at source A is less
than or equal to the value at
source B, the instruction is
logically true.
Here, Source A must be an
address. Source B can be
either a program constant or an address.

COMPARISON
INSTRUCTIONS

5. GRT Instruction
If the value at source A is
greater than the value at
source B, the instruction is
logically true.
6. GEQ Instruction
If the value at source A is
greater than or equal to
the value at source B, the
instruction is logically true.

COMPARISON
INSTRUCTIONS

7. LIM Instruction
It tests for values within or outside a
specified range, depending on how the
limits are set.
The Low Limit, Test, and High Limit value
are restricted to the following
combinations:
If the parameter is a program constant,
both the Low Limit and High Limit
parameters must be word addresses.
If the parameter is a word address, the
Low Limit and High Limit parameters can
be either a program constant or a word
address.

MATHEMATICAL
INSTRUCTIONS

Math Instructions
ADD:
Overview
Add two values
Source - address of the
SUB:
value on which the operation Subtract one value from
is to be
another
performed.
MUL:
Destination is the address Multiply two values
of the result of the operation.
DIV:
Location of math
Divide one value by another
instructions in ladder logic
determine to operation
performed (i.e. if the
operation A(B+C) is desired,
the ADD operation must
appear before the MUL).

CONTROLLER
A controller compares the actual value of output
with the reference input, determines the
deviation, and produces a control signal that will
reduce the deviation to zero or to a small value.
The manner in which the controller produces the
control signal is called the control action.

PID CONTROLLER

PID stands for:

P (Proportional)
I (Integral)
D (Derivative)
These controllers have proven to be robust and extremely
beneficial in the control of many important applications.
It provides the most accurate and stable control and is
best used in systems which have a relatively small
mass and those which react quickly to changes in the
energy added to the process.

PID CONTROLLER
CHARACTERISTICS

PID controllers are process controllers with the

following characteristics:
Continuous process control Analog input (also
known as "measurement" or "Process Variable" or
"PV")
Analog output (referred to simply as "output")
Set point (SP)
Proportional (P), Integral (I), and / or Derivative
(D) constants
Proportional Band is referred to as Gain
Integral Band is referred to as Reset
Derivative Band is referred to as Rate

PID CONTROLLER

When an error is introduced to a PID controller,

the controllers response is a combination of
the proportional, integral, and derivative
actions, as shown in Figure below.

PID CONTROLLER
Proportional Band is referred to as Gain
Integral Band is referred to as Reset
Derivative Band is referred to as Rate

PID CONTROLLER

When an error is introduced to a PID controller, the

controllers response is a combination of the
proportional, integral, and derivative actions, as
shown in Figure below.

PID CONTROLLERS ARE

EVERYWHERE
More than 90% of all controllers used in process
industries are PID controllers.
A typical chemical plant has 100s or more PID
controllers.
PID controllers are widely used in:
Chemical plants
Oil refineries
Pharmaceutical industries
Food industries
Paper mills
Electronic equipments

FUZZY CONTROL
Fuzzy logic is well suited to implementing
control rules that can only be expressed
verbally, or systems that cannot be modeled
with linear differential equations. Rules and
membership sets are used to make a decision.
Fuzzy Logic Control (FLC) or sometimes known
as Fuzzy Linguistic Control is a knowledge based
control strategy that can be used
- when either a sufficient accurate and yet not
unreasonably complex model of the plant is
unavailable, or
- when a (single) precise measure of
performance is not meaningful or practical.

EXAMPLE OF FUZZY
CONTROL
An example of a fuzzy logic controller for
controlling a servomotor is shown in Figure. This
controller rules examines the system error, and
the rate of error change to select a motor
voltage. In this example the set memberships are
defined with straight lines, but this will have a
minimal effect on the controller performance.

TYPES OF FUZZY
CONTROLLERS:
- DIRECT CONTROLLER
The Outputs of the Fuzzy Logic System Are the
Command Variables of the Plant:

TYPES OF FUZZY
CONTROLLERS:
- SUPERVISORY CONTROLLER
Fuzzy Logic Controller Outputs Set Values for
Underlying PID Controllers:

TYPES OF FUZZY
CONTROLLERS:
- PID ADAPTATION

Fuzzy Logic Controller Adapts the P, I, and D

Parameter of a Conventional PID Controller:

ALARMS AND EVENTS

MANAGEMENT
- DEFINITION

In the process control industry, the terms alarms

and events are used to describe occurrences in a
process plant which have a certain meaning. In
informal conversation, the terms alarm and event
are often used interchangeably and their meanings
are not distinct.
An alarm is an abnormal condition that requires
special attention.
An event may or may not be associated with a
condition.
Alarm and event management can help eliminate
the issues traditionally associated with alarming.

ALARMS AND EVENTS

Alarms represent warnings Events
represent
of process conditions that
normal system status
could cause problems, and
messages and do not
require an operator response. require an operator
response. A typical
A typical alarm is triggered
is
triggered
when a process value exceeds event
when a certain system
a user-defined limit. This
triggers an unacknowledged condition takes place,
such as an operator
alarm state which can be
used to notify the operator of logging.
a problem. Once the operator
acknowledges the alarm, the
system returns to an
acknowledged state.

BENEFITS

With installed Alarms and Events management softwares

that come along with the software package:
Alarm instructions are programmed only once, and then
downloaded to the controller, reducing programming
effort and errors.
Alarm conditions are detected more quickly and realtime alarming is performed in the controller.
HMI tags or alarms in Server are not required, reducing
overhead and tag mapping errors.
Alarm state is managed, processed, and preserved by
controllers, even if the computer falters.
Alarm status is communicated only when state changes,
reducing network overhead, controller processing, and
improving overall system performance.
Time stamps on alarm conditions are accurate,and not
delayed until they reach the Alarm and Event Server.