Introduction to PLC’s

Lecture 7

Engineering 475
Automated Production Systems
Relay Logic Control System

Relay logic control systems

were the dominate industrial
control method prior to
approximately 1970.

Because of its similarity to a

ladder, the figure is known
as a ladder diagram.

Geller, Fig. 1.1

 Programmable Logic Controllers
Programmable Logic Controllers (PLCs) are digital
devices that are used to control the state of output
ports based on the state of input ports. They greatly
simplify and increase the capability of relay logic
control systems.

Allen-Bradley
MicroLogix
Controller

Allen-Bradley SLC-
Allen-Bradley PICO Controllers 500 Controller
 Components of a PLC

Power
Supply

Input Output
Processor
Ports Ports

These basic components are contained in a single unit or

as separate modules which connect to a common bus.
 I/O Wiring
The primary difference between different models of PLC’s are the
number and type of inputs and outputs that the PLC can
accommodate.

I1 O1
I2 O2
I3 O3
I4 O4
PLC
I5 Model XYZ O5
I6 O6
I7 O7
I8 O8
com com
 AC Input Modules
All input switching elements are
connected to a single hot wire.

The AC supply neutral wire is

connected to a COM port on the PLC.
i
The port address serves to identify a
particular input device.

The AC input module senses the 120

VAC input and converts it to a logic
level (0-5 vdc) signal required by the
processor.
Typical AC Input Module
 Sinking DC Input Module
In this configuration, the
switches connected to the
input ports see the PLC as
the source of the current
i flowing through them.

The forward biased diode

is optically isolated from
the PLC circuitry.

The logic level voltage (0-5

vdc) seen by the processor
is due to the bipolar
transistor.
Sourcing DC Input Module

The switches connected to

the input ports see the port
as a sink for the current to
flow to.

The forward biased diode is

optically isolated from the
biloar transistor which
generates a logic level (0-5
vdc) for the processor.
Triac-Driven 120 VAC Output
Module
Not that all outputs are
optically isolated from the
PLC circuitry by solid state
triac relays.
i The outputs are arranged in a
sink configuration and have
internal fuses to limit the
current through the triac.
Sinking DC Output Module

Similar operation as an AC
output module, except the
triac is replaced by a bipolar
transistor.

The transistor is forward

biased in a sink type output
i module.
Sourcing DC Output Module

In a sourcing DC
output module, the
devices are connected
to a DC common wire.

The solid state relay is

i
switched on using a
logic level (0-5 vdc)
signal from the
processor.
 System Design
The first step in designing a PLC based control system is to
identify the type and numbers of inputs and outputs.

This will drive the type of PLC and I/O modules that need
to be purchased.

The number of I/O ports required generally expands as the

design progresses. It is always best to buy more ports than
you think is required at the beginning.

The cost of the PLC and the I/O modules is generally small
compared to the design time required to add more capability
in the future.
 System Design
(Continued)
The identification of the number and type of I/O ports
required requires a system schematic.

A fluid system schematic is generally developed first.

Once the fluid system schematic is established, the

control elements needed to control the directional control
valves, motors, etc., can be determined and a control
system schematic is developed.
 Assignment

Write a three to five page report that discusses the

different types of PLC’s available through Allen-
Bradley. Pay special attention to the numbers and types
of I/O ports that can be handled by the different devices.

Determine the basic electrical devices used in an AC

input module. Write a short report (one-two pages) that
describes how these modules work.