Section 2

Introduction To Control Systems

Introduction to Control Systems
TOPICS

History
Direct Digital Control
Centralised Computer Control
Distributed Control Systems
Programmable Logic
Controllers
Introduction to Control Systems

History
Introduction to Control Systems
HISTORY

 This chapter discusses the design and application of

process control computers used in industry.
 The topics covered include, the history of process
control computers, the basis of the computers used for
process control.
Introduction to Control Systems
HISTORY

 Before the introduction of computers, control was

achieved by stand-alone pneumatic or electronic analog
controllers.
 Still very much in use but limited in terms of
reconfiguration and communication.
Introduction to Control Systems
Analog Loop
Set point (SP)

Process Output
Variable (PV)

Process

TRADITIONAL SINGLE LOOP CONTROLLER

Introduction to Control Systems
HISTORY

 The first industrial installation of a computer system

was made by the Daystrom Company at the Louisiana
Power and Light plant in Sterlington, Louisiana.
 It was not a closed loop control system, but rather a
supervisory, data-monitoring system.
Introduction to Control Systems
HISTORY

Data and Alarm

Output Devices

Digital
Computer

Process

SUPERVISORY DATA-MONITORING SYSTEM

Introduction to Control Systems

Direct Digital
Control
(DDC)
Introduction to Control Systems
DIRECT DIGITAL CONTROL

 The introduction of personal computers in the mid-

1980s was the next significant advance in the use of
computers in process control.
 The first personal computers were relatively slow and
had limited memory and storage.
 With constant advances in speed, software, and data
storage space, however, the personal computer became
a major force in process control and data collection.
Introduction to Control Systems
DIRECT DIGITAL CONTROL

 The goal of the control systems engineer in the early

days was to bypass the process controllers and have the
computer control the process directly.
 This was the beginning of Direct Digital Control.
Introduction to Control Systems
DIRECT DIGITAL CONTROL

Direct Digital
Operator’s Control DDC
Console Computer

Specialized
Process
Digital
Controllers
Introduction to Control Systems
DIRECT DIGITAL CONTROL

 Direct Digital Control was achieved by ICI in England

using a Ferranti Argus computer on a Soda Ash plant in
1969.
 DDC offered the potential to be used for an unlimited
variety and complexity of the automatic control
functions in each and every loop but, the majority of
DDC systems were implemented as digital
approximations of the conventional three term
analogue controller.
Introduction to Control Systems
DIRECT DIGITAL CONTROL

Early digital computers had many disadvantages:

 Very slow – addition could take 4 ms typically
 Small memory, typically about 4000 words
 Limited software capability
 Programming had to be done in machine language
 User personnel had very little experience
 Problems associated with unreliability, particularly where
germanium rather than silicon transistors were used.
Introduction to Control Systems

Centralised Computer Control

Introduction to Control Systems
CENTRALISED COMPUTER CONTROL

Early digital computers had many disadvantages:

 Computers required air conditioners which could be
unreliable.
 Size was increased to allow much faster operation
 The cost went up correspondingly
 To overcome this problem, supervisory computers and
DDC computers were incorporated into the one
mainframe in a central control room.
Introduction to Control Systems
CENTRALISED COMPUTER CONTROL

Centralized Computer System

Supervisory
Supervisor’s Console Control Computer

Direct Digital Control

Operator’s Console
DDC Computer

Process

SUPERVISORY PLUS DIRECT DIGITAL CONTROL

Introduction to Control Systems
CENTRALISED COMPUTER CONTROL

Problems still remained however:

 Computers were not fully tested
 Effectively training and development took place on site.
 Communications to and from the control room were
prone to electrical noise.
 The costs and problems on early systems resulted in a
reduction of computer controlled systems.
 As a safeguard analogue systems were also included as
back-up.
Introduction to Control Systems
CENTRALISED COMPUTER CONTROL

Centralized Computer System

Supervisory
Supervisor’s Console
Control Computer

Direct Digital Control

Operator’s Console
DDC Computer

Analog Backup
Process
Instrumentation

SUPERVISORY PLUS DIRECT DIGITAL CONTROL PLUS ANALOGUE BACKUP

Introduction to Control Systems

Distributed
Control System (DCS)
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM
I/A Series System Architecture
Intra-Enterprise Level Internet
­ Plant Asset Management
­ Simulation/Modeling
Plant Intelligence ­ Enterprise Historian
­ Plant Information Portal
­ Batch Management
Secure Control Information
Network Maintenance
Engineering
Operator
Environment Environment
Environment
­ System Configuration ­ Asset Management
­ Visualization
­ Control Strategy ­ Alarm Analysis &
Alarm/Alert Management Optimization
Development
­ Historian ­ Condition Monitoring
­ Display Configuration
­ Real-time Performance
­ Field Device & Diagnostics
Management
Management
­ Advanced Control Wireless
­ Batch Execution Handheld
Secure, High Speed, Switched MESI Control
Intelligence Field Integration Network Control Network Legacy
Distributed Central
­ Fieldbus I/O Control Connected I/O System
Control
­ Remote I/O Migration
­ Conventional I/O ­ Bailey
­ Safety Systems ­ Fisher
­ PLC ­ Honeywell
­ Moore
­ Spectrum
Existing ­ SPEC200
I/A Series ­ Westinghouse
Safety Installations
System
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

 Because of reliability problems and the high cost of

process control computers of the 1960’s, there were
few new process computer projects in the early 1970’s.
 The rare projects which were implemented during this
period were based on medium-priced minicomputers
that were designed to be small in size and operated as
a supervisory system with DDC control.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

 At the same time, two developments occurred in

electronics that profoundly changed the application of
digital computers to process control.
 The first one was the development of the
microprocessor and integrated circuits.
 The second was the release of the Distributed Control
System by Honeywell in 1969.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

 The concept of a DCS was based on the idea of widely

distributing the control to computer modules.
 Each of these modules controlled several instrument
loops, generally eight.
 They were connected to a single high speed data
communications link, called a data highway, which made
communication possible between each of the computer
modules and central operator console. This allowed the
operator to monitor the operation of each local process.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

 In the 1970’s, microprocessor-based modules replaced

hardwired computer modules.
 This resulted in much more powerful performance with
faster responses and smaller “foot-print”
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Central Control
Console Data Highway

Microprocessor Microprocessor Microprocessor

Based Controller 1 Based Controller 2 Based Controller n

Process Control Unit Process Control Unit Process Control Unit

1 2 n

MICROPROCESSOR-BASED DCS
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Distributed Control Systems today consist of more than

one level.
 The hierarchy extends from Level 1, which is where the
process data is generated, to Level 2 where the
operations and production personnel are involved.
 Level 3 is where the control engineer and the process
engineer monitors the system.
 The highest level is level 4 where the plant
administration comes into the picture with invoicing,
production statistics and management reports.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Executive Management System Level 4

Corporate Data Highway

Plant Management System Level 3

Plant Data Highway

Operator Process Supervisory

Interface Engineering Interface Level 2
Consoles Consoles Consoles

Process Highway

Process Process Process

Controller Controller Controller Level 1
1 2 n

DISTRIBUTED CONTROL SYSTEM LEVELS

Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Functions & Features:

 A typical DCS provides a wide variety of features and
functions, such as control and monitoring, an interface
to operations, maintenance programmers and advanced
application software.
 The most important function, however, is controlling
and monitoring the process.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring:

 Process control and monitoring is performed by DCS
controllers, input/output (I/O) systems and their
associated field devices.
 The main control functions performed are process
interfacing, logic and interlocking, controlling analogue
loops plus sequencing and batch control.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring:

 The most important function is handling input and
output signals between the process and the DCS.
 This is performed by the I/O system which consists of
special purpose PCB’s which are generally located in
metal enclosures near the process equipment.
 The purpose of the I/O modules is to provide the signal
conversions required by a wide variety of measurement
devices and control elements.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring ( continued):

 The typical DCS controller provides control functions from the
simplest level, pressure, temperature and flow loops to
complex strategies involving inter-related loops and advanced
process calculations.
 Most of these control functions are part of the DCS software.
 The operator or engineer only needs to provide information
about the I/O points to be controlled and the DCS configures
the system.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring ( continued):

 To add further control and computing power, other

specialized functions are available which make it
possible to design customized control algorithms and
complex calculations for unique applications.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring ( continued):

 DCS controllers have built-in software logic functions

that make it possible to do interlocking and simple
sequencing in addition to continuous control.
 To obtain the required logic functions the control
engineer will generally use simple Boolean statements.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Control & Monitoring ( continued):

 For batch processing, distributed control systems have
advanced sequencing and batch control functions which
can handle everything from single product, single stream
processes to multi-product, multi-stream applications.
 These capabilities include advanced logic and sequencing,
continuous control, integration of discrete and continuous
functions, recipe management and batch sequencing and
reporting.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

Operator Interface:
 The DCS console gives operations personnel the ability
either to control and monitor across a broad stretch of the
plant or to focus on a specific area.
 The typical DCS console provides high resolution graphics
units that can change colours, levels, messages and other
data to display changing process conditions.
 Peripheral actions such as printing shift reports, alarm
listing and details of process changes can be developed.
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM

OPERATOR INTERFACE
Introduction to Control Systems
DISTRIBUTED CONTROL SYSTEM
Application Software:
 DCS application software can do more than provide advanced
control and monitoring of a process plant. It is also able to
integrate the control system with plant and business computers.
 By giving these computers access to the DCS process database,
application software facilitates functions such as process analysis,
modeling and optimization, production statistics, inventory
control, maintenance scheduling and production reports.
 Other features include long term data storage, retrieval and
analysis.
 Process simulation is also a feature where operators can be
trained and control strategies can be developed.
Introduction to Control Systems

Programmable Logic Controllers

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Introduction
 Programmable logic controllers, also called
programmable controllers or PLCs, are solid-state
members of the computer family, using integrated
circuits instead of electromechanical devices to
implement control functions.
 They are capable of storing instructions, such as
sequencing, timing, counting, arithmetic, data
manipulation, and communication, to control industrial
machines and processes.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Process
or
Machine

Measure Control

Programmable
Field Controller Field
Inputs Outputs

CONCEPTUAL IDEA OF A PLC

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Introduction
 Programmable controllers have many definitions.
However, PLCs can be thought of in simple terms as
industrial computers with specially designed
architecture in both their central units (the PLC itself)
and their interfacing circuitry to field devices
(input/output connections to the real world).
 Programmable logic controllers are mature industrial
controllers with their design roots based on the
principles of simplicity and practical application.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

History

 The Hydramatic Division of the General Motors

Corporation specified the design criteria for the first
programmable controller in 1968.
 Their primary goal was to eliminate the high costs
associated with inflexible, relay controlled systems.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
History
 The specifications required a solid-state system with
computer flexibility able to
(1) survive in an industrial environment
(2) be easily programmed and maintained by
plant engineers and technicians
(3) be reusable
 Such a control system would reduce machine downtime
and provide expandability for the future.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

History

 The product implementation to satisfy Hydramatic’s

specifications was underway in 1968; and by 1969, the
programmable controller had its first product
offsprings.
 These early controllers met the original specifications
and opened the door to the development of a new
control technology.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

History

 The first PLCs offered relay functionality, thus

replacing the original hardwired relay logic, which used
electrically operated devices to mechanically switch
electrical circuits.
 These controllers were easily installed, used less space,
and were reusable.
 The controller programming, although a little tedious,
had a recognizable plant standard: the ladder diagram
format.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Today’s Position

 Many technological advances in the programmable

controller industry continue today.
 These advances not only affect programmable
controller design, but also the philosophical approach
to control system architecture.
 Changes include both hardware (physical components)
and software (control program) upgrades.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Today’s Position
The following details describe some recent PLC hardware
enhancements:
 Faster scan times are being achieved using new,
advanced microprocessor and electronic technology.
 Small, low-cost PLCs which can replace four to ten
relays, now have more power than their predecessor,
the simple relay.
 High-density input/output (I/O) systems provide space-
efficient interfaces at low cost.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Small PLC with built-in

I/O and detachable,
handheld programming
unit.
(courtesy Mitsubishi)
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Today’s Position
Intelligent, microprocessor-based I/O interfaces have
expanded distributed processing.
 Typical interfaces include PID (proportional-integral-
derivative), network, CAN bus, fieldbus, ASCII
communication, positioning, host computer, and
language modules (e.g., BASIC, Pascal).
 Mechanical design improvements have included rugged
input/output enclosures and input/output systems that
have made the terminal an integral unit.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Today’s Position

Special interfaces have allowed certain devices to be

connected directly to the controller.

 Typical interfaces include thermocouples, strain

gauges, and fast-response inputs.
 Peripheral equipment has improved operator interface
techniques, and system documentation is now a
standard part of the system.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

PLC SYSTEM WITH HIGH-DENSITY I/O - 64-POINT MODULES.

( COURTESY MITSUBISHI ELECTRONICS )
Introduction to Control Systems
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Today’s Position
 All of these hardware enhancements have led to the
development of programmable controller families, as
shown on the next slide.
 These families consist of a product line that ranges from
very small “microcontrollers,” with as few as 10 I/O
points, to very large and PLCs, with as many as 8,000
I/O points and 128,000 words of memory.
 These family members, using common I/O systems and
programming peripherals, can interface to a local
communication network.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

ALLEN-BRADLEY FAMILY OF PLC’S

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Principles of Operation

A programmable controller, as illustrated, consists of two

basic sections:

 The central processing unit (CPU)

 The input/output interface system (I/O)
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

PROGRAMMABLE CONTROLLER BLOCK DIAGRAM

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Principles of Operation

 The central processing unit (CPU) governs all PLC

activities.
 The following three components form the CPU:
• the processor
• the memory system
• the system power supply
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

BLOCK DIAGRAM OF MAJOR CPU COMPONENTS

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Principles of Operation
 The operation of a PLC is relatively simple. The I/O
system is physically connected to the field devices that
are encountered in the machine or that are used in the
control of a process.
 These field devices may be discrete or analog
input/output devices, such as limit switches, pressure
transducers, push buttons, motor starters, solenoids, etc.
 The I/O interfaces provide the connection between the
CPU and the information providers (inputs) and
controllable devices (outputs).
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Principles of Operation
 During its operation, the CPU completes three processes:
(1) it reads, or accepts, the input data from the field
devices via the input interfaces
(2) it executes, or performs, the control program stored
in the memory system
(3) it writes, or updates, the output devices via the
output interfaces
 This process of sequentially reading the inputs, executing
the program in memory, and updating the outputs is
known as scanning.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
SCAN

READ (1)

EXECUTIVE (2)

WRITE (3)

ILLUSTRATION OF A SCAN SEQUENCE

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Principles of Operation

 The main purpose of the interface is to condition the

various signals received from or sent to external field
devices.
 Incoming signals from sensors (e.g., push buttons, limit
switches, analog sensors, selector switches, and
thumbwheel switches) are wired to terminals on the
input interfaces.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Principles of Operation

 Devices that will be controlled, like motor starters,

solenoid valves, pilot lights, and position valves, are
connected to the terminals of the output interfaces.
 The system power supply provides all the voltages
required for the proper operation of the various central
processing unit sections.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

INPUT / OUTPUT INTERFACE

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Input / Output Interface
The most basic function PLC’s perform is to examine the
status of inputs and in response, control some process
through outputs.
 The logical combinations of inputs, to produce an
output, is called control logic.
 Several logic combinations are usually required to carry
out a control plan or programme.
 This control plan is stored in memory using a
programming device.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Input / Output Interface

 Once in memory, the control plan is periodically

scanned by a processor, usually a high-speed
microprocessor, in a predetermined sequence.
 The period required to examine the inputs and outputs,
perform the control logic and execute is called the scan
time
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Input / Output Interface

 In simple terms the PLC consists of an input module

which converts the incoming signal to an acceptable
value.
 A logic unit which carries out the instructions which
have been set up as part of the programme.
 An output module which converts the logic unit signals
back to values which are required by the field devices.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

The Processor
 The processor consists of one or more standard or custom
microprocessors as well as other integrated circuits which
perform the logic, control and memory functions of the PLC.
 The processor reads the inputs, executes the logic as
determined by the application programme, performs
calculations and controls accordingly.
 The processor controls the operating cycle or processor scan
of the PLC. This operating cycle consists of a series of
operations which are performed sequentially and repeatedly.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

The Memory
 Usually located in same housing as the CPU
 Used to store the control programme of the PLC
 Information stored in memory determines how the input
and output data will be processed.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
The Memory (continued)
 Memory stores individual pieces of data called bits.
 A bit has two states: 1 or 0.
 Memory units are mounted on circuit boards and are usually
specified in thousands or “K” increments, where 1K equals 1024
words of storage space.
 The more complex the programme, the more memory is required.
 The capacity of a PLC can vary from less than 1000 words to over
64K words, depending on the manufacturer of the programmable
controller.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
The Memory (continued)
Memory can be volatile or non-volatile.
 Volatile memory will lose it’s programmed contents if all
operating power is lost.
 Volatile memory is easily altered and is quite suitable for
most programming applications where it is supported by
battery back-up or the recorded copy of a programme.
 Non-volatile memory will retain data even if there is a
complete loss of operating power.
 The most common type of a volatile memory is RAM or
Random Access Memory.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

The Memory (continued)

 Electrically erasable programmable read only memory

(EEPROM) is a non volatile memory.
 It is programmed through application software running
on a personal computer or through a micro PLC hand
held programmer.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

The Memory (continued)

 The user can access two areas of memory in a PLC
system - programme files and data files.
 Programme files store the control application
programme, sub routines and the error file.
 Data files store data associated with the control
programme.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
The I/O System
 The I/O system provides the physical connection between
the process equipment and the microprocessor.
 Several input circuits are used to sense and measure the
physical quantities of the process, such as temperature or
flow etc.
 Based on the status it senses, the processor sends
response signals to output modules.
 The output modules drive field devices such as motors,
pumps, valves and alarms to exercise control over a
machine or process.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Input Types
 The inputs from field instruments or sensors supply the
data and information that the processor needs to make
logical decisions that control the process or machine.
 These input signals come from such devices as push-
buttons, hand switches, thermocouples, strain gauges
amongst others.
 These signals are connected to input modules where they
are filtered and conditioned for use by the processor
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Output Types:
 The outputs from PLC’s energize and de-energize
control devices to regulate processes or machines.
 Generally voltage outputs and not high power signals.
 Output modules are not normally connected to the
power supply but rather through relays to contactors on
the final control elements.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
I/O Structure:
 PLC’s are usually classified as micro, small (mini), medium
and large, depending on the I/O count.
 Micro PLC’s generally have an I/O count of 32 or less.
 Small PLC – up to 256 I/O
 Medium PLC – up to 1024 I/O
 Large PLC – more than 1024 I/O
Micro PLC’s are self contained units where all the basic
components are in one housing and are therefore referred to
as package controllers.
Larger sizes are called modular controllers where the
components can be separate units.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

I/O Structure: (continued)

 The advantage of a micro PLC is that the unit is smaller,
costs less and is easy to install.
 As an example, the Allen-Bradley Micro 1000 has nine
inputs and five outputs.
 The unit is powered by 120Vac.
 It has an internal power supply to operate the internal I/O
circuits
 Also, there is a built-in microprocessor to generate the
24Vdc for the field mounted switches and contacts.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

I/O Structure: (continued)

 In medium and large PLC systems, the I/O modules are normally
installed or plugged into a slot in a “universal” housing.
 The term “universal” in this context means that any module can
be inserted into any I/O slot in the housing.
 Modular I/O housings are also normally designed so that the I/O
modules can be removed without turning off the main power
supply or removing the field wiring.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Power CPU
Supply

4 I/O Slots

Power CPU
Supply

8 I/O Slots

Power
CPU
Supply

12 I/O Slots

TYPICAL I/O MODULAR HOUSING

Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Discrete Inputs / Outputs:

 Discrete (or Digital) is the most common type of
input/output in a PLC system.
 This type of interface connects field devices that have
two discrete states, such as ON/OFF or OPEN/CLOSED to
the processor.
 Each discrete I/O module is designed to be activated by a
field supplied voltage signal, such as +5V, +24V, 120Vac
or 220Vac.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Discrete Inputs / Outputs: (continued)
 In a discrete input (DI) module, if an input switch is closed, an
electronic circuit in the input module senses the supplied voltage.
 This is then converted into as logic- level signal which is acceptable
to the processor in order to indicate the status of that device.
 For a field input device or switch a logic 1 indicates ON or CLOSED,
and a logic 0 indicates OFF or OPEN.
 Most input modules will have a light- emitting diode (LED) which
indicates the status of each input.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Discrete Inputs / Outputs: (continued)

 In a discrete output (DO) module, the output interface
circuit switches the supplied control voltage that will
energize or de-energized the field device.
 If an output is turned ON through the control
programme, then the interface circuit switches the
supplied control voltage to activate the referenced
(addressed) output device.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Analogue Inputs / Outputs:

 The analogue I/O module make it possible to monitor
and control analogue voltages and currents which are
compatible with many sensors, motor drives and
process instruments.
 By using analogue I/O, most process variables can be
measured and controlled with the appropriate
interface.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Analogue Inputs / Outputs: (continued)

 Analogue I/O interfaces are generally available for
several single polarity and positive /negative ratings
 In most cases, a single input or output interface can
accommodate two or more different ratings and can
satisfy either a current or voltage requirement.
 The different ratings can usually be selected in terms of
either hardware (i.e switches or jumpers) or software.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Discrete Inputs / Outputs: (continued)
 In a discrete (or digital) output module, the module can be thought
of as a simple switch through which power can be provided to
control the output device.
 During normal operation, the processor sends the output state,
determined by the logic programme, to the output module. The
module then switches the power to the field device.
 A fuse is normally provided in the output circuit of the module to
prevent excessive current from damaging the wiring to the field
device. If it is not, then it should be provided during the system
design stage.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Digital Input / Output Modules
 Digital I/O modules are similar to discrete I/O modules in that
discrete ON/OFF signals are processed.
 The main difference is that discrete I/O interfaces require only a
single bit to read an input or an output.
 On the other hand, digital I/O modules process a group of
discrete bits in a parallel form.
 Some of the devices which typically interface with a digital input
are bar-code readers, thumbwheel switches etc.
 Instruments which are driven by a digital output module are LED
displays and intelligent display modules
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS
Special Purpose Modules
 Discrete, digital and analogue modules will normally cover
about 90% of the signals encountered in PLC applications.
 There is a need for special purpose modules to handle non-
standard signals from devices such as thermocouples, pulse
counters or where the input signal has to be conditioned.
 Special purpose I/O modules can also have an on-board
microprocessor which adds intelligence to the interface
independently from the main CPU (e.g. communication
functions to other systems.)
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Power Supply.
 The power supply converts ac line voltage to dc voltages to power
the electronic circuits in a PLC system.
 These power supplies rectify, filter and regulate voltages and
currents so as to supply the correct amounts of voltage and
current to the system.
 The power supply normally converts 120 Vac. or 240 Vac. to
direct current (dc) voltages such as +5 V dc, –15 V dc or + 15 Vdc
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Power Supply: (continued)

 Can be a separate unit, be usually integrated into a single
housing with the processor, memory and I/O modules.
 As the system expands, to include more I/O/modules,
additional power supplies are required.
 PLC power supplies are designed to eliminate noise and
are also designed to operate properly in high temperature
and high humidity environments.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

Configuration

 Although not generally considered a part of the

controller, the programming device, usually a personal
computer or a manufacturer’s mini-programmer unit, is
required to enter the control program into memory.
 The programming device must be connected to the
controller when entering or monitoring the control
program.
Introduction to Control Systems
PROGRAMMABLE LOGIC CONTROLLERS

PERSONAL COMPUTER USED AS A PROGRAMMING DEVICE

AND A MINIPROGRAMMER UNIT.
End of This
Section