Chapter Five

Basic Ladder Logic and Control

 Contents
➢Programmable Logic Controller (PLC)
➢Supervisory control and data acquisition
(SCADA)
➢Distributive Control System (DCS)
 Programmable Logic Controller (PLC)
❖ Control Engineering has evolved over time. In the past, humans
were the main method of controlling a system. Later on,
electricity has been used for controls and early control systems
were based on relays

❖ It is common, even now, to use relays to make simple logical

control decisions
❖ The development of low cost computer has brought the most

recent revolution, the PLC

❖ The advent of the PLC begins in 1970s and has now become the
most common choice for control systems
❖ In brief terms, a PLC is a digital electronic device that contains a
programmable (changeable) memory in which a sequence of
instructions is stored

❖ Those instructions enable the PLC to perform various useful

control functions like relay logic, counting, timing, sequencing,
and arithmetic computation as required in automation

❖ These functions usually are used to monitor and control

individual machines or complex processes via input and
output field devices connected to the PLC

❖ The PLC continuously reads inputs, processes them through a

program, and generates outputs
 Relays
• An electromagnetic relay is a switch, which is driven
electromagnetically and is used in cases of low power control
• Those relays are mainly applied in control circuits, communication
systems and data transmission
Cont.
PLC and Control Relay Comparison
 Advantages of using PLC
❖ All requirements of a relay control system and even more
complex tasks can be done with a PLC
❖ Same basic controller can be used with a wide range of
control systems just by changing the program
❖ Easier and faster modifications/correction can be effected
without any rewiring/change of components
❖ High reliability
❖ Smaller physical size than hard wired solutions
❖ Lower Power consumption
❖ PLCs have integrated diagnostics and over-riding capabilities
❖ Easier troubleshooting
❖ Overall cost reduction in control systems
 Digital and Analogue inputs
❖ Physical quantities like temperature, pressure, flow or level
are changed into electrical signals by Sensors which may give
either Digital or Analogue signals

❖ Analogue devices give signals whose size is proportional to the

size of the variable being monitored

❖ Digital devices can give either discrete signals or pulses

❖ Devices which give discrete signals are ones where the signal
is either “on” or “off ” (either a “voltage” or “no voltage
"condition). e.g. Switch, Push button
• .
Layout of a PLC system
 Processing of input/output
❖ CPU of the PLC are digital devices and must have an input of digital signals
of a particular size, normally “0” to “5” volts. The output from CPU will be
digital normally “0” to “5”Volts.
❖ Input devices(sensors) may give either digital or analogue signals of
varying magnitude.
❖ Output devices(actuators) may need either an analogue or digital signal of
varying magnitude to operate.
There is a need to manipulate
1. the input signals from the sensors
2. the output to the actuator , so that they are compatible with the input
and output of the processor of PLC
 Cont.
• Signal conditioning (sizing) for “analog” and “digital”
signals from sensors and signal conversion for only
“analog” signals from sensors are done in input
modules
• Signal conditioning (sizing) for “analog” and
“digital” output signals required for actuators and
signal conversion of “digital” PLC output into analog”
signals required for actuators are done in output
modules
Signal Conditioning
✓ Digital signal that is generally
compatible with processor in the
PLC is 0-5V DC
✓ Signal conditioning in the
input module, enables a wide
range of input signals to be
connected to the processor
✓ Output from the processor will
be digital 0-5V DC
✓ Signal conditioning in the
output module, processor can
be connected to a range of
output devices
Analogue to Digital Conversion An Example
ADC & Multiplexer
• Analogue signals can be fed to PLC if the
input channel is able to convert the signal to
a Digital signal using a Analogue-to-Digital
converter.

• This can be achieved by mounting a suitable

card with an ADC in the rack

• Instead of using one card for each

analogue signal, one card can be used
with a multiplexer. Number of ADCs
required can thus be minimized

• Many Analogue inputs are connected to a

multiplexer and each input can be
selected in turn by a channel selection
signal

• Multiplexers which can take in 16 inputs are

available .
Digital to Analogue Converter
• Analogue outputs are frequently
required by some of the
actuators,
• Analogue outputs can be provided
by the Digital-to-analogue
converters at the output channel
• The input to the converter is a
sequence of bits with each bit along
the parallel line.
• A bit in the 0 line gives a certain
size output pulse. A bit in line 1
gives double the size of output
pulse as for line 0. A bit in line 2
gives an output pulse double the
size of output pulse as for line 1
and so on.
• All the pulses add together to give
the analogue version of the digital
input
Optocoupler/Optoisolator
• The input/output modules provide the interface
between the PLC system and the “sensors” and
“actuators” which are external to the system.

• Electrical isolation of the processor in the CPU of PLC

from the external sensors and actuators is provided
by the Optoisolators in the input/output modules.
While these allow the input signals to be passed on to
the processor, any electrical faults in the external
devices will not affect the processor.

• When a digital pulse passes through the LED, a pulse

of infra-red radiation is produced and this pulse is
detected by a photo-transistor and gives rise to a
voltage in that circuit

• The gap between the LED and the photo-transistor

gives the electrical isolation.
 Function of “input” Modules
• Input devices, also known as “sensors” are field devices and are connected to PLCs via

Input Modules

• Input devices give discrete, digital or analogue signals

• Input devices are connected to PLCs via Optocouplers (Optoisolator) in Input Modules

• Optocouplers give electrical isolation of the processor of PLC from sensors

• Signal conditioning is used to size the input signals to a value acceptable to the processor

which can take in input only of 0-5V.

• Digital/discrete signals are signal conditioned before connecting them to the Processor.

• Analogue signal from Sensors have to be converted to digital signals and Signal

conditioned before feeding them to the processor since it can only accept only digital

inputs of a certain magnitude.

• Signal conversion is effected by Analogue-to-Digital converters(ADC) in input modules

• Optoisolator, Signal-conditioning Circuits and ADCs are incorporated in the input

modules
 Function of “output” Modules
• Output devices, also known as “actuators” are field devices and are connected
to PLCs via Output Modules

• Output devices may need digital or analogue signals to operate

• output devices are connected to PLCs via Optocouplers (Optoisolator) in

Output Modules. Optocouplers give electrical isolation of the processor of PLC
from actuators.

• Only Signal conditioning is required to size the output of the Processor to a

value as required for the actuators which need digital signals to operate

• Digital output from the processor has to be converted to analogue signals

and Signal conditioned for actuators which need an analogue signal of a
particular magnitude to operate

• Signal conversion is effected by Digital-to-Analogue converters(DAC) in output

modules

• Optoisolator, Signal-conditioning Circuits and DACs are incorporated in

the output modules
 Input/output interface
• The input/output interface consists of the Input and Output Modules, to
which all of the field devices are connected

• If the CPU can be thought of as the “brains” of the PLC, the I/O modules can
be thought of as the “arms and legs” of the PLC

• An input module accepts a variety of digital or analogue signals of varying

magnitude from the “sensors” and converts them into a logic signal that can be
accepted by the processor

• Output modules converts control instructions from the processor into a

digital or analogue signal of varying magnitude that can be used to control
various field devices. (actuators)

• Optocouplers/optocouplers are included in the input/output modules to

provide electrical isolation of the processor from the input and output devices
to prevent any damage to the processor due to external faults in the field
 Operation of PLC – “Scanning”
During its operation (when the PLC is switched to RUN) , the CPU
completes three processes
(1) it reads, or accepts, the input data from the field devices via the
input interfaces(modules)
(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
(modules).
This process of sequentially reading the inputs, executing the program
in memory, and updating the outputs is known as Scanning
A Typical “Shoe Box” PLC
Terminal Connections
 Input Devices
• Mechanical Switches
• Proximity Switches
• Photoelectric sensors
• Encoders
• Temperature Sensors
• Displacement Sensors
• Strain Gauges
• Pressure, Level & Flow sensors
 Programming of PLC
• Programming means feeding a set of instructions to the PLC
and directing its control operations to be as instructed

• Programmes for PLC have to be written in a language and

converted into a machine code, this being a sequence of binary
code numbers to represent the program instructions

• A software is used to translate the program into machine code

for use by the processor

• Programming can be made much easier by use of high level

languages like C,BASIC,PASCAL,FORTRAN,COBOL but
writing programs with these languages requires skill in
programming
 Cont.
• IEC 61131-3 currently defines five programming languages
for programmable control systems
✓Function block diagram (FBD)
✓Ladder diagram (LD)
✓Structured text (ST, similar to the Pascal
programming language )
✓Instruction list (IL, similar to assembly
language)
✓Sequential function chart (SFC)
• The most common format for programming are Ladder
Diagram and Instruction List
Ladder Diagram
Fig.1 is a schematic which shows a control
circuit of a motor which is switched ON by
closing the Switch contacts. Hard wired
controllers have a schematic drawn to
depict the mode of control
Fig. 2 is an equivalent Ladder Diagram
which represents the schematic in a
horizontal form as a RUNG of a ladder. The
supply lines are replaced by thick vertical
lines and are referred as RAILS of the
ladder. The switch is replaced by a NO
contact and the motor is replaced by a
circle marked as OUTPUT. Conversion of
the schematic into an equivalent Ladder
Diagram is the prelude in programming
 Cont.
• A schematic diagram is converted into a Ladder Diagram which serves
as means of feeding a set of instructions or a programme into the
memory of the PLC
• The Ladder Diagram is a symbolic and schematic way of representing
both the system hardware (sensors and actuators) and the process
controller. It is called a ladder diagram because the various circuit devices
connected in parallel across the ac line form something that looks like a
ladder, with each parallel connection a “rung” on the ladder
• Each rung of the ladder is composed of a number of conditions or input
states and a single command output. The nature of the input states
determine whether the output is to be energized or not energized
• Many symbols that are used to represent the various circuit
elements in a schematic are reduced to just few symbols like NO/NC
contacts to represent inputs and a circle, parenthesis or rectangle to
represent outputs in ladder diagrams
 Addressing inputs/outputs
• Addresses are identifications of inputs and output signals for
storing in and retrieving from memory

• Each manufacturer may have his own method of addressing

• With a small PLC, it may be just a number, prefixed by a letter to

indicate whether it is input or output. e.g. X401,X402 inputs and
Y430,Y431 outputs, X indicating inputs and Y indicating outputs
in a Mitsubishi/Toshiba make PLC.

• Before programming a PLC, the make of the PLC is ascertained and

the form of addressing as given by the manufacturer of the PLC is
to be used
Addressing in different makes of PLC
Rules governing Ladder Diagrams
1.Vertical lines of the diagram represent the Power.
2. Each rung of the ladder defines one operation in the control
process.
3. Each rung must start with input or inputs and must end
with an output.
4. Electrical devices are shown in their normal condition. A
switch which is shown normally open until some object closes
it, is shown as open.
5. Contacts made by one output can appear in more than one
rung.
6. The inputs and outputs are all identified by their addresses,
the notation used depending on the manufacturer.
7. END indicates the end of the program. If you forget to
include the END, the programme will not execute and the error
message
“NO END INST” will be displayed.
8. A ladder diagram is read from left to right and top to bottom.
9. When the PLC is in its PROGRAM mode, the ladder diagram
is fed to the PLC and a software will convert the ladder diagram
into a machine code which then becomes a program to be
stored in the memory of PLC
10. When the PLC is in its RUN mode, it goes through the entire
ladder program from start to the end and promptly resumes
from the start, the process termed as a Scan Cycle
Execution of Ladder Program (Scanning)
• The PLC operating system execute a
ladder program by scanning the
logic states of inputs and outputs
stored in the image memory.
• Scanning is a continuous and
sequential process of reading the
status of inputs, evaluating the
control logic and updating the
outputs whenever the PLC is put in
“RUN” or “MONITOR” mode.
• Scan time refers to the time taken
by the CPU to complete one cycle of
the process of reading the inputs,
executing the program and updating
the outputs
• Scan time specifications indicates
how fast the controller can react to
field inputs and correctly solve the
control logic, The faster the scan
pattern, the most efficient the
system becomes to high speed
 What takes place during a “Scan Cycle”?
⚫ SELF TEST(SANITY SCAN) –Checks to see if all the cards are error free, reset watch-dog
timers. A watchdog timer will energize and initiate an alarm and shut down the PLC in the
event of a fault in the system.

⚫ INPUT SCAN – Reads input values from the chips in the input cards, and copies their
present values to memory by using an input image table. The time taken for the input scan
depends on the number of inputs, the clock speed of the CPU etc

⚫ LOGIC SOLVE/PROGRAM SCAN – Based on the input table in memory, the program is
executed, as per instructions in the memory, one step at a time and updates out put and
stores them in an output image table in the memory. The program execution time depends on
the length of the program. A 20-30 rungs program may take an execution time of few

milliseconds

⚫ OUTPUT SCAN – The output image table is copied from the memory to the output chips,
These chips then drive the output devices

⚫ During program scan, the inputs are taken from the memory and not from their physical
states. If the input has a short time, there is a possibility of it being missed out during the
scanning process.
 Instruction List
• Programming by using “Ladder Diagram” is
Graphical programming, programming by
“Instruction List” is Textural Programming.
• Instruction List is prepared using the elements of
a Ladder Diagram and converting them into
“Mnemonics”.
• Different manufacturers of PLCs use different set
of mnemonics
Mnemonics followed by 3 different PLC Makers
Preparing “Instruction List” from a Ladder Diagram
Mitsubishi PLC
Instruction is made for each
element in a rung of a ladder
diagram.
An instruction list is a
compilation of instructions for
each element in a rung of a
ladder programme.
Each instruction consists of the
instruction code (Mnemonic code)
and the address of the element.
Picture shows one rung of a
ladder programme and the
instruction list using Mitsubishi
PLC.
An END instruction to be added
after the end of a complete
programme which may have one
or several rungs
Instruction List – 1 (Omron PLCs assumed)
Instruction List – 2 (Omron PLCs assumed)
Instruction List – 3 (Omron PLCs assumed)
Instruction List – 4 (Omron PLCs assumed)
Instruction List – 5 (Omron PLC assumed)
Instruction List – 6 (Omron PLC assumed)
Instruction List – 7 (Omron PLC assumed)
 Steps in Programming
• List out inputs and outputs
• Assign addresses for inputs and outputs
• Draw an equivalent ladder diagram from schematic.
• Prepare instruction list for the elements of the ladder
diagram
• Feed the ladder diagram into the PLC for Graphical
Programming
• Feed the instruction list into the PLC for Textural
Programming
Programming a DOL Starter
DOL with indicator lights
 Example (Sequential operation)
Write a ladder program that will switch on two
motors when the start switch is operated, then
switch off one motor after 200 s and the other
motor after a further 100 s. When both motors
have been switched off, a third motor is to be
switched on for 50 s. The cycle is then to repeat
itself unless a stop switch has been activated
“Entering Programmes in memory”
Entering programs into memory of the
Microprocessor in CPU can be by
a. Keypad of a Programming console
b. Desktop/Laptop Computer
Entering by drawing Ladder Diagram is known a
graphical method whereas Keying in Instruction
Lists is considered as Textural method of
programming.
 Entering Program by using
Handheld Programming Console
• In order for the PLC to operate, you must first put a
program into the Central Processing Unit. The
program is made by sequentially inputting commands
using the Programming Console.
• PROGRAM mode is used for preparing programs or
for making modifications or corrections to existing
programs.
• MONITOR MODE is used when changing the setting
value of the counter and timer while the PLC is
actually in operation.
• RUN mode is used when it is time to execute the
program that has been entered into the PLC
• The console has a keypad having keys with symbols
depicting the various elements of the ladder diagram
and keying them in so that the ladder Instruction list
appears on the display screen
• A software in the console converts the keyed
instruction into a machine code which can be fed to
the PLC by a connecting cable.
Drawing Ladder Program by using a Desktop/Laptop Computer

• Computers can be used to draw up a Ladder programme.

• This involves loading the computer with the relevant software and
then selecting items from menus on the screen..

• If Ladder is selected, a blank ladder diagram consisting of just two

parallel rails appears initially on the screen.

• At the bottom of the screen, a series of ladder symbols appear. By

selecting the relevant symbol and entering it in the appropriate
place, a ladder diagram can be drawn on the screen.

• The Computer is connected to the PLC by a cable which feeds the

ladder diagram into the PLC for conversion into a machine code.
•
Graphical Programming – 1 Drawing the Ladder Diagram
Graphical Programming – 2 Entering the Ladder Diagram
Built in Devices
Internal Relays
• In PLCs there are elements that are used to hold

data, i.e. Bits and behave like relays, being able to

be switched on or off and switch other devices on

or off. These are called internal relays.

• Such internal relays do not exist as real world

switching devices but are bits in the storage

memory and behave in the same way as relays.

• Internal relays are also called Markers, Flags,

Coils, Relays and Bit storages and addressed

accordingly.

• For programming, they can be treated in the same

way as an external relay output and input.

 Cont.
• To distinguish internal relay outputs from external relay
outputs, they are given different types of addresses as per the
make

• Siemens call them as Flags and address them as F----

• Mitsubishi, as Markers and address them as M-----

• Toshiba, as Relays and address them as R-----

• Sprecher+Schuh, as Coils and address them as C---- etc.

• Some internal relays have battery back-up so that they can be

used in circuits to ensure a safe shutdown of plant in the
event of a power failure and so enable it to restart in an
appropriate manner.
Systems with many inputs
Latching Programs
Timers
In many control tasks, there is a need to control
time e.g.
a. A motor might need to be controlled to
operate for a particular interval of time or
b. A motor to be switched on after some time
interval.
PLCs have timers as built-in devices
Timers count fractions of seconds or seconds
using the internal CPU clock
For programming, a common approach is to
consider timers to behave like relays with coils
which when energized result in the closure or
opening of the contacts after a preset time
All PLCs generally have on-delay timers. Small
PLCs have only on-delay timers. However, on-
delay timers can be used to produce Off-delay
and On-off cycle timers
Fig.1(a) shows a basic timer circuit.
Fig. 1(b) shows the ladder programming and
instruction list for PLCs of Mitsubishi make

Sequencing
 Cont.
• timing relays are used to delay the opening or
closing of contacts for circuit control
• On-delay timers (TON) come on after a particular
time delay
• As the input goes from 0 to 1, the elapsed time
starts to increase, and when it reaches the time
specified by the input , the output goes to 1
• Off-delay timer (TOF) is on for a fixed period of time
before turning off
• The timer starts when the input signal changes from
1 to 0
• ON-delay operation is the operating mode most
often used for automated machines
 Counter
Counter allows a number of
occurrences of input signals to be
• counted.
A. This might be in a situation
where items pass along a conveyor
B. It might be counting the
number of revolutions of a shaft or
C. It might be number of people
passing through a door.
Counters for such applications are
provided as in-built elements in
PLCs. A counter is set to some
preset value and when this value
of input pulses has been received,
it will operate its contacts. Two
types of counters, Down counters
and Up counters count from preset
value to zero and from zero to
preset value
respectively.Fig.1(a) shows a basic
counting circuit. When there
Is a pulse input to input 1 (‘0000’). The
counter is reset. When there is an input to
input 2 (‘00001’), the counter starts
counting. If the counter is set for, say, 10
pulses, then when 10 pulses are received
at ‘00001’, the counter contact will be
closed and there will be an output 1.
Fig 1(b) shows how the above program and
its program instruction list would appear
with a Mitsubishi PLC
 Fault finding
• Once you get over the "black box" syndrome, PLCs are
actually easier to troubleshoot than traditional hard-
wired control systems.
• Generally, greater percentage of faults( 80-90%) in PLC
controlled systems are likely to be with sensors,
actuators and wiring than within the PLC itself.
• Of the faults within the PLC, most faults are likely to be
in the input/output channels and the power supply than
in the Processor.
• Many PLCs provide built-in fault analysis procedures
which carry out self-testing and display fault codes with a
brief message which can be decoded in a trouble-shooting
guide
 PLC Power Supply
• Supply of power to the Processor and the
input/output modules at all times is a prime
necessity in the operation of a PLC system
• The POWER LED on the power supply unit
indicates that DC power is ON. This LED could
be OFF if
1.Fuse is blown
2. Voltage drops below the normal value
 Testing of inputs/outputs
Input devices ,e.g. Limit switches can be manipulated to
give the open and closed contact conditions and the
corresponding LED on the input module is observed. It
should be illuminated when the input is closed and
extinguished when open.

Failure of an LED to illuminate could be because of

a. The input device is not correctly operating

b. There are incorrect wiring to the input module

c. The input device is not correctly powered

d. LED or input module is defective

For Output devices that can be safely started, PBs might have
been installed so that each output can be checked.

Alternative method to test inputs and outputs is by

FORCING. Forcing involves software and used with keying in the
instructions from the programme console to turn on/off
inputs/outputs instead of mechanically manipulating them.

Forcing means inputs and outputs are turned on/off regardless

of the physical inputs or the program results. Forcing can make
programs perform erratically and is to be discouraged and used
only in extreme conditions. This method is used when PLCs are
put in MONITOR or TEST mode.
 In-built Fault techniques
a. Timing checks – A watchdog is used for a timing
check that is carried out by the PLC to check that some
function has been carried out within the normal time. If
the function is not carried out within the normal time,
then a fault is assumed to have occurred and the
watchdog timer trips setting off an alarm or closing down
the PLC. Alarm is set off if the function is not carried out
in the normal time.
b. Last output check – involves the use of status lamps
to indicate each output as it occurs. The program is
designed to turn off the previous status lamps and turn on
a new status lamp as each new output is turned on. The
program indicates at which point in the sequence the fault
has occurred.
c. Replication- The system repeats every
operation twice and if it gets the same
result, it is assumed that there is no fault.
d. Expected value checks – Software
errors can be detected by checking
whether an expected value is obtained
when a specific input occurs. If the
expected value is not obtained, then a
fault is assumed to be occurring
 Few common faults
Fault 1 - An output device failing to turn ON though the output LED
A. Check output voltage of PLC. If OK,
B. Check wiring between PLC and the output device. If OK,
C. Check the output device
Fault 2 – All the inputs are failing
A. Maybe the result of a short circuit. Check wiring for possible shorts
B. May be the result of a ground fault. Isolate inputs one by one to find the
defective input device/circuit and rectify.
Fault 3 – Entire system stops
A. Maybe a power failure
B. Someone e switching off inadvertently
C. A circuit breaker tripping
D. Reset system and restart
 Advantages of PLC
✓ Reliability
✓ Flexibility in programming and reprogramming
✓ Cost effective for controlling complex systems
✓ Small physical size, shorter project time
✓ High speed of operation
✓ Ability to communicate with computer systems in
the plant
✓ Ease of maintenance /troubleshooting
✓ Reduced space
✓ Energy saving
 Disadvantages of PLC
✓PLC devices are proprietary it means that part
or software of one manufacturer can’t be use
in combination with parts of another
manufacturer
✓Limited design and cost option
✓Fixed Circuit Operations
✓PLCs manufacturers offer only closed architectures
 DCS
• A distributive control system (DCS) is a network
based system
• Distributive control involves two or more PLCs
communicating with each other to accomplish
the complete control task, as illustrated in next
figure
• PLC controls different processes locally and the
PLCs are constantly exchanging information
through the communications link and reporting
on the status of the process
Distributive control system (DCS)
 Cont.
The main features of a distributive control system can be
summarized as follows
✓ Distributive control permits the distribution of the
processing tasks among several controllers
✓ Each PLC controls its associated machine or process
✓ High-speed communication among the computers is done
through CAT-5 or CAT-6 twisted pair wires, single coaxial
cables, fiber optics, or the Ethernet
✓ Distributive control drastically reduces field wiring and
heightens performance because it places the controller
and I/O close to the machine process being controlled
✓ Depending on the process, one PLC failure would not
necessarily halt the complete process
✓ DCS is supervised by a host computer that may perform
monitoring/supervising functions such as report
generation and storage of data.
 Components
✓ Sensors
• Provide inputs from the process and from the external
environment
• Convert physical information such as pressure, temperature,
flow rate, and position into electrical signals
✓ Human Machine Interface (HMI)
• Allows human inputs through various types of programmed
switches, controls, and keypads to set up the starting
conditions or alter the control of a process
✓ Signal Conditioning
• Involves converting input and output signals to a usable form
• May include signal-conditioning techniques such as
amplification, attenuation, filtering, scaling, A/D and D/A
converters
✓ Actuators
• Convert system output electrical signals into physical action
 Human machine interface (HMI)
• Human machine interface (HMI) equipment provides a
control and visualization interface between a human and a
process
• HMIs allow operators to control, monitor, diagnose, and
manage the application
• Depending on the requirements and complexity of the
process, the operator may be required to
✓ Stop and start the process
✓ Operate the controls and make the adjustments required for
the process and monitor its progress
✓ Detect abnormal situations and undertake corrective action
• Human machine interfaces give the ability to the operator
and to management to view the operation in real time
 HMI

HMI installed in an industrial environment

HMI
SCADA
 Cont.
• In some applications, in addition to its normal
control functions, the PLC is responsible for
collecting data, performing the necessary
processing, and structuring the data for
generating reports
• As an example, you could have a PLC count parts
and automatically send the data to a spreadsheet
on your desktop computer
• Data collection is simplified by using a SCADA
(supervisory control and data acquisition) system.
 Cont.
• The additional supervisory control output
capabilities allow you to tweak your processes
accurately for maximum efficiency
• In general, unlike distributive control systems, a
SCADA system usually refers to a system that
coordinates but does not control processes in real
time
• In a typical SCADA system, independent PLCs
perform I/O control functions on field devices
while being supervised by a SCADA/HMI software
package running on a host computer
• Process control operators monitor PLC operation
on the host computer and send control commands
to the PLCs if required.
 Cont.
• The great advantage of a SCADA system is that
data are stored automatically in a form that can
be retrieved for later analysis without error or
additional work
• An alarm is an announcement to the operator
initiated by a process variable passing defined
limit as it approaches an undesirable or unsafe
value
• The announcement includes audible sounds
visual indications, and messages.
 Cont.

Typical SCADA system