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MODULE # 1
Introduction to Control System

1. Introduction:
In General, Control System is the collection of electronic devices and
equipments that provide the stability, accuracy and eliminate any unwanted
transition in the production or manufacturing process. In a complete control
system, the sensors/ input devices collects data and provide it to the processing
unit, the logical operations are performed by the processing unit and the outputs
like actuators, contactors, relays are controlled based on the decisions made by
the processor.
In the beginning of Industrial revolution, the automated machines were
controlled with the electromechanical relay logic, hardwired together in the
control panel, but there was too many and complicated wiring involved in these
complicated control system, which were called the Conventional Control Panel.
But with the advancement in technology, complicated control tasks are
accomplished with microprocessor based automated control system, such as
PLCs (Programmable Logic Controllers), SCADA (Supervisory Control And
Data Acquisition) and with Host Computer, etc. Besides connection with the
field devices such as operating panels, motors, sensors, switches, solenoid
valves and etc, as shown in fig 1.1, it has the capabilities in network
communications like data sharing. Every single component plays an important
role in control system regardless of their size. For example, without a switch or
a sensor, PLC would not know what is going on in the field process.

Fig 1.1 Input and Output field devices with PLC and Host computer
2. Programmable Logic Controller (PLC):

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Programmable Logic Controller (PLC). It was called Sequence Controller

before. It was named Programmable Logic Controller (PLC) by NEMA
(National Electrical Manufacture Association) in 1978 and is defined as
electronic equipment.
In automated system, PLC is the central part of the process control system. With
execution of a program stored in the program memory, PLC continuously
monitor the signal status from the input field devices and read the external input
signal and feedback signals from such as switches, sensors and keypad etc.
Based on the logic implemented in the program, using Microprocessor to
execute the calculations of logic, sequence, timer, counter and formula
according to the status and the value of the input devices. PLC will execute the
action with the output device, such as open or close of relay or solenoid, control
of AC or DC motors and other control equipments.
PLC may be used to control simple and repetitive tasks or may be used with the
other PLCs and host computers through a sort of communication network, in
order to integrate the control of complex process.
3. PLC Input Devices:
Intelligence of an automated system depends on the ability of a PLC controller
to read signal from different types of sensors and input devices (Real world).
Keyboards, pushbuttons and bi-function switches are used to operate a machine
manually. But on other hand, to detect colors, view a mechanism in motion,
check presence of objects and pressure or fluid level, you need specific
automatic devices such as proximity sensors, inductive sensors, limit switches,
photoelectric sensors, pressure and level sensors, etc.
Thus, input signals can be logical (ON/OFF) or analog signal. Smaller PLC
controllers usually have only digital inputs lines which operates on simply
ON/OFF logic while larger controllers also accepts analog inputs through
special analog I/P modules attached to controllers CPU unit. The analog I/P
module accepts 20mA ~ +20mA current signal or 10VDC ~ +10VDC voltage
signal generated by different sensors. These sensors are used for different
purposes in the Industries i.e., for measurement of pressure, temperature,
current etc.
4. Input Devices Function and their Interfacing:

Now lets see that how the input devices work and how we can connect it with
PLC Input module. Lets take a simple normally open type limit switch; its
function is to provide the close connection when the actuator is energized
mechanically. For example, if a trolley is running in Reverse/Forward direction
between some limits. Then the limit switches can control it easily. If you place
one limit switch on the reverse limit location and another on the forward limit
location, then depending on your logic you can stop or REV/FWD the trolley

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motor. Usually there are two contacts on the every limit switch, i.e. NC
(Normally Close) and NO (Normally Open), which we will discuss later. If we
are using the Normally Open contacts of limit switch then whenever the trolley
touch the limit switch, the NO contact will close/ complete the circuit. When the
NO contact closes then alternately the NC contact will open.
Similarly all the sensors, which work on the ON/OFF logic, have the NO/NC or
both contacts and they operate on actuation mechanical/ electrical etc
For input devices interfacing, connect Positive terminal of the power supply
with common point S/S in our case on the PLC input module and connect the
Negative terminal of the power supply with the input device NO contact of
the push button point and other point of the NO contact of push button with
the input point of the PLC input module X0 in our case as shown in the Fig.1-
2. Kindly note that the connections can be used in reverse logic as the PLC
input can be configured for both logics, however care must be taken when using
NPN or PNP type sensors, in that case appropriate connections shall be made.

Fig 1-2 Connection of Limit Switch as an External Input Device with PLC
5. PLC Output Devices:

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Automated systems are not complete if it is not connected with some output
devices. Output devices are used for the control of field devices. PLC output
can be digital signals (ON/OFF) these output devices work like a switch. Some
of the most frequently used output devices are motors, relays, solenoid valves,
contactors, lamps, indicators, buzzers and sound signalization etc. Some motors
can be directly controlled by connecting it to the PLC output modules like
servo, stepper motors or AC induction motors can be operated by using heavy-
duty relays and contactors or variable frequency drives (VFDs). Motors can be
used for motion control of machines, for example a conveyor belt can be easily
moved in Rev/Fwd direction with help of a motor. The flow of any liquid can be
easily controlled with control valves, etc.
PLC also have analog outputs can, analog outputs can give a current (0~20mA)
or voltage (0~10V) output signals which can be used to control valves, variable
frequency drives etc.

PLC Output Devices Function and Interfacing:

All the output devices, which are digital i.e. ON/OFF logic, can be directly
controlled from the PLC output module. For example, if we want to operate a
lamp directly from PLC output module. Then connect the one wire of lamp with
the Neutral (N) side of 220VAC Power Supply and the Live (L) wire of the
220VAC Power Supply with the common point (C0) of the PLC. So whenever
the PLC output point is high/ activated the lamp will start glowing as shown in
Fig.1-3. For high load currents interposing relays are required as shown in fig
(1-3)

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Fig 1-3 Connection of Light as an External Output Device with PLC

6. Conventional Control Panel:
At the time of Industrial Revolution i.e. sixties and seventies, relays, timers, and
counters were used to operate the automatic machines, and these were
interconnected using wires inside the control panel. So the control was
complicated and the control panel was too big and in some cases a control panel
covered an entire wall. The logic and wiring of such a control panel were also
complex and difficult. To discover an error or troubleshooting of the system
were also a time consuming tasks in more complicated control systems.
On top of everything, life of the relays contacts was limited, so relays had to be
replaced. If replacement is required, machines and production also had to be
stopped. Tracing of faulty relays were not too easy and it takes days and some
time weeks to troubleshoot the control panels. The control panel was used only
for one particular task and it wasnt easy to adapt to the requirement of a new
system. If a minor change were required then the whole control panel wiring
was disturbed. As far as maintenance is concerned, electricians had to be very
skillful in finding errors. In short, conventional control panels proved to be very
inflexible and complicated. Typical example of conventional control panel is
shown in the fig. 1-4 or can be seen in any old industrial control room.

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Fig. 1-4 Conventional Control Panel

Disadvantages of Conventional Control Panel:
Most frequently mentioned disadvantages of a classic conventional control
panel are:
Too much work is required in connecting wires.
Minor changes and replacements are difficult and time consuming.
Troubleshooting and finding errors are too difficult.
Require skillful technician for troubleshooting.
When troubleshooting is required, machines and production had to be
stopped, so the production losses increased.
Modification is also too difficult.
Power consumption can be too high.
Drawings are not updated for years due to continuous changes.
Cost of the conventional control panel is also high.
7. PLC Based Control Panel:
With invention of programmable controllers (PLC), much has changed in how a
process control system is designed. The control design and concept improve
tremendously. PLC based control system can be seen in any Modern Industries
as shown in the fig.1-5.

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Fig. 1-5 PLC based Control Panel

Some typical advantages of the PLC controller based control panel are:
Wiring of the control panel is greatly reduced by about 80% compared
to conventional control panel.
Power consumption is greatly reduced as PLC consumes much less
power.
PLC self-diagnostic functions enable easy and fast troubleshooting of
the control system.
Programming through the ladder logic software can easily do
modification of the control sequence or application without changing
any wiring, even if any new I/O devices are not added.
No spare parts are required for relays and timers etc as compared to
conventional control panel.
Machine function is improved and fast due to the speed of PLC, so
production is increased.
It cost much less compared to conventional system when the number of
I/Os is very large and control functions are complex.
The reliability of the PLC is higher than the conventional system.
The documentation of the PLC control system is easy and PLC program
can be printed in minutes and so can be easily maintained.

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