Industrial Automation Lab

INTRODUCTION TO PLC
(PROGRAMMABLE LOGIC CONTROLLER)
What is a PLC?

A PLC :
 Is a digital computer used to automate electromechanical processes
in plants
 Is designed for multiple input and output arrangements so a user
can get the data from the sensors, work with it and command the
actuators
 Uses programmable memory to store instructions and functions
such as on/off control, timing, counting, data handling etc.
Advantages of PLCs

 MIMO (Multi input multi output)

 Faster response time
 Reduced hard wiring
 Increased reliability
 Built in timers and counters
 Hardware robust
 Simpler to program and
troubleshoot
Advantages contd.

• Various built-in communication ports

(RS-232, Ethernet, Wi-Fi etc.)

• Modular design (easy to repair and expand)

PLC brands and models

 Allen-Bradley
 SLC-500
 Micrologix 1000/1200/1500

 Controllogix

 PLC-5

 Siemens
 S7200

 Mitsubishi
In lab:
 Microllogix 1200 (14 inputs, 10 outputs, 256 timers, 256 counters)
 Programming software : RSLogix 500
Ways to program a PLC

 Ladder Logic
Suitable for user from electrical engineering industry

 Statement List
Suitable for user from the world of computer technology

 Functional Block Diagram

Suitable for user from the world of circuit engineering
Ladder Logic

Ladder Diagram:
 Is specialized schematics commonly used to document
industrial control logic systems
 Uses a specific set of various symbols
 Resembles a ladder
Vertical lines = Power rails
Horizontal lines = Rungs
Addressing

The memory space in a PLC can be divided into two broad

categories:-
 Program files: Areas of processor memory where ladder
program is stored
 Data files: Portions of the processor memory that stores
input and output status, processor status, the
status of various bits and numerical data
Data Files
Address Format

How would you write address for:

An input = An output =
A timer = A counter =
An internal relay =
Basic Instructions in RSLogix

1. Examine if closed (XIC)

 Normally open contact
 Used to determine if a bit is on
if the bit addressed is on (1), then the instruction is evaluated as TRUE
if the bit addressed is off (0), then the instruction is evaluated as FALSE

Instruction Symbol Usage in a rung

Contd.

2. Examine if open (XIO)

 Normally closed contact
 Used to determine if a bit is off
if the bit addressed is on (1), then the instruction is evaluated as FALSE
if the bit addressed is off (0), then the instruction is evaluated as TRUE

Instruction Symbol Usage in a rung

An XIO instruction inverts the state of bit it references!

Contd.

3. Output energize (OTE)

 Output coil
 Used in conjunction with XIC, XIO or any other input instruction
If the logic preceding the OTE instruction is true (1), the OTE instruction
will be energized

Instruction Symbol Usage in a rung

An OTE instruction can only be the last instruction on a rung!

Contd.

4. Output latch (OTL)

 The OTL instruction is used only to turn a bit on and latch it on

Instruction Symbol Usage in a rung

5. Output unlatch (OTU)
 The OTU instruction is used only to turn a bit off and latch it off

Instruction Symbol Usage in a rung

Contd.

6. Internal Utility Relays

 Programmable bit used to simulate a relay within the PLC
 No connection to an output card
 Can be used to store information.
 Can be used when more series contacts are required than
the rung allows etc.
Branches

 Branches can be inserted to create parallel combinations of various

elements.

 Multiple Series/Parallel Branches