B010-PLC Basics

Learning Path and Time

This course is divided into the following three lessons:

Lesson 1: What are PLCs?

Lesson 2: Basic Configuration
Lesson 3: OMRON PLC family

Review questions will be presented after each lesson to help prepare you for the post-
assessment at the end of this course.So, have fun with the quizzes!

It will take about 50 minutes to navigate through this course prior to taking the post-assessment .

B010-PLC Basics

Learning Outcomes

Considering the information presented in this course and the available resource material, the learner
will correctly:

Choose the correct definition of PLC from three possible definitions.

Recognize programmable operation, as an advantage over hard wired sequential circuits.

Recall the configuration of PLCs consisting of Input Unit, Output Unit, and CPU.

Identify on a diagram, two kinds of memory blocks that are used internally in every PLC.

Select suitable PLC type from Compact or Modular if the necessary information is given to choose.

Definition
P Rogrammable L Ogic C Ontrollers, Or PLCs , Operate According To User-Programmed
Internal Logic.

Unlike Office Computers, PLCs Are Designed To Be Operated In Industrial Environments For
The Control And Operation Of Manufacturing Process Equipment And Machinery.

In The Figure Below, The PLC is located in the control panel. 

B010-PLC Basics
Invention

Until the mid-1970's, most machines were controlled by relays housed in large electrical panels.

The invention of a PLC originated from a comment by an US automobile manufacturer.

"We remake our equipment each time we introduce a new model. We want to decrease this work
and decrease costs."

It was too much work to hard-wire the logic In control panels and connect wires for the circuits of
relays and timers.The

result of competition between manufacturers was the invention of the first PLC in 1969.This PLC let
you easily make or change circuits functions.

Role

The PLCs react to changes in signals from sources such as push buttons, program execution, and
output signals to external loads such as indicators.The

operation of the loads can be easily created and changed by user program.

PLCs control the motor to carry food and dishes according to the input from push buttons or limit
switches detecting the upward or downward motion.

When the button is pushed by a cook, the elevator starts moving to the upper floor.

After the elevator arrives upstairs, the motor automatically stops.

When the button is pushed by a server, the elevator starts moving to the floor below.

After the lift arrives downstairs, the motor automatically stops.

Note: You need to use a contactor to switch a large load, such as a motor.

Advantage of PLCs -1
Why are PLCs used in so many places? There are many advantages of PLCs. Let's review

them.With PLCs, it is necessary to rewire devices to change operations of machines.

With PLCs, it is easy to change operations of machines only by editing the program.

Easy Change of Operations!

Advantage of PLCs-2

PLCs have many advantages over hard wired logic.

More flexibility and less chance of making wiring errors

Less time needed to perform changes in the logic

Less space is used on the production floor

More information is available to the operators for faster diagnosis

Faster reaction time to changing input conditions

System diagnostics, as well as, process or machine diagnostics, scheduling of preventative

maintenance.Example

: Identifying failure alarms or hardware failures; if a cylinder takes more than 5 seconds to retract,
then send a message to the operator to check for a leaking cylinder.

B010-PLC Basics

Advantage of PLCs -3

Current PLCs can perform:

 Network and field device communications

You can connect a PLC to other PLCs and computers to enable communications between
them.In a large factory, machines do not operate independently.Each process has one or more
PLCs which are linked with the PLCs for other processes.Communications are necessary to
monitor and control all processes from a remote computer.

 Fast and complex calculations

PLCs can process numeric data and do calculations, such as the addition and subtraction of
numbers.

 Complex motion control and high-speed counting

 Extensive HMI possibilities

 Programmable in a wide variety of languages ( Ladder, Structured text, SFC, FBD, IL )

Devices PLCs can control-1

 PLCs can control various devices.It is able to categorize the devices according to types of data
shown below. 

 -Digital-  The On or Off Data Example

1. Push Buttons

2. Limit switches

3. Photo Sensors

4. Proximity sensors

5. Relays

 Analog data examples

6. Measurement sensors

7. Thermocouples

8. AC Drive

 Pulse train examples

9. Encoders

10. Photo sensors

11. Servo motors

Devices PLCs can control-2

Let's look at the PLC is able to handle these three types of data. 
Overview
Let's think about why you can bring an umbrella on a rainy day.When

you look up into the sky ( eyes ), it is raining.You

recall an umbrella will prevent you from getting wet ( brain-memory )

.So you can judge logically "I must bring an umbrella when I see rain.", And instruct your muscles
to move your hands and legs in order to take the umbrella ( brain-execution ).

The mechanism of PLCs is similar to you.

 Instead of eyes , PLCs have Input Unit .
 Instead of brain , PLCs have CPU ..
 Instead of muscles , PLCs have Output Unit .

I / O address
Devices Connected To The The PLC Are Given A Specific Numeric Identifier. We Call It An I / O
( I Nput / O Utput) Address.
 The address is a unique number to identify I / O (Input / Output) devices.
 An address is composed of a word (CH = channel) address and a bit number in decimal
form.
 Each digital device which is connected to Input Units or Output Units is assigned a single
bit.
 The devices are allocated addresses depending on the terminal numbers in which inputs
and outputs are connected.
 The addresses where are generally used for I / O devices are called the "CIO (Core IO)"
area.

Digits Are Different Depending On The PLC Model. The CP1 And CJ2 Models Manage Devices
By Six-Digit Addresses.

For Example,
CIO 000000 Means Word (CH) 0000 Bit 00 .
CIO 010003 Means Word (CH) 0100 Bit 03 .

You Can Omit "0" In Higher-Digit Of Address, And Put The Dot Between CH And Bit Number To
Identify It Clearly.
For Example,
CIO 0.00 The Indicates Word (CH) 0000 Bit 00 .
CIO 100.03 Indicates Word (CH) 0100 Bit 03 .

CPU-I / O memory -1
The ON / OFF status of an input device is sent from the Input Unit to the CPU Unit.The CPU Unit
receives the information and stores it in the memory.This memory is called I / O memory .ON
status is handled as 1 in the I / O Memory . OFF Status Is Handled As 0 In The I / O Memory.

Please Click The Push Button In The Diagram, Then You Can Watch As The I / O Memory
Changes At The Input Address.

CPU-I / O memory -2
The smallest unit of memory is called a bit.There are 8 bits in one byte.Bit address starts from 00
to 15. Unifying 16 bits forms a word or channel address (CH) in a PLC memory.There you can
say 1 CH = Bit = 1 16 Word .

Programming Device
You use the Programming Device to enter and monitor the program.To access the Programming
Device, you would use our Support Software.CX

-Programmer:
The CX-Programmer is widely used for programming and monitoring of PLCs.CX

-One:
The CX- Programmer is included in the FA Integrated Tool Package, CX-One.The CX-One
strives to reduce user's total cost of ownership by providing a seamless environment to operate
the Support Software required for all processes, from FA system design to operation and
maintenance.
List of software included in CX-One.
 
B010-PLC Basics

CPU-User memory
The user program is stored in user memory of PLC's CPU unit.The microprocessor in the
CPU unit executes the program.Ladder diagrams are commonly used to create programs for
PLCs.

According to this ladder diagram, CIO 100.03 comes ON when CIO 0.00 turns ON. An END
instruction is always necessary at the end of the program.A 

ladder diagram is similar to a schematic for a set of relay circuits.

Power Supply
PLC's power supply gets the power from an external source and changes it to DC power for use
in the PLC

Summary
Input Unit
Monitors the change in status from an input device connected to the

PLC.Output Unit
Generates signals to be sent to an output device.CPU

Unit
Governs all PLC activities.The primary function is to examine the status of inputs, execute the
program, The CPU unit contains the memory used to hold user program and

data.Programming Device
Enter and monitor user program.Power

Supply
The power supply provides power to the CPU and the bus connection between each unit.
 Overall Operation -2

1. The CPU Unit executes the program step by step from the first list of the program to the
END instruction.According to the result, CPU stores 1 or 0 data in the appropriate I / O memory.
2. After executing the END instruction, the CPU Unit performs I / O refreshing where
exchanges data between the input / output units and the I / O memory of CPU unit.
3. The output devices will be activated or inactivated depending on the data and CPU will
accept the input data via Input Units.

And again, the CPU Unit executes program from the first list of program according to the status
of input updated.CPU unit repeats these actions cyclically at very fast rate.The

program in user memory is listed and executed in the mnemonic code order.The mnemonic A
ladder program is converted to mnemonic code automatically.You can make a ladder diagram
without thinking mnemonic.

Cyclic Operation
The following flowchart shows the overall operation of the CPU Unit.This cycle is executed
repeatedly.The time required for one cycle from Common Processing to Peripheral Servicing is
called the cycle time.

Startup Initialization
Initialize the hardware, check user memory.Common

Processing
Check the battery, and check the I / O bus and user program memory.Program
Execution
Execution of the user

program.I / O Refreshing
Exchange data between the Input / Output Units and the I / O memory of CPU Unit.

Peripheral Servicing
Execute any requests from the equipment attached to the peripheral and serial ports as well as
other services.

Cycle Time
If you connect a device whose signal is shorter than the cycle time of the PLC, there is a
possibility that the PLC cannot detect the

signal.There, if you need to detect short signal (pulse) , you use the special input function like
High -speed Counter Inputs.

B010-PLC Basics
Cycle Time
If you connect a device whose signal is shorter than the cycle time of the PLC, there is a
possibility that the PLC cannot detect the

signal.There, if you need to detect short signal (pulse) , you use the special input function like
High -speed Counter Inputs.

The cycle time is determined by such factors as CPU model, contents of user program, and
usage of special units, etc.

Classification
Hardware sections are integrated in Compact type or combined in Modular type.With Modular
PLCs, the user selects and mounts the required CPU unit, Input / Output Units.

Compact PLCs contain all section: power supply section, Input / Output Units, and a CPU unit in
one housing. They have small I / O capacity. (Less than about 60 points)

Modular PLCs to which required Units are mounted.The User can customize the configuration
of PLCs.Please click on the picture to see the combined figure of PLCs.

Compact type
Maximum I / O capacity of Compact PLCs is around 60points (36 Inputs, 24 outputs) .Up

to 15 words (CH) can be expanded when Expansion Units and Expansion I / O Units are
connected.

Modular type
Maximam I / O capacity of CS1 is 5120 points.Various types of high function units are
provided.Modular

PLCs have a wide range of functions, can be used as multi-application controllers.