Topic 2_2

PROGRAMMABLE LOGIC CONTROLLERS

Dr. Mahesh S. Narkhede

Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/
 COURSE OUTCOME

After studying this topic you will be able to

• Explain Block Diagram of PLC
• Explain SCAN cycle of PLC
• List remote digital and analog I/Os.
• Compare Relay based and PLC based control systems

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BLOCK DIAGRAM OF PLC

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 BLOCK DIAGRAM OF PLC

• A typical PLC can be divided into five components. These

components consist of the processor unit, memory,
power supply, input/output section (interface) and the
programming device. Some manufacturers refer to the
processor as a C.P.U. or central processing unit. The
components are shown in previous Fig.
• The power supply is required to convert 240 volts AC
voltage to the low voltage DC required for the logic
circuits of the processor and the internal circuits of the
input and output modules. DC power for the input and
output devices, if required is generally provided from a
separate source.
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 BLOCK DIAGRAM OF PLC

• The input module and output modules are referred to a

I/O section (I for input and O for output). The real word
input devices like push buttons, limit switches, analog
sensors are wired to input module and real word output
devices like contactors, solenoid valves indicator lights,
positioning valves etc., are wired to the output modules.
• Real word input and output devices are of two types:
discrete and analog. Discrete I/O devices are either ON
or OFF (open or closed), while analog devices have
infinite number of possible values.
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 BLOCK DIAGRAM OF PLC

• Examples of discrete input devices are pushbutton

and limit switch while analog input device are
temperature probes, Pressure transducers etc. which
gives varying voltage and current.
• The input from the analog input device is converted
by the analog module called Analog-to-Digital
Convener (ADC) into a proportional binary number
and stored in memory of the PLC for further use by
the processor
• Discrete output devices like contactors, solenoid
valve coils, indication lamps are either energised or
de-energized, but Analog output devices require
varying current or voltage to control the output.
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 BLOCK DIAGRAM OF PLC
• Example of analog output device is the positioning
valve, which gives variable opening of the valve
depending upon the variable voltages/current
applied to the valve which is obtained using the
Digital-to Analog Converter (DAC) as the output
module.
• The processor unit operates on low DC voltage of 5
volts. Input modules thus contains circuitry that
converts input voltages of 120-240 V AC or 0-24 DC,
etc., from discrete input devices to low level DC
voltage typically 5 V DC.
• Analog input modules converts the 4 -20 milli ampere
signals from sensors to low-level DC voltages for the
processor unit.
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 BLOCK DIAGRAM OF PLC

• Similarly, the output modules change low level DC

signals from the processor to 120-240 AC or low level
DC voltages or give output currents in range 4-20 milli
ampere.
• The programming device for a PLC can be a Hand-
held programmer, Dedicated programmer or Personal
computer. The program is entered using Relay Ladder
Logic, Statement Lists or Control System flow charts
but the most popular method of programming is the
Relay Ladder logic.

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CONTROL PANEL OF PLC

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 COMPONENTS OF PLC

Central Processing Unit (CPU)

Input Output Modules , Remote Input Output
Modules
Power Supply
Bus system

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 COMPONENTS OF PLC
Central Processing Unit
It is a micro-controller based circuitry. The CPU consists
of following blocks :
• Arithmetic Logic Unit (ALU),
• Program memory
• Process image memory (Internal memory of CPU)
• Internal timers and counters
• Flags
CPU performs the task necessary to fulfill the PLC
functions. These tasks include Scanning, I/O bus traffic
control, Program execution, Peripheral and External
device communication, special functions or data
handling execution and self diagnostics. 11
 COMPONENTS OF PLC
Input module
These modules act as interface between real-time status
of process variable and the CPU.
 Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
(mV)
Digital input module : Typical input to these modules is
24 V DC, 115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off
status 12
 COMPONENTS OF PLC
Output module
These modules act as link between the CPU and the
output devices in the field.
 Analog output module : Typical output from these
modules is 4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration
Digital output module : Typical output from these
modules is 24 V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump
valve on off control
Remote I/O module
These modules are attached to computers which are
connected to network 13
 COMPONENTS OF PLC
Power Supply
The power supply gives the voltage required for
electronics module (I/O Logic signals, CPU, memory
unit and peripheral devices) of the PLC from the line
supply.
The power supply provides isolation necessary to
protect the solid state devices from most high
voltage line spikes.
As I/O is expanded, some PLC may require additional
power supplies in order to maintain proper power
levels.
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 COMPONENTS OF PLC

Bus System
It is path for the transmission of the signal . Bus
system is responsible for the signal exchange
between processor and I/O modules
The bus system comprise of several single line i.e.
wires / tracks

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 PHYSICAL ADDRESSING IN PLC

• In PLC the inputs and outputs are hard wired.

• BIT – an address within the PLC. It can be of an hard
wired input/output or internal coil, among others.
• Hard wired means physical connection from real
world

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 PHYSICAL ADDRESSING IN PLC
• The address of a bit is:
• [type]:[word]/[bit]
• PLC uses the capital letter “I” to designate a
hardwired input & “O” for Output
• The typical address that references an output of a
PLC is O:0/0. i.e. (“O”: zero/zero)
• O:0/5 means that it is a physical output.
• O:0/5 means that it uses Slot 0
• O:0/5 means that it is the sixth output on the PLC.

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 PHYSICAL ADDRESSING IN PLC

• An address that describes an input is I:4/0.

• Similar to the output structure,
• I:4/0 means that it is a physical input.
• I:4/0 means that it uses Slot 4 (the 5th slot in the
rack).
• I:4/0 means that it is the first input on the card.

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 PHYSICAL ADDRESSING IN PLC
• Internal Coil is a programmable bit used to simulate a
relay within the PLC.
• The internal coil has no connection to the outside
world. It does not connect to an output card.
• Internal coils are used to store information.
• The “contacts” of this “relay” can then be used
multiple times in other parts of the program.
• The “B3” (binary) file is commonly used for all the
internal coils.
• B3:0/0 means that it references an internal Binary file
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 PHYSICAL ADDRESSING IN PLC

• B3:0/0 means that it uses the first word in the table

• B3:0/0 means that it is the first bit in the word.
• Note that, unlike the Output and Input files, you have
to use the file number in the address. In this case, the
default file number is 3.

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 MEMORY ORGANIZATION IN PLC
• Memory organization refers to how certain areas of
memory in a PLC are utilized.
• Physical addressing, discussed in a previous section,
is the ability to read data from a specific module
terminal or write information to a specific module
terminal.
• When information is read from a contact or input it is
stored in memory.
• A portion of memory, the input image map, is
designated to store this input information.
• Each input typically has, at a minimum, a single bit
designated to store its information. 21
 MEMORY ORGANIZATION IN PLC

Associating input and output data with its corresponding memory

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 MEMORY ORGANIZATION IN PLC

• Data resulting from logical analysis by the CPU is

stored in memory labeled as the output image map.
• From this point the information is transferred to a
designated output module and then to the particular
field device.

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 MEMORY ALLOCATION IN PLC
• Each segment is assigned a specific function or assists
in the performance of a function. For instance, the
Timer file stores all information related to any timer
utilized by the PLC. This includes status, control, and
bit information. Timer information will not be stored
in the counter file.
• When referencing timers and counters, each will be
identified as T4:0 and C5:0, respectively.
• The T4 corresponds to the file location.
• The 0 identifies the specific timer instance.

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MEMORY ALLOCATION IN PLC

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 SCAN CYCLE OF PLC
• The PLC’s CPU monitors the status of all inputs. It
takes these values and energizes or de-energizes the
outputs according to the ladder diagram/user
program. This is referred to as scanning.
• A scan does not consist of a PLC executing ladder
diagrams rung by rung.
• Instead the PLC performs an I/O and program scan.
• The I/O scan transfers data to and from the output
and input modules, respectively. The information is
transferred in the form of bits and stored in image
tables.
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 SCAN CYCLE OF PLC

• The image tables are blocks of memory designated to

store the input and output bit state.
• The input and output modules are the portion of the
PLC that interface with the outside world.
• The actual bridge between the physical world and the
internal world of the PLC is the optical isolation
circuitry.

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 SCAN CYCLE OF PLC

PLC scan cycle .(Simple Illustration)

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 SCAN CYCLE OF PLC
• The scan begins by transferring data from the output
image table to the output module. This is followed
by the PLC taking a snapshot of the current input
signals registered in the input module.
• This snapshot of data is transferred from the input
module to the input image table.
• The next phase is the program scan. The CPU utilizes
the snapshot of the input image table to perform a
logical evaluation via the ladder logic. Results of this
logical evaluation are written to the output image
map during the final step of the program scan cycle.
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 SCAN CYCLE OF PLC
• If a coil is true (active, high) a one is written to the
corresponding bit in the output image table,
otherwise a zero is written to the bit denoting the
contact as false (inactive, low).
• Therefore, the CPU bases its decisions on states of
the inputs prior to entering the program scan. If an
input is changed during the scan it will not register
until the next scan cycle. Completion of the program
scan ends a single scan cycle and then the process
begins again with the I/O scan.

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SCAN CYCLE OF PLC

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 SCAN CYCLE OF PLC

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 SCAN CYCLE OF PLC
Scanning Steps
• Transfer output map bits to the output module (I/O scan)
• Input module signals are frozen i.e. snapshot is taken (I/O
scan)
• Transfer input module bits to the input image map (I/O
scan)
• CPU reads all data bits currently in the input image map
(Program scan)
• CPU evaluates/performs ladder logic on current set of
data bits (Program scan)
• Results of evaluation transferred to the output image
map 33
 LIST OF REMOTE DIGITAL AND ANALOG I/OS

Types of I/O Modules

• Analog input and output
• Discrete input and output

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 LIST OF REMOTE DIGITAL AND ANALOG I/OS
Analog Inputs
• Typical analog signals come from temperature,
pressure, position, and motor speed.
• Analog input modules convert analog signals to digital
words.
• Typical Analog Inputs are
0 to 10 volts DC, -10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps , 0 to 20 milliamps,
-20 to +20 milliamps
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 LIST OF REMOTE DIGITAL AND ANALOG I/OS
Analog Output
• Typical Analog field devices are Variable Frequency
Drive (VFD), A Valve position actuator
• Typical Analog outputs are
0 to 10 volts DC
-10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps
0 to 20 milliamps
-20 to +20 milliamps 36
 LIST OF REMOTE DIGITAL AND ANALOG I/OS

Discrete Input
• Discrete or digital input signals are two-state signals:
Input ON or OFF, 1 or 0
• Start / Stop Push buttons

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 LIST OF REMOTE DIGITAL AND ANALOG I/OS
Discrete Output
• Motor starter coils
• Pilot lights
• Solenoids
• Alarms
• Valves
• Fans
• Control relays
• Horns
• Start / stop signals to variable speed drives 38
 LIST OF REMOTE DIGITAL AND ANALOG I/OS

Remote I/Os are connected via a network cable 39

COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS

Control Panel – Control Panel – PLC Based System

Relay Based System
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 COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS
• Relay logic is a hard wired control system using
instrumentation, switches, timers, relays, contactors,
motors and actuators. Automating a machine using
relay logic requires a mass of wiring and magnitude
of devices to perform even the simplest of tasks.
• Relay logic in a PLC is the method of formulating
logical expressions in order to automate machinery
and processes in industrial applications. The
programming language that is used to create relay
logic in a PLC is called Ladder Logic.

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 COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS

Some of the other problems with implementing relay

logic are:
• Requires a lot of switchboard space.
• Installation is very labour intensive.
• Trouble shooting is extremely difficult.
• Modifications to the control functionality are
complicated and seriously tedious.

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 COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS
Main advantages of a PLC over relays are:
• It is easier to develop complex logical expressions with
ladder logic software.
• PLC based systems are more reliable with long life
typically more than 10 years.
• It is easier and cheaper to modify or expand the control
system at a latter date.
• It has reduced design, installation and component costs.

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 COMPARISON BETWEEN PLC BASED AND RELAY
BASED SYSTEMS

• These systems are virtually maintenance free compared

to relays.
• They have superior monitoring and reporting
functionality making process trouble shooting and
optimization easier.

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 HAPPY LEARNING!
Dr.Mahesh S. Narkhede
Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/ 45