BASIC PLC

Technical Support Group

Process Enhancement Products Corp.
 OBJECTIVES

Upon the completion of the training,

participants shall be able to:

understand the basic PLC concepts and

ideas
INTRODUCTION

identify the major components of a PLC,

its functions and performance
characteristics

design, test and troubleshoot a simple

application program
 PLC DEFINED

“ A digitally operating electronic system, designed for use in an

industrial environment, which uses a programmable memory for
PLC DEFINED

the internal storage of user-oriented instructions for

implementing specific functions such as logic, sequencing,
timing, counting and arithmetic, to control through digital or
analog inputs and outputs, various types of machines or
processes. Both the PLC and its peripherals are designed so
that they can be easily integrated into an industrial control
system and easily used in all their intended functions.”

- IEC 1131, Part1

 PLC DEFINED

DIGITAL APPARATUS

PROGRAMMABLE
MEMORY
PLC DEFINED

LOGIC
SEQUENCING
TIMING
ARITHMETIC

ANALOG OR DIGITAL I/O

MACHINE OR PROCESS
 PLC DEFINED

A PLC is therefore nothing more

PLC DEFINED

than a specialized computer,

designed to withstand the
harshness of industrial
environment and to perform a
specified task.
 Advantages of PLC

As it replaced conventional relays, customized

board controllers and computers, it has
achieved the end-user’s requirements:

• Flexibility and Functionalities

• Simple programming, modification and
PLC DEFINED

troubleshooting
• Requires minimal panel space
• Safer Pilot Running
• Visualization
• Easily Documented
• Security
 PLC TYPES

COMPACT (SHOE BOX)

• CPU, Power Supply,

I/O Modules in an
enclosure
PLC DEFINED

• maybe expandable
but only handles
limited I/O’s
 PLC TYPES

MODULAR
PLC DEFINED

• parts/functions are individually enclosed

and inter-connectible with each other
• can handle huge amount of I/O’s
 PLC TYPES

HYBRID
PLC DEFINED

• PLC is combined with Human

Machine Interface (HMI)
• Expandable
 TYPES OF PLC ACC. TO NO. OF I/O’S
HANDELD

PLC Sizes

Micro (up to 32 I/O)

PLC DEFINED

Small (up to 128 I/O)

Medium (64I/0 to 1024 I/O)

Large (512 I/0 to 4096 I/O)

Very Large (2048 I/O to 8192 I/O)
PLC
ARCHITECTURE
 PLC ARCHITECTURE

POWER SUPPLY

INPUT OUTPUT
MODULE MODULE

CPU
PLC ARCHITECTURE

PROGRAMMING
DEVICE

HUMAN
MACHINE INTERFACE

SERIAL DEVICES
 POWER SUPPLY

for ac compact types,

power is converted and
PLC ARCHITECTURE

regulated within the

same enclosure

for dc types and modular
types, an independent
power supply is needed
 INPUT\OUTPUT MODULES

Categorized according to its signal

associated with its application:
PLC ARCHITECTURE

Discrete

Analog

High Speed Pulse

Register (BCD)
PLC ARCHITECTURE
 DISCRETE INPUT
ELECTRO-MECHANICAL SWITCHES FIBER OPTIC
SENSORS LIMIT SWITCHES

PROXIMITY PHOTOELECTRIC LASER

PLC ARCHITECTURE

SENSORS SENSORS SENSORS

ON or OFF

LIGHT
CURTAINS
 ANALOG INPUT
RTD’s TACHOGENERATORS
THERMOCOUPLE

LOAD CELL PRESSURE SENSORS

PLC ARCHITECTURE

4-20 mA
1-5 Vdc
0-10 Vdc
-10 to +10 Vdc
PLC ARCHITECTURE PULSED INPUT

High Speed Pulse

RELATIVE ROTARY
ENCODER
 REGISTERS (BCD) INPUT

THUMBWHEEL
SWITCH

ABSOLUTE ROTARY
ENCODER
PLC ARCHITECTURE

BCD, GRAY CODE

 INPUT MODULE

INPUT INTERNAL CIRCUIT

PLC ARCHITECTURE
 INPUT MODULE
INPUT INTERNAL CIRCUIT
PLC ARCHITECTURE
 DISCRETE OUTPUT

ON or OFF
PLC ARCHITECTURE

LAMPS RELAY
COILS CONTACTOR
COILS
SOLENOID
VALVES
SSR
 ANALOG OUTPUT

4-20 mA
1-5 Vdc
0-10 Vdc
-10 to +10 Vdc
PLC ARCHITECTURE

VARIABLE
VARIABLE
VALVE
VALVE POSITIONER
POSITIONER FREQUENCY PANEL METERS
FREQUENCY DRIVE
DRIVE
(ANALOG
(ANALOG INPUT)
INPUT)
 PULSED OUTPUT

High Speed Pulse

PLC ARCHITECTURE

STEPPER MOTORS ROBOCYLINDERS

PLC ARCHITECTURE REGISTER (BCD) OUTPUT

BCD
 OUTPUT MODULE

TRANSISTORIZED OUTPUT
PLC ARCHITECTURE
 OUTPUT MODULE
TRANSISTORIZED OUTPUT
PLC ARCHITECTURE
 OUTPUT MODULE

TRANSISTORIZED OUTPUT
PLC ARCHITECTURE
 OUTPUT MODULE

RELAY OUPUT
PLC ARCHITECTURE
 OUTPUT MODULE

RELAY OUPUT
PLC ARCHITECTURE
 Central Processing Unit

CPU contains:

• Microprocessor
RAM
KEYE
NCE
PLC ARCHITECTURE

FLA
S
KEH ROM
YEN
• Memory System
CE

• supporting circuitry
PLC ARCHITECTURE MICROPROCESSOR

- controls the overall activities

of the PLC
- executes the program
- processes the I/O signals
- communicates with external devices
 MEMORY SYSTEM

PLC memory system is divided into:

SYSTEM
PLC ARCHITECTURE

MEMORY Operating System

APPLICATION
MEMORY User program and Data
Registers
 MEMORY SYSTEM

DOUBLE
MICROPROCESSOR
LAYER
CAPACITOR

RAM FLASH ROM

PLC ARCHITECTURE

INPUT REGISTERS

OUTPUT REGISTERS

TIMER/COUNTER VALUES

DATA MEMORY

FORCED VALUES

USER PROGRAM
 MEMORY SYSTEM

MICROPROCESSOR

RAM
PLC ARCHITECTURE

DATA
INPUT REGISTERS
WRITTEN
OUTPUT REGISTERS
IN RAM
TIMER/COUNTER VALUES

DATA MEMORY

FORCED VALUES

USER PROGRAM
 MEMORY SYSTEM
MICROPROCESSOR
DOUBLE MICROPROCESSOR
LAYER
CAPACITOR
VOLATILE

RAM
PLC ARCHITECTURE

INPUT REGISTERS
At power
interruptions,
OUTPUT REGISTERS
capacitor holds
TIMER/COUNTER VALUES the data at
DATA MEMORY RAM for 120
FORCED VALUES days at 25OC
operating
USER PROGRAM temp.
 MEMORY SYSTEM
MICROPROCESSOR
DOUBLE MICROPROCESSOR
LAYER
CAPACITOR

RAM FLASH ROM

PLC ARCHITECTURE

At save command,
data is copied to
the flash ROM
 MEMORY SYSTEM
MICROPROCESSOR
DOUBLE MICROPROCESSOR
LAYER
CAPACITOR

RAM FLASH ROM

PLC ARCHITECTURE

Flash ROM can retain

After power
data up to 10 years at
interruption, during
25OC operating temp.
startup, data is
and can be rewritten
reloaded to the RAM
up to 100,000 times
from the flash ROM
 INPUT SCAN

015 014 013 012 011 010 009 008 007 006 005 004 003 002 001 000
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 200
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

INPUT REGISTER
 INPUT SCAN

015 014 013 012 011 010 009 008 007 006 005 004 003 002 001 000
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 200
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

INPUT REGISTER
 INPUT SCAN
015 014 013 012 011 010 009 008 007 006 005 004 003 002 001 000
0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1
115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 200
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

INPUT REGISTER
 INPUT SCAN
015 014 013 012 011 010 009 008 007 006 005 004 003 002 001 000
0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1
115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 200
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
315 314 313 312 311 310 309 308 307 306 305 304 303 302 301 300
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

INPUT REGISTER
 OUTPUT PROCESSING

515 014 513 012 511 510 509 508 507 506 505 504 503 502 501 500
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
615 614 613 612 611 610 609 608 607 606 605 604 603 602 601 600
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
715 714 713 712 711 710 709 708 707 706 705 704 703 702 701 700
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
815 814 813 812 811 810 809 808 807 806 805 804 803 802 801 800
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
915 914 913 912 911 910 909 908 907 906 905 404 903 902 901 900
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

OUTPUT REGISTER

PS
 OUTPUT PROCESSING

515 014 513 012 511 510 509 508 507 506 505 504 503 502 501 500
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
605 604 603 602 601 600 609 608 607 606 605 604 603 602 601 600
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
715 714 713 712 711 710 709 708 707 706 705 704 703 702 701 700
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
805 804 803 802 801 800 809 808 807 806 805 804 803 802 801 800
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
915 914 913 912 911 910 909 908 907 906 905 404 903 902 901 900
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

OUTPUT REGISTER

PS
 OUTPUT PROCESSING

515 014 513 012 511 510 509 508 507 506 505 504 503 502 501 500
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1
605 604 603 602 601 600 609 608 607 606 605 604 603 602 601 600
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
715 714 713 712 711 710 709 708 707 706 705 704 703 702 701 700
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
805 804 803 802 801 800 809 808 807 806 805 804 803 802 801 800
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
915 914 913 912 911 910 909 908 907 906 905 404 903 902 901 900
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

OUTPUT REGISTER

PS
 OUTPUT PROCESSING

515 014 513 012 511 510 509 508 507 506 505 504 503 502 501 500
0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1
605 604 603 602 601 600 609 608 607 606 605 604 603 602 601 600
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
715 714 713 712 711 710 709 708 707 706 705 704 703 702 701 700
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
805 804 803 802 801 800 809 808 807 806 805 804 803 802 801 800
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
915 914 913 912 911 910 909 908 907 906 905 404 903 902 901 900
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
PLC ARCHITECTURE

OUTPUT REGISTER

PS
 OUTPUT PROCESSING

515 014 513 012 511 510 509 508 507 506 505 504 503 502 501 500
0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1
605 604 603 602 601 600 609 608 607 606 605 604 603 602 601 600
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
715 714 713 712 711 710 709 708 707 706 705 704 703 702 701 700
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
805 804 803 802 801 800 809 808 807 806 805 804 803 802 801 800
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
915 914 913 912 911 910 909 908 907 906 905 404 903 902 901 900
PLC ARCHITECTURE

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

OUTPUT REGISTER

PS
PLC OPERATION
 PLC OPERATION
START
Housekeeping Input Scan
Internal checks on The status of
memory, speed RE external inputs
A D
and operation.
I FY (terminal block
Service any
E R voltage) is
communication V written to the
requests, etc. Input Table
PLC OPERATION

SCAN CYCLE

E
UT
W

EC
RI

EX
TE

Output Scan
The Output Table data is
transferred to the external
output circuits, turning the
output devices ON or OFF.
Program Scan
Each ladder rung is scanned
using the data in the Input file.
The resulting status (Logic
being solved) is written to the
Output file (“Output Image”).
 PLC OPERATION

PROGRAM DOWNLOAD

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

Microprocessor

Power
Supply AC
 PLC OPERATION
READ INPUT
STATUS RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
EXECUTE RUN MODE
PROGRAM

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
WRITE
OUTPUT RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 0 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION

RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 0 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION
RUN MODE

INPUT REGISTER USER PROGRAM

000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 1 0 0 0 0 0
PLC OPERATION

MicroProcessor

Power
Supply AC
 PLC OPERATION

RUN MODE

USER PROGRAM
000 001 002 500 OUTPUT REGISTER
005 004 003 002 001 000 503 502 501 500
0 0 0 1 1 1 0 0 0 0
1
PLC OPERATION

MicroProcessor

Power
Supply AC
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK: