PL CL - Gen Z

PROGRAMMABLE
LOGIC
CONTROLLER
Prolific Systems and Technologies Pvt Ltd

History
 Early control systems consisted of huge control boards consisting of

hundreds to thousands of electromechanical relays.
 An engineer would design the system logic, electricians would receive

a schematic outline of logic then implement the logic with relays.
 The schematic was commonly called “Ladder Schematic”
 The ladder displayed all switches, sensors, motors, valves, relays etc in
the system.
 Problems: Long commissioning time, dependency on mechanical

reliance, Any system logic design change required the power to the
control board to be isolated stopping production.

History
 General Motors was among the first to recognize a need to replace

the systems “wired control board”
 Hydramatic Division of GM specified the design criteria for the

programmable controller in 1968.
 Goal – Eliminate the high cost associated with inflexible, relay

controlled systems.

History
New Controller Specifications:

 Solid State System
 Computer Flexibility
 Operate in Industrial Environment (vibrations, heat, dust etc.)
 Capability of being reprogrammed
 Easily programmed and maintained by electricians and
technicians.

History
 In 1969 Gould Modicon developed the first PLC.

 Strength – Programmed with Ladder Logic
 Initially called Programmable Controllers PC’s
 Now - PLC’s, Programmable Logic Controllers
 PLC’s have evolved from simple on/off control to being able to
communicate with other control systems, provide production
reports, schedule production, diagnose machine and process
faults.

Advantage of PLC Over Relay Style
RELAY PLC
1-Hard wiring 1-Less wiring
2-Changes difficult 2-Easy modification
3-More power 3-Low power
4-More maintenance 4-Less maintenance
5-Difficult to expand 5-Ease of expansion

Control Systems Types
 Programmable Logic Controllers

 Distributed Control System
 PC- Based Controls

NEMA Definition year 1978
National Electrical Manufacturers Association
The PLC, also known as programmable controller is defined by the

National Electrical Manufacturers Association (NEMA) in 1978 as:

"a digitally operating electronic apparatus which uses a programmable
memory for the internal storage of instructions for implementing
specific functions, such as logic, sequencing, timing, counting and
arithmetic, to control through digital or analog input/output, various
types of machines or process".

Programmable Logic Controllers
 Sequential logic solver

 PID Calculations.
 Advanced Subroutines
 BIT Operations.
 Data Transfer.
 Text Handling.

Applications :
 Machine controls, Packaging, Palletizing, Material handling, similar
Sequential task as well as Process control
Advantages of PLC :
 They are fast and designed for the rugged industrial environment.
 They are attractive on Cost-Per-Point Basis.
 These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)
 These Systems are upgraded to add more Intelligence and Capabilities
with dedicated PID and Ethernet Modules.
Disadvantages of PLC :
 PLC were Designed for Relay Logic Ladder and have Difficulty with
some Smart Devices.
 To maximize PLC performance and Flexibility, a number of Optional
Modules must be added
 PLC holds only one copy of program
PLC Types
 Nano (Small)
 Micro (Medium)
 Large
Basic criteria for PLC Types

 Memory Capacity
 I/O Range
 Packaging and Cost per Point

Sizing of PLC
Micro PLCs: I/O up to 32 points

Small PLC: I/O up to 128 points
Medium PLC: I/O up to 1024 points
Large PLC: I/O up to 4096 points
Very Large: I/O 4096 Onwards

Most Basic of PLC Systems
In the most basic of PLC systems, a self contained (shoe box) PLC has 2
terminal blocks, one for Inputs and one for Outputs
Today, most PLC’s in this category are know as Micros. Typically they
provide front panel LED status indication of I/O and Processor states
Outputs
Inputs
C
R

Modular Chassis Based PLC’s
The vast majority of PLC’s installed today are modular chassis based
systems consisting of:
1. Processor Module (CPU)
2. Input & Output Modules
3. Chassis
4. Power Supply

Modular Chassis-less PLC Systems
Also available from many vendors are “Chassis less” but still Modular
PLC systems. These systems still require a Processor, I/O Modules, and
Power Supply, but in place of a chassis these components mount
directly onto a panel, din rail, and many use a tongue and grove system
to allow easy insertion and removal

P L C Components
 Central Processing Unit (CPU)

 Input Output Modules
 Power Supply
 Bus system
 Programming Device IN CPU OUT m
MODULE MODULE
PROGRAM
DEVICE

Basic PLC Schematic
 CPU
 Power Supply
 Memory
 Input Blocks
 Output Blocks
 Communications
 Expansion Connections

P L C : Central Processing Unit
 It is a micro-controller based circuitary. The CPU consists of

following blocks :
Arithmatic Logic Unit (ALU), Timing / Control ckt, Program
memory, Process image memory (Internal memory of CPU)
Internal timers and counters and Flags, Address stack and
instruction registers
 The Central Processing Unit (CPU) Module is the brain of the

PLC.

Self Scan
CPU Module Check Inputs
PLC Program
SCAN
Update Execute
Outputs Code
 Primary role to read inputs, execute the control program, update

outputs.
 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.

Memory
 The memory includes pre-programmed ROM memory containing

the PLC’s operating system, driver programs and application
programs and the RAM memory.
 PLC manufacturer offer various types of retentive memory to save

user-programs and data while power is removed, so that the PLC
can resume execution of the user-written control program as soon as
power is restored.

Memory
 Many PLCs also offer removable memory modules, which are plugged
into the CPU module.
 Memory can be classified into two basic categories: volatile and non-
volatile.
Volatile memory loses state (the stored information) when
power is removed.
Nonvolatile memory, maintains the information in memory
even if the power is interrupted.

Memory
Some types of memory used in a PLC include:

 ROM (Read-Only Memory)
 RAM (Random Access Memory)
 PROM (Programmable Read-Only Memory)
 EPROM (Erasable Programmable Read-Only Memory)
 EEPROM (Electronically Erasable Programmable Read-Only
Memory)
 FLASH Memory
 Compact Flash – Can store complete program information, read &
write text files

I/O Modules
 Input and output (I/O) modules connect the PLC to sensors and
actuators.
 Provide isolation for the low-voltage, low-current signals that the PLC
uses internally from the higher-power electrical circuits required by
most sensors and actuators.
 Wide range of I/O modules available including: digital (logical) I/O

modules and Analog (continuous) I/O modules.

PLC : Input module
 These modules act as link between field input sensors and the CPU.
 Analog input module : Typical input to these modules is 4-20 mA,
0-10 V, Ohms, mV
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

PLC : Input module
 Transfer of data:-I/P sensor to CPU

 Conversion:- 24vdc/230vac to 5vdc
 Isolation :- By Opto Coupler

Input Devices
 Pushbuttons
 Selector Switches
 Limit Switches
 Level Switches
 Photoelectric Sensors
 Proximity Sensors
 Motor Starter Contacts
 Relay Contacts
 Thumbwheel Switches

Digital Inputs Modules
The list below shows typical ranges for input voltages.

 5 Vdc – used when Microcontroller based sensors are used as I/P
 12 Vdc Now not much used
 24 Vdc – Widely used (Standard for I/P)
 48 Vdc - Was used high power devices pneumatic / hydraulic cylendors /
limit switches
 12 Vac not being used
 24 Vac discontinued
 120 Vac Sensors are at long distance from controller
 240 Vac – Not much used

SOURCING vs. SINKING DC Inputs
SINK SOURCE
+VDC
Field VDC
Device IN1 + IN1
DC DC
+ DC Power
DC Supply Field Input
Power Device Module
Input
Supply -
Module
- DC COM
C
IN1

Analogue Inputs/Outputs
 Analogue input cards convert continuous signals via a A/D

converter into discrete values for the PLC
 Analogue output cards convert digital values in then PLC to
continuous signals via a D/A converter.
 Resolution can be important in choosing an applicable card
 Example, for a temperature input of 0 to 100 degrees C
 For 8 bit resolution the value in the PLC is 0 to 255
 For 12.5 bit resolution the value in the PLC is 0 to 6000
Analogue Cards
 Typical Analogue Input  Analogue Output signals

signals are: control:
 Analogue Valves
 Flow sensors
 Actuators
 Humidity sensors  Chart Recorders
 Load Cells  Variable Speed Drives
 Potentiometers  Analogue Meters
 Pressure sensors
 Temperature sensors
 Typical Analogue Signal Levels
 4-20mA
 Vibration
 1-5 Vdc
 0-10 Vdc
 -10 – 10Vdc

PLC : Input module

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

PLC : Output module - Types
 Relay type -For AC or DC

 Transistor Type Logic(TTL) - For DC
 Triac (Triode AC) type - For AC
 Isolated common type -For different device

PLC : Output module

Output Devices
 Valves  Relays
 Motor Starters  120 VAC/VDC
 Solenoids  240 VAC
 Control Relays  24 VAC/VDC
 Alarms  Triac
 Lights  120/230 VAC
 Fans  Transistor MOSFET
 Horns  24 VDC

Relays
 The most important consideration when selecting relays, or relay

outputs on a PLC, is the rated current and voltage.
 For transistor outputs or higher density output cards relay terminal

blocks are available.
 Advantage of individual standard replaceable relays

I/O Specifications
 INPUT VOLTAGE – Magnitude and type of voltage

 ON-STATE INPUT VOLTAGE RANGE – voltage at which signal is
recognized
 Nominal current per input – Min. current to operate input circuit
 AMBIENT TEMP RATING – Max temp of surrounding the I/O
module
 INPUT DELAY – Time duration for input signal to be on before
known as valid input. ( 9-ms to 25ms)
 NOMINAL OUTPUT VOLTAGE – It is min and max o/p operating
voltage.e.g. Rated 120 v ac o/p ckt. Works in 92 to 138 v range.
 MAX O/P CURRENT RATING – Max current a single o/p or
module can safely carry under load
 OFF –STATELEAK CURRENT PER O/P – Max value of leak current
flows through the o/p in OFF position
 ELECTRICAL ISOLATION – Max volts between I/o and logic ckt.

P L C : 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.

P L C : 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 ie wires / tracks
 Types of Bus
Address bus - Location
Data
bus - Carries Data
Control
bus - Synchronization

Special Modules
 Fast Response (Interrupt)

 RF ID
 PID
 Voice
 Loop Controller
 Gas Flow Calculation
 BASIC Cards
 Weigh Cell
 RS232 Comm’s
 Hydraulic Servo
 Modbus ASCII/RTU
 ASCII
 Ethernet Comm’s
 Fuzzy Logic
 High Speed Counters
 Temperature Sensor
 Position Control Cards
 Temperature Control
 Peer to Peer Comm’s
 Heat/Cool Control
 Controller Link
 Field Bus Cards
 DH+
 DeviceNet, Profibus etc
 Modbus Plus
 Lonworks, BACNet

PLC Operating Cycle
START
Housekeeping Input Scan

Internal checks on The status of external inputs
memory, speed and (terminal block voltage) is written to
operation. Service any the Input image (“Input file”).
communication requests,
etc.
Output Scan Program Scan

The Output Image data is Each ladder rung is scanned using
transferred to the external the data in the Input file. The
output circuits, turning the resulting status (Logic being
output devices ON or OFF. solved) is written to the Output
file (“Output Image”).
This scan cycle can be interrupted if required using interrupts

PLC Signal Flow
Input Module Processor Memory Output Modules
Input Data Output

Image Table Image Table
I:0/6 O:0/7
I:0/6
O:0/7
I:1/4 O:1/5
Input Devices Output Devices

Ladder Program
I:0/6 O:0/7
I:1/4 O:1/5
I:1/4 O:1/5
Programming Terminal
PLC Architecture Evolution
 Mid - 1970s : Discrete Machine Control
Programming
Terminal
Connection is Point to Point
PLC
Programming Language :
- Relay ladder logic

I/O - Flexibility in altering
Control system operation

 Early - to - Mid 1980 : Discrete and Process Control
MS - DOS
Reasonable Computer
Running PLC
Programming Software
PLC
Programming Language :
- Ladder Program
- PID
I/O - Data Storage

 Late 1980’s to early 1990’s : Discrete and Process

Control Windows
PC running
PLC Programming Software
Connection in networked allowing
Multiple PLC
PLC PLC
PLC became a part of the

I/O developing enterprise resource
system
Today : Distributed I/O Modules

PL
C
Distributed I/O scanner
Data Communication Bus
Distributed I/O modules

Today : Hot Redundant System

Level of redundancy
Power Supply
CPU
I/O
Communication
TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
Remote I/O
Today : Ethernet Technology in PLCs
Workstation Workstation Workstation Workstation
Switched Hub
Controller
Controller
Controller Controller
Today : Wireless communication

PLC
Wireless Modem / GSM Communication
Remote
Platform
Wireless Modem / GSM Communication
PLC
HMI PC
Prolific Systems and Technologies Pvt
Display Ltd
Configuration of PLC : Modicon
Built in display for I/O Programming Terminal PC Connection

(in-rack, AS-i) and Diag
8 Analog Inputs 1
Analog Output
I/O Modules
Up/Down Fast
Counter
Up Counter TSX37-22
Unitelway Port for connection PCMCIA communications port

of up to 5 Slaves
PCMCIA memory expansion port

Configuration of PLC : Siemens
CPU
I/O Modules
External Power
Supply

Configuration of PLC : Allen Bradley
CPU
I/O Modules
Power Supply

Configuration of PLC : GE FANUC
I/O Modules Back plane
CPU

PLC Programming Standards
The open, manufacturer-independent programming

standard for automation is IEC 61131-3. You can thus choose what
configuration interface you wish to use when writing your
application :
 Ladder Diagram
 Statement List
 Instruction List
 Function Block Diagram
 Sequential Function Chart
 Structured Text

Scan Rate
 The completion of one cycle of the sequence is called-

SCAN
 Time required for one cycle is called SCAN TIME

Binary System
 BIT – Each digit of a binary number

 BYTE – Group of 8 bit
 WORD – Group of one or more byte
 LSB – Least significant bit or smallest
value 7 6 5 4 3 2 1 0
 MSB – Most significant bit or largest

value 8 BIT ( 1 BYTE )
MSB LSB
BYTE BYTE
16 BIT (1 WORD)
PLC : Terminology
 INPUT is referred by – I
 OUTPUT is referred by – Q / O
 TIMER is referred by – T
 FLAGS are referred by – M /B
 COUNTERS are referred by – C

PLC : Communication Protocol
It is a set of rules for data transmission when PLC is connected to

network
 RS-232 (Recommended standard)
 RS-485
 MPI(Multi point Interface)
 Profibus
 DH(Data Highway)
 Ethernet
 Controlnet
 Devicenet

Baud rate (Communication Speed)
It is rate of data transmission on network Unit is bits/second

Range:-
120 bits /sec
to
100 Mega bits per second

Selecting a PLC
 Number of logical inputs and outputs

 Memory
 Number of special I/O modules
 Expansion Capabilities
 Scan Time
 Communication
 Software
 Support
 Cost

Manufactures – Major Brands
 OMRON
 Allen Bradley
 Schneider
 GE Fanuc
 Siemens
 Automation Direct (Koyo)
 Toshiba
 Mitsubishi
 Hitachi
 Keyence
 VIPA

PLC Standardization
 IEC 61131
 Based on IEC 1131 (1992) standard, developed to be a
common and open framework for PLC architecture.
 IEC 61131-1 Overview
 IEC 61131-2 Requirements & Test Procedures
 IEC 61131-3 Data Types & Programming
 IEC 61131-4 User Guidelines
 IEC 61131-5 Communications
 IEC 61131-7 Fuzzy Control
 IEC 61131-7 Guidelines for the application and implementation
of programming languages

PLC Programming
 The purpose of a PLC Program is to control the state of PLC

outputs based on the current condition of PLC Inputs
 Different PLC’s support different languages, but the most

popular PLC language is know as “Ladder Logic”.
 PLC Ladder Logic purposely resembles Relay Logic

IEC 61131-3
 IL (Instruction List) – mnemonic programming

 LD (Ladder Diagram) – Relay logic
 ST (Structured Text) – A BASIC like programming language
 FDB (Functional Block Diagram) – Graphical dataflow
programming language
 SFC (Sequential Flow Chart) – Graphical method for structured
programs

Ladder Logic Concepts
Read / Conditional Write / Control
Instructions Instructions
Start (Rung #1) || ()
|| |/| ()
|| || |/| ()
|| |/| ()
||
End (Rung #5) || |/| ()

Ladder Logic Concepts
Read / Conditional Write / Control

Instructions Instructions
|/| || ()
True False False
No Logical Continuity
|/| |/| ()
True True True
Logical Continuity

Logical AND Construction
IF input 4 AND input 5 have power

THEN energize output 0
On
I/4 I/5 O/0
|| || ()
T T T
Logical Continuity

Logical OR Construction
IF input 4 OR input 5 have power

THEN energize output 0
T
I/4 O/0 On
|| ()
Logical Continuity
F I/5
||
F On
I/4 O/0
|| ()
Logical Continuity
T I/5
||
Typical Construction
I/4 I/0 I/1 I/9 I/10 O/0

|| |/| || || || ()
I/5 I/1 I/7 I/8
|| |/| |/| |/|
I/2 I/3
|| ||
I/11 I/1
|/| ||

Addressing Examples
L1 L2
PB1 LS1 PS2 SOL6 I/5 I/6 I/7 O/0
|| || || ()
DEVICE ADDRESS
HHP Logix
PB1 I/5 I:0/5
LS1 I/6 I:0/6
PS2 I/7 I:0/7
SOL6 O/0 O:0/0

Relay Logic to Ladder Logic
PB1 LS1 SOL2 I/4 I/6 O/0
|| || ()
I/7 I/5 B/0

LS1 PB2 CR3
|| || ()
LS3 I/8
||
B/0 O/1
I/9
CR3 LS4 M1 |/| || ()
|/|
INPUT Address Assignment:

PB1- I/4 PB2- I/5
LS1- I/6 LS2- I/7
LS3- I/8 LS4- I/9
OUTPUT Address Assignment:

SOL2- O/0 M1- O/1

Available Instructions
 Increment/Decrement
 Sequence  Conversion
 Input
 ASCII
 Output
 Number Systems
 Control
 Math
 Logic  Floating Point Math
 Timer and Counters  Statistics
 Comparison  Scaling
 Range Comparison  PID
 Data Movement  PID with Auto tune
 Data Shift  Clock / Date
 Step / Step Next  Block Processing
 Serial Communications  IF,THEN,ELSE,LOOP
 Text String Processing Table Processing
 File Manipulation  LIFO, FIFO

Few more Instructions
 SEQUENCERS
 SHIFT REGISTERS
 DATA HANDLING
 HIGH SPEED COUNTER
 SUBROUTINES

Thanks ….

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PROGRAMMABLE

Prolific Systems and Technologies Pvt Ltd

 Early control systems consisted of huge control boards consisting of

 An engineer would design the system logic, electricians would receive

 The schematic was commonly called “Ladder Schematic”

 Problems: Long commissioning time, dependency on mechanical

Prolific Systems and Technologies Pvt Ltd

 General Motors was among the first to recognize a need to replace

 Hydramatic Division of GM specified the design criteria for the

 Goal – Eliminate the high cost associated with inflexible, relay

Prolific Systems and Technologies Pvt Ltd

New Controller Specifications:

Prolific Systems and Technologies Pvt Ltd

 In 1969 Gould Modicon developed the first PLC.

Prolific Systems and Technologies Pvt Ltd

1-Hard wiring 1-Less wiring

2-Changes difficult 2-Easy modification

3-More power 3-Low power

4-More maintenance 4-Less maintenance

5-Difficult to expand 5-Ease of expansion

Prolific Systems and Technologies Pvt Ltd

 Programmable Logic Controllers

Prolific Systems and Technologies Pvt Ltd

The PLC, also known as programmable controller is defined by the

Prolific Systems and Technologies Pvt Ltd

 Sequential logic solver

Prolific Systems and Technologies Pvt Ltd

Basic criteria for PLC Types

Prolific Systems and Technologies Pvt Ltd

Micro PLCs: I/O up to 32 points

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

 Central Processing Unit (CPU)

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

 It is a micro-controller based circuitary. The CPU consists of

 The Central Processing Unit (CPU) Module is the brain of the

Prolific Systems and Technologies Pvt Ltd

 Primary role to read inputs, execute the control program, update

Prolific Systems and Technologies Pvt Ltd

 The memory includes pre-programmed ROM memory containing

 PLC manufacturer offer various types of retentive memory to save

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

Some types of memory used in a PLC include:

Prolific Systems and Technologies Pvt Ltd

 Wide range of I/O modules available including: digital (logical) I/O

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

 Transfer of data:-I/P sensor to CPU

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

The list below shows typical ranges for input voltages.

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

 Analogue input cards convert continuous signals via a A/D

 Typical Analogue Input  Analogue Output signals

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

Prolific Systems and Technologies Pvt Ltd

 Relay type -For AC or DC