Automation

Addis Ababa Science and Technology University
Programmable Logic Control (PLC)
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Programmable Logic Control (PLCs)
1 Introduction to Relay control system
2 Programmable Logic Control (PLC)
PLC components
PLC Programming Languages
Elements of Ladder Diagram
3 PLC Digital Programming
Timers/Counters
Ladder Diagram (LAD) Programming
4 PLC Analog Programming
Conversion Operation
PLC Compare Instruction
5 Technical Specification
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Introduction to Relay control system
Relay/Hard wired control systems
Relay controlled systems are hard-wired control system because

They are difficult to modify when production requirement
changes regularly. Any modification in control program
involves rewiring of the circuit
They are difficult to maintain because any small problem in
design could be a major problem in terms of tracing and
rewiring
Relays are used in hard wired control systems. For example: In
Electrical control, the wiring of control elements such as sensors,
solenoids, counters etc. are through relays control.
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Introduction to Relay control system
Hard wired control systems consists of 3-parts
Input section: Consists of push buttons, switches and

sensors. They transfer signals to the processing section
Processing section: Consists of relay coils and contacts.
They determined the relationship between the inputs received
and outputs required
Output section: Consists of solenoids, lamps, and contactor
coils etc. The processed signals are transferred to this section.
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PLC is a user friendly device designed to control the operation of

industrial equipment and processes.
PLC is one of industrial automation device designed to replace relay

logic boards (high costs and inflexible) which accepts input from a
series of sensors and sends output to actuators.
Although relays are used for control logic, they are still essential for
switching large power loads.
There are input and output ”relays” (implemented by transistors

rather than actual relays) that send and receive information from
the outside world. The outputs are set according to the inputs.
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PLC Circuits
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PLC
It is a special form of microprocessor-based controller that uses pro-
grammable memory to store instructions and to implement functions
such as logic, sequencing, timing, counting, and arithmetic in order
to control machines and processes
PLC is designed for multiple inputs and outputs arrangements, so It

can get the data from the sensors, and command the actuators.
Areas of applications
Manufacturing / Machining
Food / Beverage
Mining
Petrochemical / Chemical
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Advantages of PLCs
Wiring between input and output devices are done in the PLC
program, because relays lack flexibility
Troubleshooting aids make programming easier and faster to
make changes
Reliable components of PLC makes these to operate for years
before failure, because PLC’s are rugged and designed to
withstand vibrations, temperature , humidity and noise
Various PLC vendors exist:

Siemens
Rockwell
Mitsubishi
Schneider
Omron
Allen-Bradley
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Comparison between Relay and PLC
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PLC components
PLC Basic Components

PLC is essentially a microcomputer, tailored specifically for certain
control tasks.
Hardware: consists of the actual device technology, i.e. the
PCBs, integrated modules, wires, battery housing etc.
Firmware: is the software part stored in ROM, known as
executive software, that is permanently installed and supplied
by the PLC manufacturer. The internal program provided by
the manufacturer executes the user’s program. The executive
software determines
what functions are available to the user’s program
how the program is solved
how the I/O is serviced, what the PLC does during power up
and down and fault conditions
Software: is the user program which is stored in the RAM.
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PLC components
PLC Hardware Components
The major hardware compo-

nents are
1 Power Supply module
2 Input module
3 Central processing unit
4 Output modules
5 Programming Section
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PLC components
Power Supply Module

Usually input output modules require 24V DC and processor
require 5V DC. Usually power supply is integral part of PLC.
Power supply units convert 120/230 V AC line voltage to
standard supply of 24 VDC or 5V DC using standard rectifier
circuits
Input Module
Input devices include sensors, switches and push bottons. The
function of the input module is to covert high voltages from
input devices to low level logic voltages that the CPU uses
internally for processing
Input module can process both analog input and digital input. Ana-
log input module is used to convert analog signal form analog de-
vices like temperature sensors, pressure sensors etc. to digital signals
using ADC (Analog to digital convertor).
Analog signal is varying voltage in the range of 0-10 V or current in

the range of 4-20 mA. These values of current or voltage is converted
into integer value (say 16 bit word) 12 / 63
PLC components
Digital input module is used to convert digital (24V/0V) input

to 5V/0V digital signals that CPU uses internally to execute a user
program.
Central Pocessing Unit
CPU controls and processes all operations within the PLC. The
CPU can perform various arithmetic and data manipulation
function with the local and remotely located Input/output
sections. It also perform many communication functions with a
personal computer and other PLCs
Output Modules
Output devices are actuators such as relay, solenoid coils,
lamps and motors. Output module amplifies the low level logic
signals generated by the CPU and pass these modified signals
to the final control elements to operate the output devices.
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PLC components
Connection of input-output devices with PLC
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PLC components
Circuit of Input module

It converts a high voltage signal to the 5V dc logic levels used on
the data bus. Basically the circuits condition the input to drive an
optocoupler. This electrically isolates the external electrical circuitry
from the internal circuitry. Other circuit components are used to
guard against excess or reversed voltage polarity.
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PLC components
Circuit of Output module

It must convert the 5Vdc logic levels on the PLC data bus to external
voltage levels. Basically the circuits use an optocoupler to switch
external circuitry. This electrically isolates the external electrical
circuitry from the internal circuitry. Other circuit components are
used to guard against excess or reversed voltage polarity.
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EN 61131-3 defines five PLC programming languages

Ladder Diagram (LD): graphic language derived from circuit
diagram of directly wired relay controls.
Function Block Diagram (FBD): functions and function blocks
are represented graphically and interconnected into networks.
Instruction List (IL): textual assembler-type language
consisting of an operator and an operand.
Structured Text (ST): high level language based on Pascal.
Sequential Function Chart (SFC): a language resource for the
structuring of sequence-oriented control programs.
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Examples
LD: Ladder Diagram
FBD: Function Block Diagram
ST: Structured Text

Sleeve-in : = (Part-TypeA OR Part-TypeB) AND Part-present
AND Drill-ok;
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IL: Instruction List:

LD Part-TypeA
OR Part-TypeB
AND Part-present
AND Drill-ok
ST Sleeve-in
SFC: Sequential Function Chart
Instruction List (IL) Mnemonics
IL Codes used differ to some extent from manufacturer to

manufacturer, and IEC 1131-3 is the proposed standard to unify IL
codes.
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There are five program elements/operations commonly used in PLC
ladder diagram
Bit logic operations

Timer Operations
Counter operations
Comparison operations
Conversion operations
Bit logic operation is for digital programming, where Comparison

and Conversions are used for analog programming. But we can use
timing and counting operations for both digital and analog program-
ming.
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PLC Digital Programming
PlC Digital Programming

Bit logic operation: Some important programming elements for
bit logic operations are
NO contact
NC contact
Coil
Each of these elements can be selected from the program window.
NO and NC elements should not be confused with the hardware NO
and NC contacts of switching devices.
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NO Contact of PLC
The NO contact scans for the signal state ON (1) at the specified
bit address.
Power flows through NO contact if the scanned bit address has a

signal state ON (1).
This contact is used for scanning the signal state of input devices
or output devices or other internal program elements such as timer
and counter.
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NO PLC contact position using NO push button
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NO PLC contact position using NC push button
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NC Contact of PLC
PLC NC contact scans for the signal state OFF (0) at the specified
bit address.
Power flows through NC contact if the scanned bit address has a

signal state OFF (0).
NC contact is used for scanning the signal state of input devices or

output devices or other internal program elements such as timer and
counter.
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NC PLC contact position using NO push button
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NC PLC contact position using NC push button
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Latch Circuit
Coil Sets a bit when the rung is true(1) and resets the bit when the
rung is false (0)
After being energized,
latch circuit
maintains that state.
If power fails, latch
rung will be
de-energized. When
power is restored,
machine will not
automatically
restarted, it can be
manually restarted by
pressing START
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Timers/Counters
Timers/Counters
Timers/counters instructions results in internal outputs (in the form

of software modules) that provides the same functions as hardware
timers/counters.
These are used to activate or deactivate a device after an expired

intervals/counts.
Both of these require an accumulator to store the elapsed count/time

and a register to store the preset value.
Timers can be linked together, the term is cascade, to give larger

delay times than is possible with just one timer.
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Timers/Counters
PLC Timers
Timer instructions used to create programmed time delays an output

for a certain time or wait a certain time before operating an output.
The number of timers that you can use in your user program is
limited only by the amount of memory in the CPU.
Each timer uses a 16 byte IEC − Timer data type DB structure

to store timer data that is specified at the top of the box or coil
instruction.
There are many types of timers but the most common types are
PLC on delay timer
PLC off delay timer
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Timers/Counters
PLC on delay timer

The instruction Generate on-delay delays setting of the output Q by
the programmed duration PT.
The instruction is started when the result of logic operation (RLO)

at input IN changes from 0 to 1 (positive signal edge). The pro-
grammed time PT begins when the instruction starts.
When the duration PT expires, the output Q has the signal state
1. Output Q remains set as long as the start input is still 1. When
the signal state at the start input changes from 1 to 0, output Q is
reset.
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Timers/Counters
The timer function is started again when a new positive signal edge
is detected at the start input.
The current time value can be queried at the ET output. The time
value starts at T #0s and ends when the value of duration PT is
reached. The ET output is reset as soon as the signal state at the
IN input changes to 0.
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Timers/Counters
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Timers/Counters
PLC off delay timer
The instruction Generate off-delay delays resetting of the output Q

by the programmed duration PT. The Q output is set when the
result of logic operation (RLO) at input IN changes from 0 to 1
(positive signal edge).
When the signal state at input IN returns back to 0, PT starts.

Output Q remains set as long as the duration PT is running. When
duration PT expires, the Q output is reset.
If the signal state at the IN input changes to 1 before the duration

PT expires, the time is reset. The signal state at the output Q will
continue to be 1. The current time value can be queried at the ET
output.
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Timers/Counters
The time value starts at T #0s and ends when the value of dura-
tion PT is reached. When the duration PT expires, the ET output
remains set to the current value until input IN changes back to 1.
If input IN switches to 1 before the duration PT has expired, the

ET output is reset to the value T #0s.
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Timers/Counters
PLC Counters
Counters are used to detect pieces numbers and events. There are
two basic counter types a) Count Up (CTU) b) Count down (CTD)
Example: When the input to count up counter goes true the accu-
mulator value will increase by 1. If the accumulator value reaches
the preset value the counter bit will be set.
A count down counter will decrease the accumulator value until the
preset value is reached.
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Timers/Counters
Count Up
The CTU counter counts up by 1 when the value of parameter CU
changes from 0 to 1. The CTU timing diagram shows the operation
of unsigned integer count value (where PV = 3).
If the value of parameter CV (current count value) is greater
than or equal to the value of parameter PV (preset count
value), then the counter output parameter Q = 1.
If the value of the reset parameter R changes from 0 to 1,
then the current count value is reset to 0.
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Timers/Counters
Count Down
The CTD counter counts down by 1 when the value of parameter CD
changes from 0 to 1. The CTD timing diagram shows the operation
for an unsigned integer count value (where PV = 3).
If the value of parameter CV (current count value) is equal to
or less than 0, the counter output parameter Q = 1.
If the value of parameter LOAD changes from 0 to 1, the
value at parameter PV (preset value) is loaded to the counter
as the new CV (current count value).
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Timers/Counters
Procedure for programming
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LAD Programming
The ladder diagram provides graphic display of program flow and
strongly resembles to relay logic. It provide a method to symbolically
show how relay control schemes are implemented.
The ladder diagram consists of two vertical lines representing the

power rails, and circuits are connected as horizontal lines.
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PLC Ladder Programming Conventions
The vertical lines of the diagram represent the power rails

between which the circuits are constructed.
Each rung on the ladder defines one operation in the control
process.
A LAD is read from left to right and from top to bottom.
Each rung must start with an input/s and must end with at
least one output.
Electrical devices are shown in their normal conditions, e.g. a
normally closed switch is shown closed.
A device can appear in more than one rung of a ladder.
The inputs and outputs are all identified by their addresses,
the notation used depending on the PLC manufacturers.
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Rail, Rungs and Power flow in Ladder diagram
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Example1
Switching a lamp using push button using Omron PLC
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LAD for motor start-stop
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Example for OFF Delay Timer

Enabling the indicator to be ON immediately when switch pressed
and OFF after a 5 sec delay by the switch.
Number of PLC Inputs Required
X1 – Start Switch.
Number of PLC Outputs Required
Y1 – Output Indicator
Number of PLC Timer Required
T0 – 5 second Timer, 100 ms Time Base. (K50 Preset Value for
Timer)
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PLC Ladder Program Description
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Example for ON Delay Timer
Enabling the indicator to be ON after a 3 sec delay when switch

pressed and OFF immediately by the switch.
Timer)
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When X1 = ON, TMR instruction will be executed. Timer T1

will be ON and start counting for 3 sec. When T1 reaches its
set value, the NO (Normally Open) contact T1 will be
activated and indicator YI will be ON.
When X1 = OFF, TMR instruction will not be executed.
Timer T1 will be OFF and so will NO contact T1. Therefore,
the indicator Y1 will be OFF.
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Example for ON Delay and OFF Delay Timer

Enabling the indicator to be ON after a 5 sec delay and OFF after
a 3 sec delay by the switch.
Timer)
Timer)
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When X1 = ON, T0 will start counting for 5 sec. When T0
reaches its set value, the NO contact T0 will be ON while NC
contact T1 will remain OFF, which makes the indicator Y1 to
be ON and latched.
When X1 = OFF, T1 will start counting for 3 sec. When T1
reaches its set value, the NC contact T1 will be activated
while the NO contact T0 will remain OFF, which makes the
indicator Y1 to be OFF.
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Example
The process of making tea every day in the morning for seven days
(water in the tank is enough for 7 days) is given in the figure below
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Procedure
When pressing the start button, valve1 (V1) opens, so the water
pass through the valve to the heating tank.
When the water level reaches the float switch (FS), the valve should
close and heating must begin.
When the temperature reach the required level the thermostat dis-
connects the heater element E and opens valve2 (V2) for 10 seconds
then the alarm bell B is activated to show the sign that tea is ready.
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PLC Analog Programming

In contrast to binary signals that can assume only the two signal
states ”Voltage present +24V” and ”Voltage not present 0V”, ana-
log signals within a certain range can assume any number of values.
Some examples of analog variables in control engineering:

Temperature −50... + 150o C
Flow 0 ... 200l/min
Speed 500 ... 1500 r/min
Using a transducer, these variables are converted into electrical volt-
ages, currents or resistances.
For example: The speed range of 500 ... 1500 r/min can be con-
verted by means of a transducer into a voltage range of 0 ... +10V.
If a speed of 865 rpm is measured, the transducer would read out a
voltage of +3.65 V. 53 / 63
In order to process the signal, voltages, currents or resistances are

connected to an analog module to digitalizes the signal using ADC.
Therefor, 3.65V is stored in a series of binary digits as information.
The more binary digits are used for digital representation, the finer
is the resolution. with 1 bit, the range is divided into 2; 0...+5V
or +5V ... +10V. With 2 bits, the range can be divided into 4
individual ranges; i.e. 0 ... 2.5/2.5 ... 5/5 ... 7.5/7.5 ... 10V
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Data types processed by PLC
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Note: For analog value processing, the data types ’INT’ and ’REAL’
play an important part since entered analog values are present as
integers in the format ’INT’ and for accurate further processing,
only floating point numbers ’REAL’ can be used because of the
rounding off error in the case of ’INT’.
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This operation is very important for analog signals, such as temper-

ature and level signals processing
There are two basic conversion operations

Normalizing Instructions
Scaling Instructions
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Normalizing Instructions
If an analog input value is present as digitalized value, it usually
has to be normalized so that the numerical values correspond to
the physical values in the process. Likewise, the analog output to
the output word usually takes place only after the output value is
normalized.
Normalizes the parameter VALUE inside the value range specified

by the MIN and MAX parameters:
OUT = (VALUE − MIN)/(MAX − MIN)

Where (0 ≤ OUT ≤ 1.0)
Scaling Instructions
Scales the normalized real parameter VALUE where (0.0 ≤ VALUE ≤
1.0) in the data type and value range specified by the MIN and MAX
parameters: MIN ≤ OUT ≤ MAX
OUT = VALUE (MAX − MIN) + MIN
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Compares two values of the same data type. When the LAD contact
comparison is TRUE, then the contact is activated.
The SIMATIC S7-1200 compare instructions
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Example: normalizing and scaling an analog input value

An analog input from an analog signal module or signal board using
input in current is in the range 0 to 27648 for valid values. Suppose
an analog input represents a temperature range from -30 to 70 o C
where the 0 and 27648 represents -30 and 70.0 o C , respectively.
Normalize the input to a value between 0.0 and 1.0, and then scale it
between -30.0 and 70.0 o C . The resulting value is the temperature
represented by the analog input in o C :
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Example: normalizing and scaling an analog output value

An analog output to be set in an analog signal module or signal
board using output in current must be in the range 0 to 27648 for
valid values. Suppose an analog output represents a temperature
range from -30.0 to 70 o C where the 0 and 27648 represents -30.0
and 70.0, respectively.
Normalize the value in engineering units to a value between 0.0 and

1.0, and then scale it to the range of the analog output, 0 to 27648:
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Example of tank level control
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Technical Specification
Technical Specification Analog Input
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Addis Ababa Science and Technology University

Programmable Logic Control (PLC)

Relay/Hard wired control systems

Relay controlled systems are hard-wired control system because

Hard wired control systems consists of 3-parts

Input section: Consists of push buttons, switches and

Programmable Logic Control (PLC)

PLC is a user friendly device designed to control the operation of

PLC is one of industrial automation device designed to replace relay

There are input and output ”relays” (implemented by transistors

PLC is designed for multiple inputs and outputs arrangements, so It

Various PLC vendors exist:

Comparison between Relay and PLC

PLC Basic Components

PLC Hardware Components

The major hardware compo-

Power Supply Module

Analog signal is varying voltage in the range of 0-10 V or current in

Digital input module is used to convert digital (24V/0V) input

Connection of input-output devices with PLC

Circuit of Input module

Circuit of Output module

PLC Programming Languages

EN 61131-3 defines five PLC programming languages

FBD: Function Block Diagram

ST: Structured Text

IL: Instruction List:

IL Codes used differ to some extent from manufacturer to

Elements of Ladder Diagram

Bit logic operations

Bit logic operation is for digital programming, where Comparison

PlC Digital Programming

Power flows through NO contact if the scanned bit address has a

NO PLC contact position using NO push button

NO PLC contact position using NC push button

Power flows through NC contact if the scanned bit address has a

NC contact is used for scanning the signal state of input devices or

NC PLC contact position using NO push button

NC PLC contact position using NC push button

Timers/counters instructions results in internal outputs (in the form

These are used to activate or deactivate a device after an expired

Both of these require an accumulator to store the elapsed count/time

Timers can be linked together, the term is cascade, to give larger

Timer instructions used to create programmed time delays an output

Each timer uses a 16 byte IEC − Timer data type DB structure

PLC on delay timer

The instruction is started when the result of logic operation (RLO)

PLC off delay timer

The instruction Generate off-delay delays resetting of the output Q

When the signal state at input IN returns back to 0, PT starts.

If the signal state at the IN input changes to 1 before the duration

If input IN switches to 1 before the duration PT has expired, the

Procedure for programming

The ladder diagram consists of two vertical lines representing the

PLC Ladder Programming Conventions

The vertical lines of the diagram represent the power rails

Rail, Rungs and Power flow in Ladder diagram

LAD for motor start-stop

Example for OFF Delay Timer

PLC Ladder Program Description

Example for ON Delay Timer

Enabling the indicator to be ON after a 3 sec delay when switch

PLC Ladder Program Description

When X1 = ON, TMR instruction will be executed. Timer T1