Advanced Industrial Automation PLC

programming in simplest way with 110

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 Dedicated to my father ‘Shri Raj Kishore Singh’
You have always inspired me to keep moving and not to accept
defeat.
Topics Page
No.
Introduction to controllers 3
PLC history 4
PLC Vs Micro controller 5
PLC block diagram and explanation to each 7
important part
Types of PLC 8
Basics of PLC programming 10
Contact and Coil instruction 15
Truth table trick for basic programming 23
Latch 31
Flag 35
Timer 36
Easy method for programming 41
Important points for programming 49
PLC scan 59
Pulse 63
Counter 83
Set/ Reset 91
Digital inputs 129
Digital output 133
PLC wiring 135
Hydraulic and pneumatic system programming 151
Arithmetic operation 177
Compare instruction 179
Bit/ byte/ word concept of programming 185
Programming without output coil using variable 187
addresses
Move 188
Types of MOVE 194
Jump instruction 196
Master control 197
Subroutine 197
Mitsubishi 198
Time base of a timer 199
Allen Bradley 205
Siemens 207
Auto/ manual operation programming 212
HMI 216
SCADA 233
AC Drive/ VFD 247
Analog input output programming 265
Analog value scaling 271
PID 275
NO/ NC type of push button programming concept 297
Being an engineer or technician our major role in industry is to maintain the
system running without fail. If any machine gets shutdown, we need to
restart it in short time. In today’s industries where production rate and
product demand are very high, machine should not get shutdown. If it is
shutdown then it should be restarted very fast. Now our fist problem is that
from where to start finding the problem in the machine which is very large in
size and spread in large area. Actually, we have not to be worried about the
largeness of the machine as largeness is just a mechanical structure. Often,
we don’t get any problem in structure once machine running trail is checked
OK. So, we have not to be worried about the largeness of machine but we
have to concentrate on three parts i.e.
INPUT CONTROLLER OUTPUT
These three parts of machine are the important parts in terms of finding
problem. Most of time, machines are shutdown because of its input/ output
issues. We find issues in controllers rarely. Now we go to find problem
among inputs and we face another issue i.e., large number of inputs. It can
be 100 or 1000. You can imagine how difficult is it to find problem among
such large number of inputs and it will take time also to do shut
troubleshooting. The same problem we face among outputs. If we have
advanced controller with advance featured software, we can find problem in
5 to 10 minutes.
We shall have a discussion about controller. A controller monitors and
controls any machine system. Initially when industry started it was all manual
operation. Manual means a man was the controller.it was a man/ operator
who used to monitor the system and he/ she was taking decision of
operation too. This manual system was not accurate and was so time taking
system. Very first automatic controller came in industry was relay logic
controller.
It was a large complicated electrical electronics circuit full of many small and
big devices. The logic was designed through wires with the help of electrical
and electronic devices such as relay, contactor, hardware timer/ counter,
diode resistor, capacitor etc. it was complicated but automatic system. This
relay logic can be seen in some old industries. Railways also use relay logic
control. Now it is being replaced with advanced controller. It was a good
controller but obviously it has a lot some limitations. Once it was shutdown, it
was so difficult to find problem in that large complicated circuit as it was no
any monitoring system that time. Another issue was, once the circuit was
ready for one application, it was very difficult to modify that circuit for another
application. In fact, small modification was also difficult. You can see one
example of relay logic control in college machine lab. The motor is on and off
by two push buttons. Green and red coloured generally. Push button has
spring system inside it. When pushbutton is pressed, it conducts and supply
reaches to motor. When push button is released, due to spring, push button
gets off and signal does not pass through it but motor still runs. How? There
is no any microcontroller there you can see. It is continuously on because of
relay logic. Motor is latched by a relay.
Another very famous controller came was micro controller.
This is a very famous controller especially in academics. It is a very good
controller as it is very compact in size, very cheap in cost and the best part
programmable. If you are able to program your controller, you can make
modification in your existing system as per requirement. But still it is not used
in industries to control machines and this is the reality. Micro controller is a
very good controller but it has some limitations because of which it is not the
main controller in manufacturing industries.
The main controller to control machines in industry is PLC (Programmable
Logic Controller). It was originated in 1968 in automotive industry in USA
on the proposal request of GM Hydramatic (General Motors) for replacement
of relay logic control system. This proposal was written by Er. Edward R
Clark. The selected proposal came from Bedford from Bedford Associates.
First PLC ‘084’ was built in 1969. It was their 84th project so named it 084.
Bedford started a company dedicated to developing, manufacturing, selling
and servicing the new product MoDiCon (Modular Digital Controller). Dick
Morley, one of the people who worked on the project is considered father of
PLC. This brand MODICON was sold to GOULD Electronics in 1977 and
later to Schneider Electric, the current owner. The first model 084 is still with
Schneider which was presented by GM when the unit was retired after nearly
20 years of uninterrupted service. Modicon used ‘84’ moniker at the end of
its product range until the 984 made its appearance. In a parallel
development ODO Josef Struger is sometimes known as father of PLC. He
involved in the invention of Allen Bradley PLC during 1958 to 1960. He
invented the PLC acronym. Allen Bradley is now own by Rockwell
Automation. Struger played a leadership role in developing IEC61131-3 PLC
programming language standards.
In general PLC is an electronic digital device which takes input and
generates output as per logic developed. It is a digital device. Only digital
input/ outputs are directly connected to its I/O terminals. Analog I/Os are not
directly connected to PLC directly. ADC (analog to digital converter) and
DAC (digital to analog converter) are used to connect analog I/Os with PLC.
Some PLCs provide few analog I/O terminals on its main unit. In that case
ADC/ DAC are placed inside main module. In industry generally ADC/ DAC
is used separately because the number of analog I/Os will be more. PLC is
used to control machines in any kind of manufacturing industry such as
Automobile industries, Cement plants, Power plants, Oil & Gas plants, Food
processing industries, Chemical plants, Pharmaceutical industries, printing
and packaging industries etc.
Before we discuss the limitation of microcontroller, let me clarify that
advanced controllers also work on the working principle of microcontroller.
Advanced features of advanced controller were not added to microcontroller
but a new controller was introduced to sell at higher cost. Let us understand
the limitation of microcontroller because of which it is not used in today’s
industries.
Microcontroller PLC
Programming languages: It has 6 programming languages.
Its programming language is User can select language as per
based on C language. It is not comfort. Ladder diagram is the
that easy language to be learned easiest language. It can be
by all. understood very easily by
maximum learner. Ladder
diagram is preferred by
industries because
troubleshooting is very easy in it.
Download/ Upload timing: It takes fraction of second or a
It takes more time to send few seconds to send program to
program to controller. controller.
Program receive option: Existing program of PLC can be
It has no program receive option. received very easily even in
If you don’t have program running condition of machine. If
backup file then you cannot your program backup file is lost
recover program from controller. from your computer then you can
You will have to rewrite that logic receive program from PLC.
again. Without receiving existing
program of controller,
troubleshooting is also very
difficult as we won’t be able to
understand the machine
operation logic.
Monitor/ online mode: It has good monitor mode in its
Its software has no good monitor software which helps a lot in
mode to check running status of troubleshooting machines. If any
machine. Its monitor mode is not problem occurs in machine, we
that much helpful in follow few steps to reach to the
troubleshooting machine. exact issue.
Take laptop/ computer which
have that PLC software installed
in. connect PLC communication
 cable’s one end to PLC and
another to laptop/ computer.
Open the software. Set
communication and click receive/
upload/ read/ PLC to PC option
given in that software. The
existing program will be received
in that PLC software. Now go to
monitor/ online mode. You will be
able to monitor the running/
present status of addresses used
in that program. You can search
your output which is not working
as per sequence. You can easily
monitor that why the main supply
does not reach to that output.
You will easily reach to problem
within minutes. Without program
receive and monitor mode it is
very difficult to troubleshoot any
complicated system.

Online edit: Now PLC software has option to

Online option is latest and the rewrite modified ladder without
best option in automation stopping machine using online
software Many times it is not edit feature of software.
possible to stop machines to
avoid production lose but some
modifications are required for
efficiency. If you modify existing
program then you need to rewrite
it to PLC and it will stop machine.
Microcontroller has no online edit
option.
Handling: It is manufactured to work in
It is not that much robust. It has extreme conditions in industry. It
less I/Os and registers available. has large number of I/Os and
It has not that much life registers handling capacity. The
compared to PLC. first PLC ‘084’ was retired after
20 years of uninterrupted service

Usages:
Generally, it is used for small
applications or mostly in-home
appliances where it is replaced
with new one when out of order.
that too because that unit was
retired. PLC can work long life.
It is used to control small to big
machines in industries with a
large number of logic sequence.

PLC input output terminals are not directly connected to PLC CPU. Signal is
sent through light from terminal to CPU and from CPU to terminals through
Opt couplers that is why PLC CPU last long. If nay wrong connection is
made from field device then light is not going to harm CPU.

Let it be any brand or any type of PLC it has some essential components/
parts in it. Let us understand it using block diagram.
Power supply: To work on any electronic device we need to power it on.
PLC provides terminals to connect power cables to it. It is manufacturer
decided that you have to provide AC or DC power to PLC. If it is AC power
supply then directly L, N and earth terminals of PLC will be connected to the
socket. If it is DC power supply needed then it will be 24 V DC. An SMPS
(Switch Mode Power Supply) will be the power source and the PLC terminals
+ - will be connected to it.
Low voltage: This low voltage is for PLC’s internal use and we do not
provide it from outside but it is converted by PLC itself from its power supply.
This low voltage is 5 or 3.3 V DC in old and new PLC respectively. As PLC is
a digital device, its internal work takes place on 0/ 1. Old PLC had 5 V DC as
1 and new PLC has 3.3 V DC as 1. PLC also converts power supply into 24
V DC as low voltage for its I/O wiring purpose.
CPU: Central Processing Unit is the brain of PLC. It is a microprocessor
which monitors and controls the logic and communication execution.
Processor name is different in different brand of PLC. Z80, TSX, Dallas
8051, Powerpc, 6803 etc. are few processors used in different brand.
I/ O: input/ output in block diagram refer to input output terminals not the
physical I/ Os like push button, sensors, motor, relay etc. initially I/ Os we
had of three types named relay, transistor and triac but now we have only
two types Relay and Transistor. If you have a relay type PLC then you will
have all its I/ O terminal relay (initial two terminal can be transistor type in
some brands for high-speed signal use). If you have a transistor type PLC
then all its I/ Os will be transistor. As per our project requirement we select
Relay or Transistor type PLC. When we have high speed/ high frequency I/
O signal then we must select transistor type PLC because relay cannot read
or generate high frequency signal. Let us see which type of application can
have high speed/ frequency signal. In many applications we need to take
number of motor rotation feedback. For this proximity or photo sensor can be
arranged. It will give on signal per rotation but it will be very high speed/
frequency on of signal which cannot be read by a relay. The main device to
take rotation feedback of motor is encoder. For each rotation it generates
number of pulses. For example, it can give 36000 pulses per rotation. It
depends on manufacturer. By dividing it by 360 we calculate number of
pulses per degree of rotation if needed. 36000 pulses in one rotation is very
high speed signal and it can be read by transistor terminal. Now let us see
application where we need to generate high speed output signal. Whenever
we use stepper or servo motor in in our project, we need transistor type PLC
as number of pulses is required to run a stepper or a servo motor. A stepper
motor can require more than hundred pulses and a servo motor can require
more than lakh pulses for one rotation. Large number of pulses is required
for high precision work. More number of pulses, more angular division will be
possible.
Memory location: PLC has two memory locations, program and data
memory location. The memory location where program is saved is program
memory. Memory location where all addresses (addresses that we use in our
program) are pre located is data memory. It is EEPROM. PLC RAM and
EEPROM is battery backed.
Communication port: It is used to communicate PLC with other devices
such as laptop/ computer, HMI/ SCADA PC/ Drives etc. different
communication ports can be found on different PLC. On branded PLC you
can find RS 232, RS 422, RS 485 etc. you can have more than 1
communication port on one PLC but its cost will increase as number of
communication port increases.
Extension port: on maximum of PLC, you will find extension port to extend
its physical capacity. One small PLC CPU can control 100s of I/Os but on
main unit of PLC you will find limited I/O terminals. If you want more digital
I/O terminals then you can purchase I/O extension unit and you can connect
it to PLC main unit through that extension port. Special purpose units such
as ADC, DAC, high speed I/O module, communication module etc. are also
connected through extension port of PLC.

Type of PLC
As per its I/O terminal it is of 2 types i.e., Relay type and Transistor type. As
per its size it was initially of three types’ micro, mini and modular PLC. Micro
PLC had I/O capacity 64, Mini had 256 and Modular had 4096. Now we have
only two types micro and modular. Micro has 256 maximum I/Os capacity
and modular has more than 5000 I/Os capacity. Exact number of I/Os
capacity varies brand to brand. You can recognize a micro or a modular
PLC by seeing it. When all essential parts of block diagram are assembled in
single unit is micro-PLC.
We cannot remove any part. Modular PLC is assembled and can be
dissembled easily. Almost each part of block diagram is as an individual
module. Modular PLC is also called rack type and base type PLC. Initially it
was manufactured very large in size and was arranged on rack so it is called
rack type PLC. It has a base board with some connectors and slots.
Modules/ cards are inserted to the slots. First slot is always reserved for
power module and second slot is reserved for CPU. After that any other
module such as digital I/O, analog I/O etc. can be inserted. Power module
has power terminal and one indicator on it. CPU has few indicators, hard key
for start/ stop, communication and memory on it. Digital and analog modules
have terminals on it.
Let us move towards programming of PLC. Programming is the most
important and interesting part. Without learning programming, we won’t be
able to develop a new project, we won’t be able to modify the existing
program and we won’t be able to troubleshoot machine easily. People get a
bit afraid of hearing programming. Programming is always considered very
difficult but PLC programming is not that difficult if you follow some steps/
tricks. If you learn programming in proper way then programming is so
interesting. We are going to learn Ladder Diagram (LD) language. It is very
similar to basic electrical diagram, Very basic diagram. LD is symbolic
representation language you can say. Our target in this language is to send
supply to output as per required sequence/ logic. If you understand basic
electrical diagram, you will be able to understand ladder diagram easily. Our
all-electrical work starts from power socket.

Do you know what this upper terminal is for? Yes, it is for earth in AC and
ground in DC. Now tell me what this left terminal is for? It is Line, neutral or
either of these? It can be any but universally right side is LINE and lest side
terminal is NEUTRAL.

In this diagram you need to connect L N, switch and lamp to get the lamp
operated by switch.
This diagram connection is wrong. Here we have connected line and neutral
both to a switch; switch has just a contact inside it. As switch is on L and N
will get short.

This is correct. Here when switch is on, Line path will get connected and
lamp will get on. Always remember that switches are connected to single
path not to both paths L and N. in single path too it should be connected to
Line path. We don’t connect switch to neutral path. It is directly connected to
output/ appliance. Connecting switch to neutral not to Line path is not safe.
Lamp will be operated properly but, in that case, only neutral path is broken/
disconnected and line is always available to the output appliance. When
someone will go to the output for maintenance or repair purpose, he/ she can
get touch in Line, as it is directly connected to output, and can meet saviour
accident.
1> Now we have L, N, two switches and one lamp. Connect in such way
that when you press either/ any switch, lamp should be operated.
Wrong!
These are wrong solutions. Let me remind you the ladder rules again. If we
have one output in our program then we shall have only one output coil. Do
not repeat coil address. Input we can repeat many times. It means many NO
NC contacts can be used and I0 & I1 will be repeated as per need.
Now let us make the things easy. Follow some steps and you will be able to
make any basic program. When you have to make program for simple
conditions like just on and off (no complication of pulse, timer, counter etc.),
you can follow some steps.
1> Make a truth table for given conditions.
2> Go to the first output and take a coil for it. Don’t think about all outputs in
your truth table. For some examples, we shall start with coil.
3> Check the true conditions of output and add the status of inputs used in
example.
4> For input 1 take NO and for input 0 take NC.
5> Do not make program for 0 (zero) of output.
Repeat the same for other outputs.
Let us make XOR program by following above steps. 1) Make a truth table.

2) Now go to the first output Q0 (here we have only one output) and take a
coil for it.

3) Check the true conditions of output and add the status of all inputs i. e. I0
and I1. 4) For 1 of input take NO and for 0 of input take NC. 5) Do not make
program for 0 of output.
When output Q0 is 1 first time, status of inputs I0 & I1 is 0 & 1 respectively
so ladder is NC of I0 and NO of I1. When output Q0 is on again, status of
inputs I0 & I1 is 1 & 0 so ladder in parallel is NO of I0 and NC of I1.
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"I told you," he said to Halfrich, "Just a blowhole, that's all."
"The blips on the record moved," said Halfrich. "There was more than
this."
"Look around you!" cried Kellard desperately. "Do you see anything
moving, anything that could move? You were wrong, Halfrich. Do you
have to keep us here until we all die, because you can't admit you're
wrong?"
Halfrich hesitated. "I wasn't wrong. You're still lying. But we'll go back
to the ship and wait."
They turned their backs on the fire-fountain, and Kellard felt the sweat
pouring on his forehead. It hadn't happened this time, and they
couldn't wait forever, they would have to go away and—
Morgenson's voice chattered in their ears. "Blips showing, coming—"
And then he suddenly yelled, "I see them! They—"
Halfrich swung around with ponderous swiftness. There was nothing
between them and the fire-fountain, nothing around the spouting
flames.
"Above you, coming down!" shouted Morgenson. "My God, what—?"
Kellard slowly raised his head. Because he knew what to look for, he
saw them while Halfrich was still gazing around searching.
They came flashing down out of the sky. There were four of them this
time—no, five. They were like five individual swirls of shining light, so
bright that the sun-bleached heavens seemed to darken around
them.
Halfrich said bewilderedly, "I don't see—"
Kellard pointed upward. "There."
"Those flakes of flame?"
"Not flakes of flame," said Kellard. "They are the children of the
stars."
Halfrich went rigid, staring upward. And now Kellard knew that there
was no more hope. No hope at all.

The five bright things had flashed down toward the great fire-fountain.
They plunged into it, out of it, climbed swift as the eye could follow,
racing up its mighty geyser, frolicking in it joyously. The fountain raved
higher and the five sped up and whirled and danced upon its rising
plume, and Kellard thought that they were laughing.
In and out of the leaping fires they plunged, and then one of them
veered down toward the place where Halfrich and Kellard stood.
There was something so humanly purposeful in its sudden movement
that Halfrich stepped back.
"Stand still," said Kellard.
"But—" Halfrich protested.
"They won't hurt us," said Kellard, his voice flat and dull. "They're
friendly, playful, curious. Stand still."
And now all five of the flashing flames were around them, darting,
recoiling, then gliding forward again to touch their heat-armor with
questing tendrils of living force, living light.
Halfrich spoke, trying to keep his voice steady but forming the words
in a choked fashion.
"Something—in my mind—"
"They're telepathic, in a way you can't even imagine," said Kellard.
"And they're curious. They're curious about us, what we are, how we
think. They can merge minds with us, somehow." And he added, with
a last cruel impulse of dying anger, "You wanted to know. Now know."
He had time to say nothing more before the impact hit him, just as it
had that other time, the full stunning shock of unearthly minds
interlocking with his own, searching out his thoughts and memories.
Curious, yes. Like children who have found strange, ungainly
creatures and wish to know how they live. And as they entered his
mind, Kellard's mind entered theirs, fused with them, and there was
again the dizzying whirl of memories and feelings that were not his
own, that his different, more brutishly physical nature could never
apprehend more than dimly.
But that half-apprehension was staggering. He was no longer Hugh
Kellard, a man with flesh and bones who had been born on an air-
drowned heavy planet named Earth.
He was one of the children of the stars.
His memory stretched far back, for his life was almost unlimited in
time. For long and long beyond human comprehension he had lived
with his companions the strange and beautiful life of their kind.
Born of the stars, of the unimaginable forces, pressures,
temperatures, atomic conditions within the mighty suns. Born, as the
end product of an evolutionary chain almost as old as the universe
itself, a grouping of photons that grew toward consciousness, toward
individuality and volition. Their bodies were force, rather than matter,
their senses had nothing to do with sight or hearing, their movement
was an effortless flash and glide as fast as the photons of light itself.

With the other kind of life in the universe, the heavy slow-moving
things of matter that grew upon the comparatively cold, dark planets,
they had had nothing to do at all. They were of the suns, not the
planets, and those chill worlds of fixed, solid matter so repelled them
that they would not even approach most of them.
Star-child, star-child, at home in the bursting splendors of the stellar
fires, and able to move like light from star to star. And again Kellard
felt the agony of that ecstasy that was his in this shared memory.
"We things of matter, we men, who thought that space and the stars
would be ours—"
But how could the wide universe belong to solid, heavy, physical
creatures who must painfully move in bubbles of air, who crawled
between the petty planets encased in metal tombs, who could not
even approach the glories of the great suns?
No, the ecstasy was one that men would never know except at
secondhand through this brief contact! The glorious rush together of
the star-children through the vast abysses, drinking up the energy of
the radiation about them. The audacious and dangerous coasting
along the shores of dark nebulae, racing the lumbering comets and
leaving them behind, on until you felt through all your photons the
beckoning warmth of the star you approached. Ignore the cinders
called planets that creep around it, speed faster, faster, brothers, the
way has been long but we are almost there! And now the radiation
that was so weak in the outer darks is strong and lusty-roaring, and
the great prominences reach out like arms to gather us in. The shock,
the joy, of the first plunge once more into the star. Dive deep,
brothers, deep through the outer fires into the throbbing solar
furnaces where the atoms are hammered as in forges, changing,
shifting their shapes, exploding into force.
Spin in the vortices of the great stellar tornadoes, fling off and fall
headlong and then dive laughing in again. Search for the others of
your kind, if there are none here there will be at the next star. Up
again, out of the boiling fires, and then drift quiet, dreaming, in the
pearly glow of the corona, endless afternoon of warmth and light and
peace.

But on the sunward side of the tiny planet nearby, a plaything

beckons. Fire and light fountain up from the solid rock. There at least
we can go, for that place is washed by tides of solar life, not chilled
and dead. Speed down toward it, as the fire, the life it spouts higher
out of the repellantly fixed and solid matter. Frolic in the fountain,
through and around it as it rises higher. And what are the things that
move on the rock near it, the things that look grotesquely as though
matter had been endowed with life? Reach out with your thought-
senses and try to apprehend them. Mind, life—in matter! Try to
understand how matter thinks, how matter feels, plumb the grotesque
memories of them, the vistas of crawling things at the bottom of
whelming air-oceans, things of clay too frail to endure, yet things that
in their brief living have come here. But the mind recoils from such
memories, such a life.
Brothers, we go! First to refresh ourselves in the deepest streams of
the star, and then away across the abysses to another star we know.
There is nothing to hold us here—
And the oneness was gone from Kellard's mind, and he was no child
of light and stars, he was a man of clay, standing stupid and sick and
shaking by the falling fires of the fountain.
He looked at Halfrich. But Halfrich stood, with his head bowed, and
Kellard felt only pity.
He touched his arm. "We'll go back to the ship."
For a long moment, Halfrich did not respond. Then he turned and
walked, plodding with head down, not looking up once at the flaring
sky.
In the little ship, he sat later with Kellard. He had not spoken yet, and
Morgenson and the others, bewildered and awed, had still not dared
ask questions. Finally Halfrich looked at Kellard, pain still in his eyes.
"I was thinking," he said. "I was remembering my little boy, years ago.
He had just learned to walk, and he started out the door, eager to
explore the whole town. He stubbed his toe, and he sat down and
cried."
"You tried to spare me this," said Halfrich after a little while. "Thanks
for that, Kellard. It didn't work, but thanks anyway."
Kellard said, "Look, no one else knows. No one else is ever likely to
know. The only place where the men of matter and the children of
stars could meet is a place like Sunside, and how many such
meetings would ever by chance happen? We don't have to tell
everyone, to take the heart and eagerness out of them by letting them
know they'll always be second-best in space."
Halfrich thought about that. And then he shook his head. "No. We've
stubbed our toe. We've learned we're not and never will be the sole
inheritors of the universe. All right, we'll accept the fact and go on.
The planets will be ours, just the same. And someday—" He paused,
then said, "—someday, maybe, the sons of the planets and the
children of stars will take hands, know each other. No, Kellard. We'll
tell them."
THE END
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