Programmable Logic Controller

Objectives :

At the end of the Session we will be able to:

● Describe the major components of a common PLC.

● Interpret PLC specifications.
● Apply troubleshooting techniques.
● Convert conventional relay logic to a PLC language.
● Operate and program a PLC for a given application.
Contents :

● History of Programmable Controllers

● Relay Ladder Logic
● Central Processing Unit
● Input/Output System
● Programming and Peripheral Devices
● Programming Concepts
● Applications
● Troubleshooting and Maintenance
Process Control &
Automation
Process control

Recognizing Process the Actuate the

the status Information control elements

Rules &
guidelines
 Why Automation ?

Higher productivity

Superior quality of end product

Efficient usage of energy and raw materials

Improved safety in working condition

etc…
History of Process Control &
Automation

PLC Control

Electronics Control

Hard-Wire Control

Manual Control
 1. PLC -
Introduction
What does PLC stand for?

•PLC - Programmable Logic Controller

•PLC implements logic control functions by means of a

program
 Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic

apparatus uses a programming
which memorythe internal storage
for
instructions for implementing
of specific
functions such as logic, sequencing,
timing, counting and arithmetic to control
through digital or analog modules,
various types of machines or process.
 1. PLC -
Introduction
How does a PLC differ from a computer?

• A computer is optimized for calculation and display tasks

• A computer is programmed by specialists

• A PLC is designed for (logic) control and regulation tasks

• A PLC is programmed by non-specialists

• A PLC is well adapted to industrial environment

PLC Origin

• Developed to replace relays in the late 1960s

• Costs dropped and became popular by 1980s

• Now used in many industrial designs

INTRODUCTION TO PLCS
Advantages of PLCs :

• Less wiring.

• Wiring between devices and relay contacts are done

in the PLC program.

• Easier and faster to make changes.

• Trouble shooting aids make programming

easier and reduce downtime.

• Reliable components make these likely to operate for

years before failure.
INTRODUCTION TO PLCS
Advantages of PLCs :

• They are cost-effective

• They are flexible, reliable and compact

• Theyhave significant advantages over

traditional control systems based on relay or
pneumatics
 1. PLC -
Introduction
What tasks do PLC perform ?

• The logic control such as interlocking,

tasks
sequencing, timing and counting
undertaken with relays or pneumatics)
(previously

• In addition, PLCs can perform a variety

of calculation, communication and monitoring
tasks
Leading Brands Of PLC

AMERICAN: 1. Allen Bradley

2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN: 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
Leading Brands Of PLC

JAPANESE: 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
Areas of Application :

• Manufacturing / Machining

• Food / Beverage

• Metals

• Power

• Mining

• Petrochemical / Chemical
PLC Size :
Small: • It covers units with up to 128 I/O’s and memories
up to 2 Kbytes.

• These PLC’s are capable of providing

simple to advance levels or machine controls.

Medium: • Have up to 2048 I/O’s and memories up

to 32 Kbytes.

Large: • The most sophisticated units of the PLC family.

• They have up to 8192 I/O’s and memories up to 750
Kbytes.
• Can control individual production
processesor entire plant.
Major Components of a Common PLC

POWER

SUPPL
Y

I M O M
N O U O
P D T D
U U PROCESSOR P U
T U L
From T E
L
To
SENSORS OUTPUT
Pushbutto E Solenoids,
ns, contacts, contactors,
limit alarms.
PROGRAMMING
switches, etc. DEVICE Motors
etc.
 Major Components of a Common PLC

Power Supply:

• Provides the voltage needed to run the

primary PLC components

I/O Modules:

• Provides signal conversion and isolation between the

internal logic- level signals inside the PLC and the field’s
high level signal.
 Major Components of a Common PLC

Processor :

• Provides intelligence to command and govern the activities

of the entire PLC systems.

Programming Device :

• Used to enter the desired program that will determine the

sequence of operation and control of process equipment or
driven machine.
I/O Module

• The I/O interface section of a PLC connects it to external field

devices.

• The main purpose of the I/O interface is to condition the

various signals received from or sent to the external input
and output devices.

• Input modules converts signals from discrete or analog input

devices to logic levels acceptable to PLC’s processor.

• Output modules converts signal from the processor to levels

capable of driving the connected discrete or analog output
devices.
I/O Module
DC Input Module
IS NEEDED TO:
USE TO Prevent voltage
DROP transients from
THE damaging the
VOLTAGE processor.
Helps reduce the
TO LOGIC
effects of electrical
LEVEL noise

Current Buffer,
FROM Limiting OPTO- Filter, TO
INPUT ISOLA hysteresi PROCESSOR
DEVICE Resistor T OR s
Circuits
I/O Module
AC Input Module

IS NEEDED TO:
CONVERTS THE Prevent voltage
AC INPUT TO DC transients from
AND DROPS damaging the
THE VOLTAGE processor.
TO LOGIC Helps reduce the
effects of electrical
LEVEL
noise

Rectifier Buffer,
FROM Filter,
, OPTO- TO
INPUT Hysteresis
Resistor ISOLA PROCESSOR
Circuits
DEVICE T OR
Network
2
9
 I/O Module
DC/AC Output Module IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

Amplifier
FROM RELAY TO
TTL OPTO-
PROCESSOR TRIAC
Circuits OUTPUT
X’SISTO
ISOLA DEVICE
R
TOR
 OUTPUTS

INPUTS
MOTOR

CONTACTOR
LAMP

PUSH BUTTONS

PLC
INPUT D E V I C E S :

Push Button

Limit Switch

Thumbwheel SW

Level SW

Flow SW
OUTPUT D E V I C E S :
Motor

Solenoid

LED Display

Heater Coil

Lamp
Discrete Input

A discrete input also referred as digital input is an input that is either

ON or OFF are connected to the PLC digital input. In the ON condition
it is referred to as logic 1 or a logic high and in the OFF condition
maybe referred to as logic o or logic low.

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

 IN

OFF PLC
Logic 0
Input
Module
24 V dc

IN

OFF PLC
Logic 1
Input
Module
24 V dc
Analog Input

An analog input is an input signal that has a continuous

signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V. Below, a level transmitter monitors the level of
liquid in the tank. Depending on the level Tx, the signal to the
PLC can either increase or decrease as the level increases
or decreases.

Level Transmitter IN

PLC
Analog
Tan Input
k Module
Digital Output

A discrete output is either in an ON or OFF condition. Solenoids,

contactors coils, lamps are example of devices connected to the
Discrete or digital outputs. Below, the lamp can be turned ON or OFF by
the PLC output it is connected to.

OUT
PLC
Lamp
Digital
Output

Module
Analog Output

An analog output is an output signal that has a continuous

signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V.

Electric to
pneumatic
transducer
E
P
Supply air
PLC 0 to 10V
OUT

Analog

Output
Pneumatic control valve
Module
Processor
The processor module contains the PLC’s microprocessor, its supporting
circuitry, and its memory system.

The main function of the microprocessor is to analyze data coming from

field sensors through input modules, make decisions based on the user’s
defined control program and return signal back through output modules to
the field devices. Field sensors: switches, flow, level, pressure, temp.
transmitters, etc. Field output devices: motors, valves, solenoids, lamps, or
audible devices.

The memory system in the processor module has two parts: a system
memory and an application memory.
Programmable Logic Controller
Power

supply

Input CPU Output

module Program memory
module

Field Control
Input
Elements
Process / Machine
PLC Operating Principle

In-put scan

Self test
S tart

Communication

Out-put scan
PLC Operation
Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute the user
program stored in application memory, then, based on whatever control
scheme has been programmed by the user, turn the field output devices on
or off, or perform whatever control is necessary for the process application.

This process of sequentially reading the inputs, executing the program in

memory, and updating the outputs is known as scanning.
While the PLC is running, the scanning process includes the following four
phases, which are repeated continuously as individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostic
s/ Comm
PHASE 4
Outpu
t Scan
PHASE 1 – Input Status scan

 A PLC scan cycle begins with the CPU reading the status of its inputs.

PHASE 2– Logic Solve/Program Execution

 The application program is executed using the status of the inputs

PHASE 3– Logic Solve/Program Execution

 Once the program is executed, the CPU performs diagnostics and

communication tasks
As soon as Phase 4 are completed, the entire cycle begins again with
Phase 1 input scan.

The time it takes to implement a scan cycle is called SCAN TIME. The scan
time composed of the program scan time, which is the time required for
solving the control program, and the I/O update time, or time required to
read inputs and update outputs. The program scan time generally depends
on the amount of memory taken by the control program and type of
instructions used in the program. The time to make a single scan can vary
from 1 ms to 100 ms.
PLC Communications
Common Uses of PLC Communications Ports

 Changing resident PLC programs - uploading/downloading from

asupervisory controller (Laptop or desktop computer).

 Forcing I/O points and memory elements from a remote

terminal.

 Linking a PLC into a control hierarchy containing several sizes of PLC

and computer.

Monitoring data and alarms, etc. via printers or Operator Interface Units
(OIUs).
PLC Communications
Serial Communications

PLC communications facilities normally provides serial transmission of

information.

Common Standards

RS 232

 Used in short-distance computer communications, with the majority

of computer hardware and peripherals.
 Has a maximum effective distance of approx. 30 m at 9600 baud.
PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all devices plus
providing overall data exchange management or protocol, ensuring that each
device can “talk” to other machines and understand data received from them.

LANs provide the common, high-speed data communications bus which

interconnects any or all devices within the local area.

LANs are commonly used in business applications to allow several users to

share costly software packages and peripheral equipment such as printers
and hard disk storage.
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET

Square D SY/NET
Texas Instruments TIWAY
Specifications
Several factors are used for evaluating the quality and performance of
programmable controllers when selecting a unit for a particular application.
These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be connected to the
controller. There should be sufficient I/O ports to meet present requirements
with enough spares to provide for moderate future expansion.
 Working of PLC
II

CPU
•User Program memory I
V
Input I/O Bus •Internal timers
I/O Bus Output
Module •Internal counters
Module
I PII PIQ II
I

Field Field
signals Controls
 PLC Programming
PLC is software driven equipment like computer

Working of PLC (process) is decided by user through program.

Depending on process requirement program (set of instruction) is

prepared.

CPU sequentially read these instruction and operates

control elements based on input signals and program instruction.

Programming can be done On-line or Off-line.

Normally programming / change in program is done in memory of

programming unit and then simply this change is loaded in CPU
memory of PLC
Addressing Inputs &
Outputs
Slot numbers
01 2 3 4 30 31
0 ----------------
1
2

CPU
CPU 3

5
6
7

Channel Nos.
PROGRAMMING

Normally Open Normally Closed

(NO) (NC)

Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
Coils

Coils represent relays that are energized when power flows to

them. When a coil is energized it causes a corresponding
output to turn on by changing the state of the status bit controlling
the output to 1. That same output status bit maybe used to control
normally open or normally closed contact anywhere in the program.
Boxes

Boxes represent various instructions or functions that are

Executed when power flows to the box. Some of these
Functions are timers, counters and math operations.
 AND OPERATION

A B C

Rung

Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).
 OR OPERATION

A C

Rung

In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).
 NOT OPERATION

A C

Rung

In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.
 Writing
•
Program
Ladder Diagram (LAD)
–Use relay logic symbols to formulate the
control task

• Control System Flowchart (CSF)

– Use digital graphical symbols to formulate
the control task
&

• Statement List (STL)

– Use mnemonic abbreviation in
programming.
 1. PLC -
Introduction
Data Flow in the PLC
1. PLC -
Introduction
n One of the advantages of PLC is that it can be programmed by
non-specialists

n Program can be written either in the form of a

statement list: a set of mnemonic instructions representing a

function of the CPU
or a
ladder diagram: a graphical language resembling the electrical
relay diagrams
1. PLC -
Introduction
statement list
1. PLC -
Introduction
Ladder diagram
 Writing
•
Program
Circuit Diagram • Ladder Diagram
(LAD)
I 1.0 I 1.2 I 1.0 I 1.1 Q 4.1

I 1.1 I 1.3

I 1.2 I 1.3

Q 4.1
 Writing
•
Program
Circuit Diagram • Control System Flowchart (CSF)

I 1.0
I 1.0 I 1.2
&
I 1.1
I 1.1 I 1.3

>=1
I 1.2
Q 4.1
Q 4.1 I 1.3 & =
 Writing
•
Program
Circuit Diagram • Statement List
(STL)
I 1.0 I 1.2 A I 1.0
A I
I 1.1 I 1.3
1.1 O
A I 1.2
A I
Q 4.1 1.3
= Q
4.1
 (Kontaktplansprache, langage à contacts)

Ladder logic (1)

The ladder logic is the oldest programming language for PLC
it bases directly on the relay intuition of the electricians.
it is widely in use outside Europe.
It is described here but not recommended for new projects.
 Ladder Logic (2)
make contact
origin: (contact travail)02
electrica 01 relay coil
l circuit
(bobine
50 )
break contact
03 (contact repos)

01 0
2 50
corresponding run
03 g
ladder
diagram
50 05 "coil" 50 is used to move
44 other contact(s)
Ladder logic (4)
Binary combinations are expressed by series and parallel relay contact:

ladder logic representation “logic" equivalent

Series
+ 01 02 01

50 50
02

Coil 50 is active (current flows) when 01 is active and 02 is not.

Parallel + 01
40 01

02 40
02

Coil 40 is active (current flows) when 01 is active or 02 is not.

Ladder logic (5)
The ladder logic is more intuitive for complex binary expressions than literal languages

textual expression
1 2 3 4
50 !N 1 & 2 STR 3 & N 4 STR N 5
5 6 & 6 / STR & STR = 50

0 1 4 5 12
50 !0 & 1 STR 2 & 3 / STR STR 4
2 3 6 7 & 5 STR N 6 & 7

/ STR & STR STR 10

10 11 & 11 / STR & 12 =
50