PROGRAMMABLE LOGIC

CONTROLLER

The working and design Principles

HARISH Y
 Contents
►Introduction
►Structure and components
►Operation
►Programming
►Basic Terminologies
►Suppliers
►Communication
►Advantages
 Introduction
What is PLC?

PLC is a low cost, compact,

versatile, programmable
unit based on the standard
microprocessor architecture
used in the control of
machines or processes in
industry.
 Structure of a PLC
A PLC contains the following parts.

1. CPU 3. Programming Device

2. I/O Module 4. Operator Interface
 CPU
The central processor unit
(CPU) is a microprocessor
system that contains the
system memory and is the
PLC decision making unit.
The CPU monitors the inputs
& makes decisions based on
instructions held in the
program memory. The CPU
performs relay, counting,
timing, data comparison, &
sequential operations.
 MEMORY
The memory of PLC is divided into two
types.

1. Program Memory
The all instructions of the program
reside in this memory.

2. Data Memory
The all data and information is stored in
this memory.
Memory Map

The memory in the

PLC is organized as
shown in the Figure.

This is shown with

the help of a
Memory map as
shown.
 PROGRAM FILES
The user program accounts
for most of PLC system
Memory.

1. Program files contain the

logic which controls
machine operation.

2. The logic consists of

instructions programmed
in a ladder logic format.
 DATA FILES

The data files of

memory contains
input and output
status, processor
status, the status
of various bits and
numerical data.
 PLC OPERATION

SCANNING
During each operating
cycle, the processor
reads all inputs, takes
these values, and
energizes or de-
energizes the outputs
according to the user
program.
 MODES OF OPERATION
A PLC has basically two modes of
operation.
1. Program Mode
2. Run Mode

Variations of Run Mode

1. Run Mode
2. Test Mode
3. Remote Mode
 PROGRAM MODE
It is used to
Edit or update an existing program
Enter a new Program
Upload files
Download files
Document Programs
Change Software Configurations
 Variations of Run Mode
►Run Mode – is used to execute the user
program. Input devices are monitored
and output devices are energized
accordingly.
►Test Mode – is used to operate, or
monitor the user program without
energizing any outputs.
►Remote Mode – is used to operate the
PLC remotely by a personal computer
connected to the PLC Processor.
 PROGRAMMING
A program consists of a set of instructions
that accomplish a task.

PLC programs are written in a Special

application on a personal computer

Then downloaded by a direct-connection

cable or over a network to the PLC.

Stored in the PLC either in battery-backed-

up RAM or non-volatile flash memory.
 TYPES OF PROGRAMMING

There are 5 ways to

program a PLC.

1. Ladder Logic
2. Statement List
3. Function Block Diagram
4. Instruction List
5. Sequential Flow Chart
 LADDER LOGIC
The Ladder Logic is the representation of logic
through the ladders or ON and OFF switches.

Example: Timers and Counters

 STATEMENT LIST
Statement list (STL) include an operation &
an operand. The operation to be performed
is shown on the left. The operand, the item
to be operated on, is shown on the right.
 FUNCTION BLOCK DIAGRAMS
Function block diagrams (FBD) include
rectangular functions with inputs shown on the
left side of the rectangle and outputs shown
on the right side.
 LADDER PROGRAMMING
Ladder logic (LAD) incorporates programming
functions that are graphically displayed to
resemble symbols used in hard-wired control
diagrams.
 BASIC
TERMINOLOGIES
 Sensor
Sensor is a device that converts a physical condition into an
electrical signal. Sensors are connected to input of a PLC.

A pushbutton is connected to the PLC input. An electrical

signal is sent from pushbutton to the PLC indicating the
condition (open/closed) of pushbutton contacts.
 Actuators
Actuators converts an electrical signal into physical
condition. Actuators are connected to the PLC output.

A motor starter is an actuator that is connected to the PLC

output. Depending on the output PLC signal the motor starter
will either start or stop the motor.
 Discrete Input
A discrete input, also referred to as a digital input,
is an input that is either in an ON or OFF condition.
It is also referred as digital input.
 Analog Input
An analog input is an input signal that has a continuous
signal.

Here, a level transmittermonitors the level ofliquid in a

tank. Depending on the level, signal to the PLC can either
increase or decrease as the level increases or decreases.
 Discrete Outputs
A discrete output is an output that is either in an ON or OFF
condition. Discrete outputs may also be referred to as digital
outputs.

Solenoids, contactor coils, lamps, etc., are actuator devices

connected to discrete outputs. Here is a lamp that can be
turned on or off by the PLC output.
 Analog Outputs
An analog output is an output signal that has a continuous
signal. Ex: speed, weight, and temperature.

Here shown is a current-to pneumatic transducer that

controls an air-operated flow-control valve.
 SUPPLIERS OF PLCS
Well known PLC brands are,

Siemens Omron
Allen-Bradley Schneider Electric
IDEC General Electric
ABB Mitsubishi
 Communication
► PLCs have built in communications ports 9-Pin
RS232, and optionally for RS485 and Ethernet.

► Modbus or DF1 is usually included as one of the

communications protocols.

► Others' options include various fieldbuses such as

Device Net or Profibus.

► Most modern PLCs can communicate over a network

to some other system, such as a computer running a
SCADA (Supervisory Control And Data
Acquisition) system or web browser.
 Advantages
► Low cost and complexity
► User Interface
► Remote communication
► More flexibility
► No hanging of PLC
► Suitable for industrial harsh environment
► Smaller physical size than hard-wired solutions
► Integrated diagnostics and override functions
► Applications can be immediately documented
► Applications can be duplicated faster and less expensively