Unit-II

PROGRAMMABLE LOGIC CONTROLLERS

Basics of PLC, Advantages, Capabilities of PLC, Architecture of PLC, Scan
cycle, Types of PLC, Types of I/O modules, Configuring a PLC, PLC wiring.
 Evolution of PLC
• Revolutionized the automation industry
• Factory equipment to vending machines
• 1968 New years day for PLC
How before?
• Machines inside the industry was fully controlled using relays (Power relays)
• Relays has been placed between the power source and motor
• To switch on/off the relays has to be energized or de energized (Where the switching time will be controlled by
the control relay)
• Nearly 100 motors will be used in the industry which makes the control cabinet to be filled by the power and
control relays
Problem Pointed out by the personnel's:
• Have to be properly hardwired (To understand the logic)
• Troubleshooting would take an hours to identify the failure Strict maintenance schedule (Weekly/Monthly
schedule 24*7)
• Size of the cabinet (The electrical controller cabinet will be of 6*4 feet high if I use 50 to 100 relays)
• Additional changes to be difficult (Changes the place of I/O devices)
• Timing and counting actions cannot be done
Programmable Logic Controller(PLC)
INTRODUCTION OF PLC
• A PLC is a user-friendly, microprocessor based specialized computer
that carries out control functions of many types and level of
complexity. It’s purpose is to monitor crucial process parameters and
adjust process operations accordingly. It can be programmed,
controlled and operated by a person. Essentially a PLC operator draws
the lines and devices of ladder diagram and functional block diagram
with a keyboard onto the display screen. The resulting drawing is
converted into computer machine language and run as a user
program.
List of PLC manufacturers
ABB Allen Bradley Siemens Mitsubishi

Honeywell Motorola Hitachi General Electric

Modicon Schneider Electric Panasonic

Alstom Bosch Delta Devolo Echelon

Omron ON Semiconductor Qualcomm Atheros

SiConnect
PLC
PLC Advantages
• Flexibility
• Implementing Changes and Correcting Errors
• Large quantity of Contacts
• Lower cost
• Pilot Running
• Visual Observation
• Speed of Operation
• Programming method
Contd……
• Reliability and Maintainability
• Simplicity of Ordering Control Systems
• Documentation
• Security
• Ease of Changes by Reprogramming
• Newer Technology
• Fixed Program Applications
• Environmental Considerations
Application Areas
Programmable Logic Controllers are suitable for a variety of automation
tasks. They provide a simple and economic solution to many
automation tasks such as
• Logic/Sequence control
• PID control and computing
• Coordination and communication
• Operator control and monitoring
• Plant start-up, shut-down
Chemical/ Petrochemical Metals
• Batch process
• Pipeline Control
• Weighing, Mixing
• Finished Product Handling
Metal

• Blast Furnace
• Continuous Casting
• Rolling Mills
• Soaking Pit
• Steel Melting Shop
Manufacturing/Machining
• Material Conveyors, Cranes
• Assembly
• Milling, Grinding, Boring
• Plating, Welding, Painting
• Molding/ casting/forming
Hardware (The PLC System)
Architecture of
PLC
CPU
The internal structure of the CPU depends on the microprocessor
concerned. In general, CPUs have the following:

• An arithmetic and logic unit (ALU) that is responsible for data

manipulation and carrying out arithmetic operations of addition and
subtraction and logic operations of AND, OR, NOT, and EXCLUSIVE-OR.
• Memory, termed registers, located within the microprocessor and
used to store information involved in program execution.
• A control unit that is used to control the timing of operations.
Buses
The buses are the paths used for communication within the PLC. The
information is transmitted in binary form, that is, as a group of bits,
with a bit being a binary digit of 1 or 0, indicating on/off states. The
term word is used for the group of bits constituting some information.
Thus an 8-bit word might be the binary number 00100110. Each of the
bits is communicated simultaneously along its own parallel wire.
The system has four buses:
• The data bus
• The address bus
• The control bus
• The system bus
Memory
• RAM
(Random-Access Memory (RAM) is used for the user’s program)
• ROM
(System Read-Only-Memory (ROM) gives permanent storage for the
operating system and fixed data used by the CPU)

Possibly, as a bolt-on extra module, Erasable and Programmable Read-

only-memory
TYPES OF INPUT AND OUTPUT
DEVICES
• The input/output (I/O) unit provides the interface between the PLC
controller and the outside world and must therefore provide the
necessary signal conditioning to get the signal to the required level
and also to isolate it from possible electrical hazards such as high
voltages
Input / Output Units
• Input signals from sensors and outputs required for actuating devices can
be:
• Analog: A signal for which the size is related to the size of the quantity
being sensed.
• Discrete: Essentially just an on/off signal.
• Digital: A sequence of pulses.

The CPU, however, must have an input of digital signals of a particular size,
normally 0 to 5 V. The output from the CPU is digital, normally 0 to 5 V
Input Units
• The terms sourcing and sinking refer to the manner in which DC devices are
interfaced with the PLC. For a PLC input unit with sourcing, it is the source of
the current supply for the input device connected to it . With sinking, the
input device provides the current to the input unit

(a) sourcing and (b) sinking

DC input unit.
AC input unit
Input and Output Module in PLC
Multiple inputs (I) and output (O) modules are used in the PLC system. They
provide an interface between the central processing unit (CPU) and
programmable devices.
Input Module
The module which interacts with the input signal is called as Input Module. It is
required to connect input devices like different types of switches.

Output Module
The module which interacts with the output signal is called as Output Module.
The output module is required to connect output devices like electric
applications.
Classifications of the PLC Input Output
Modules
Types of PLC
• Fixed ( Integrated or Compact) PLC
• Modular PLC
 Fixed/Integrated/Compact PLC

Every type of output or input is fixed and is determined by the manufacturer.

Furthermore, the number of inputs and outputs may not be expanded in this
type of PLC.
Modular PLC

The modular PLC is a type that allows multiple expansions of the PLC system
through the use of modules, hence the term “modular”.Modules give the
programmable logic controller additional features like increased number of I/O units,
and they are usually easier to use because each component is independent of each
other
Modular Type
Advantages of using Modular PLC
• Scalability
• Number of I/O
• Easier Fault Detection
• Less Downtime
• Module Combinations
• Memory
 Fixed/Integrated/Compact PLC

Every type of output or input is fixed and is determined by the manufacturer.

Furthermore, the number of inputs and outputs may not be expanded in this
type of PLC.
Modular PLC

The modular PLC is a type that allows multiple expansions of the PLC system
through the use of modules, hence the term “modular”.Modules give the
programmable logic controller additional features like increased number of I/O units,
and they are usually easier to use because each component is independent of each
other
Advantages of using Modular PLC
• Scalability
• Number of I/O
• Easier Fault Detection
• Less Downtime
• Module Combinations
• Memory
• An analogy for the Fixed I/O and Modular I/O
• Type of PLC according to Output
• Inside CPU module of SIEMENS PLC
• The following will show the procedures that the CPU performs to
execute the scan cycle:
• Startup
• The first action that a CPU executes when it goes from Stop to Run
mode is the STARTUP routine, this routine performs the following tasks:
• The input area of the process image (I memory) is cleared.
• The outputs are initialized with the last value.
• Any interrupt events are queued for processing during RUN mode
 Executing the startup Organization Block (OB100)
• OB 100 will be executed once,
before OB 1 starts, so it is a
great place to initialize registers
and DBs, set control bits, reset
past alarms, and so on before
letting the program start.
Executing the main program (OB 1)

• Now the CPU is ready to perform the main program (ladder logic), this
main program is executed through the main OB (OB 1).
• In the main OB, you can call the functions (FC) and function blocks
 (FB), also you can deal with the system memory by using memory
flags, timers, and counters.
Executing the system Interrupts

• An interrupt occurs during any time of the scan cycle, the CPU in this
case will make the operating system call the related OB interrupt (OB
121, OB 80, OB86, …),
 CONFIGURING A PLC
The PLC configuration provides information as to which network
components are connected to each other, which PLC cards (type) are
located in which slots, and which addresses are on which PLC cards.
PLC Configuration

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 What devices does a PLC interact with?
INPUT RELAYS-(contacts)These are connected to the outside world. They physically exist and
receive signals from switches, sensors, etc. Typically they are not relayas but rather they are
transistors.
INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from the outside world
nor do they physically exist. They are simulated relays and are what enables a PLC to
eliminate external relays. There are also some special relays that are dedicated to
performing only one task. Some are always on while some are always off. Some are on only
once during power-on and are typically used for initializing data that was stored.

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COUNTERS-These again do not physically exist. They are
simulated counters and they can be programmed to count pulses. Typically these
counters can count up, down or both up and down. Since they are simulated they are
limited in their counting speed. Some manufacturers also include high-speed counters
that are hardware based. We can think of these as physically existing. Most times
these counters can count up, down or up and down. a

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TIMERS-These also do not physically exist. They come in many varieties and
increments. The most common type is an on-delay type. Others include off-delay
and both retentive and non-retentive types. Increments vary from 1ms through
1s.
OUTPUT RELAYS-(coils)These are connected to the outside world. They physically
exist and send on/off signals to solenoids, lights, etc. They can be transistors,
relays, or triacs depending upon the model chosen.

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DATA STORAGE-Typically there are registers assigned to simply store data. They are
usually used as temporary storage for math or data manipulation. They can also
typically be used to store data when power is removed from the PLC. Upon power-up
they will still have the same contents as before power was removed. Very convenient
and necessary!!

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 SWITC
HES
Non-locking Locking

Normally Open Normally Closed

P1

P2
Multiple Throw Multiple Pole

Break-before-make Make-before-break

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 TYPES OF SWITCHES
1. Basic switch, operated by a mechanical level
2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.

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 RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

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 COUNTER
Digital counters output in the form of a relay contact when a pre assigned count
value is reached.

input Input
Register
Reset

Accumulator Output
res et
Count 0 12 3 4 5 0 1

contact

output

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 TIMER
A timer consists of an internal clock, a count value register, and an
accumulator. It is used for or some timing purpose.

Clock Clock

Reset
Accumulator
reset Output

Count 0 1 2 3 4 5
Register

contact
Contact Time 5 seconds.
output

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 AN EXAMPLE OF RELAY
LOGIC
For process control, it is desired to have the process start (by turning on a motor) five
seconds after a part touches a limit switch. The process is terminated automatically when
the finished part touches a second limit switch. An emergency switch will stop the process
any time when it is pushed.

PB1
LS1 LS2
L1
LS1 PB1 LS2 R1

R 1
TIMER
TIMER R2
R1
5
Motor
R2

PR=5 R1

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 LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means of graphically
representing the logic required in a relay logic system.

start emergency stop PB2

PB1
R1

R1

R1
A

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Ladder Representation

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PLC WIRING DIAGRAM

Input PLC Output

01 01 02 20 11 A
12
02
20
03
20 11

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