T.C.

Chang

Chapter 7. PROGRAMMABLE
LOGIC CONTROLLER

Dr. T.C. Chang

School of Industrial Engineering
Purdue University

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FUNCTIONS OF CONTROLLERS
1) on-off control,
2) sequential control,
3) feedback control, and
4) motion control.

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CONTROL DEVICES
1) mechanical control - cam, governor, etc.,
2) pneumatic control - compressed air,
valves,etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.

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PROGRAMMABLE LOGIC
CONTROLLER
Invented in 1968 as a substitute for hardwired relay panels.
"A digitally operating electronic apparatus which uses a
programmable memory for the internal storage of instructions by
implementing specific functions such as logic sequencing,
timing, counting, and arithmetic to control, through digital or
analog input/output modules, various types of machines or
processes. The digital computer which is used to perform the
functions of a programmable controller is considered to be
within this scope.
Excluded are drum and other similar
mechanical sequencing controllers."

National Electrical Manufacturing Association (NEMA)

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VENDOR
S
MODICOM - GOULD
ALLEN-BRADLEY
GE
SQUARE-D
etc.

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PLC
CPU

Input

Input
Module

Flag
System
Output

Output
Module

User Ladder
Diagram

Working
memory
registers

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An Large Size PLC

The main module
measures 19 x 20 x 14.5.
have upto 10,000 I/O points
supports all functions
expansion slots to
accommodate PC and
other communication
devices.

Allen-Bradley PLC-3

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A Small Size PLC

Measures 4.72x 3.15 x
1.57.
32 I/O points
Standard RS 232 serial
communication port

Allen-Bradley MicroLogix 1000

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SWITCHES
Non-locking

Locking

Normally Ope n

Normally Clos e d

P1

SPDT

DPST

P2

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Multiple Throw

Multiple Pole

Bre ak-before -make

Make -be fore -bre ak

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TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual
circuits).
SPDT

A serial switch box (A-B box) has

two 25 pin serial ports to switch from.
A

DPST

B
Output

Input

Knob
How is this switch classified?
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TYPES OF SWITCHES

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Selector switches
Pushbutton switches
Photoelectric switches
Limit Switches
Proximity switches
Level switches
Thumbwheel switches
Slide switches

RATING:
24 Volts AC/DC
48 Volts AC/DC
120 Volts AC/DC
230 Volts AC/DC
TTL level
(Transistor-to-transistor
5V)
Isolated Input

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

coil

input

Relay coil
R1
Output contact

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R1
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COUNTER
Digital counters output in the form of a relay contact when a preassigned
count value is reached.
input

reset

Register

Accumulator

contact
output
Input
Reset
Output
Count
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12

1
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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

reset

Accumulator

Register
contact
Contact
output

Clock
Reset
Output
Count

Time 5 seconds.
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AN EXAMPLE OF RELAY LOGIC

For a process control, it is desired to have the process start (by turning
on a motor) five seconds after a part touched 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.
L1
LS1

PB1

LS2

R1

R1
R1

TIMER

R2
LS1

PB1

LS2

PR=5

TIMER
5

Motor
R2

R1

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PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring by
software programming.

Program
Loader

PC
Switches

Printer
Processor

I/O
Modules

Memory

Power
Supply

Machines

Cassette
Loader
EPROM
Loader

External Devices

Peripherals

A typical PLC
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PLC COMPONENTS
1. Processor
Microprocessor based, may allow arithmetic
operations, logic operators, block memory moves,
computer
interface, local area network, functions, etc.
2. Memory

Measured in words.

ROM (Read Only Memory),

RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electric Erasable Programmable ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.

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3. I/O

PLC
COMPONENTS
Modular plug-in periphery
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g., high speed timers,
Stepping motor controllers, etc. PID, Motion

4. Power supply AC power

5. Peripheral

hand-held programmer (HHP)

CRT programmer
operator console
printer
simulator
EPROM loader
graphics processor
network communication interface

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modular PC

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Discrete I/O
AC Voltage I/O
DC Voltage I/O
numerical input and output
special-purpose modules, for example, highspeed timers, and stepping motor controllers

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Analog I/O
Analog inputs:
Flow sensors
Humidity sensors
Potentiometers
Pressure sensors
Temperature sensors
Analog outputs:
Analog meters
Analog valves and actuators
DC and AC motor drives

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Some Special I/O

Thermocouple input

Low level analog signal, filtered, amplified, and digitized before

sending to the processor through I/O bus.

Fast input
50 to 100 microsecond pulse signal detection.

ASCII I/O
Communicates with ASCII devices.

Stepper motor output

Provide directly control of a stepper motor.

Servo interface
Control DC servo motor for point-to-point control and axis positioning.

PID control
The Proportional Integral Derivative is used for closed loop process
control.

Network module
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A Hand Held Programmer

An Allen-Bradley hand-held programmer for MicroLogix 1000

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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.

Rail

Rung

start
PB1

emergency stop
PB2

R1

R1

R1
A

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PLC WIRING DIAGRAM

Input
01

02

Output

PLC
01

02

20

11

12
20

03
20

11

External
switches

Stored program

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Input Connections

AC

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DC

TTL

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Output Connections

AC

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DC

TTL

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SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung,

from the top to the bottom. Usually, all the outputs are updated based on
the status of the internal registers. Then the input states are checked and
the corresponding input registers are updated. Only after the I/Os have
been resolved, is the program then executed. This process is run in a
endless cycle. The time it takes to finish one cycle is called the scan
time. In some controllers the idle state is eliminated. In this case, the
scan time varies depends on the program length.

Output
Input
begin
Idle
Scan cycle

Resolve
logic
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PLC Programming

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Ladder Diagram - most common

Structure Text Programming (ST)
Functional Block Programming (FB)
Instruction List (IL)
Sequential Function Chart (SFC)

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PLC Ladder Diagram

INSTRUCTIONS
1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.

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LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize, etc.

Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.
(In the notes we use the symbol "~" to represent
negation. AND and OR are logic operators. )

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AND and OR LOGIC

PB1

PB2

R1
R1 = PB1.AND.PB2

AND

PB3

PB1

PB4

R2

R2 = PB2.AND.~PB4

R1
R1 = PB1 .OR. PB2

OR

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PB2

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COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

R1

PB1

PB2

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pb3

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RELAY
A Relay consists of two parts, the coil and the contact(s).
Contacts:
a. Normally open

-| |-

b. Normally closed

-|/|-

c. Positive transition sensing

-|P|-

d. Negative transition sensing

-|N|-

()

Coil:

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a. Coil

-( )-

b. negative coil

-(/)-

c. Set Coil

-(S)-

d. Reset Coil

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Relay (continue)
Coil:
e. Retentive memory Coil

-(M)-

f. Set retentive memory Coil

-(SM)-

g. Reset retentive memory Coil

-(RM)-

h. Positive Transition-sensing Coil

-(P)-

h. Negative Transition-sensing Coil

-(N)-

(set coil latches the state, reset coil deenergize the set coil.
retentive coil retain the state after power failure.)

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TIMERS AND COUNTERS

Input
Timers:

True

a. Retentive on delay

-(RTO)-

b. Retentive off delay

-(RTF)-

c. Reset

-(RST)-

RTO counting stop

RTF

stop

True
counting
resume

counting stop

RTO reach PR value, output ON

RTF reach PR value, output OFF

Counter:

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False

a. Counter up

-(CTU)-

b. Counter down

-(CTD)-

c. Counter reset

-(CTR)-

PR value in 0.1 second

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SEQUENCE
R or processes involving
Sequencers are used with machines

repeating operating cycles which can be segmented into

steps.
Output

Step

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Dwell time

ON

OFF OFF

5 sec.

ON

ON OFF

10 sec.

OFF

OFF ON

3 sec.

OFF

ON OFF

9 sec.

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A-B PLC
I/O points are numbered, they correspond to the I/O slot on the
PLC.
For A-B controller used in our lab
I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982

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PROGRAMMING EXAMPLE 1
Bar code reader

microswitch

Stopper
Conveyor

Part

Robot

Machine

id description
MSI microswitch
R1 output to bar code reader
C1 input from bar code reader
R2 output robot
R3 output robot
C2
input from robot
R4 output to stopper
C3
input from machine
C4
input from machine
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state
1
1
1
1
1
1
1
1
1

explanation
part arrive
scan the part
right part
loading cycle
unloading cycle
robot busy
stopper up
machine busy
task complete
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SOLUTION
Input
MS1
C1
C2
C3
C4

Output

01

11

02

12

03

13

04

14

Programmable
Controller
PLC

05

01

11

14

14

02

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14

04

05

03

03

12
13

R1
R2
R3
R4

15

Rung 1. If part arrives and no

part is stopped, trigger the
bar code reader.
Rung 2. If it is a right part,
activate the stopper.
Rung 3. If the stopper is up,
the machine is not busy
and the robot is not busy,
load the part onto the
machine.
Rung 4. If the task is
completed and the robot is
not busy, unload the
machine.
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Structured Text Programming

a high level language
used to express the behavior of functions, function blocks
and programs
In IEC 1131-3 standard, it has a syntax very similar to
PASCAL
strongly typed language
Functions:

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assignments
expressions
statements
operators
function calls
flow control

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Data Types
SINT
INT
DINT
LINT
USINT
UINT
UDINT
ULINT
REAL
LREAL

short integer
integer
double integer
long integer
unsigned short integer
unsigned integer
unsigned double integer
unsigned long integer
real
long real

1 byte
2 bytes
4 bytes
8 bytes
1 byte
2 bytes
4 bytes
8 bytes
4 bytes
8 bytes

BOOL
BYTE
WORD
DWORD
LWORD

boolean
byte
16 bit bit string
32 bit bit string
64 bit bit string

1 bit
1 byte
16 bits
32 bits
64 bits

TIME time duration

DATE calendar date
TOD
time of day
DT
date and time of day
STRING character strings

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Derived Data Types

TYPE

(* user defined data types, this is a comment*)

pressure
:
REAL;
temp
:
REAL;
part_count
:
INT;
END_TYPE;
Structure:
TYPE data_packet:
STRUCT
input
:
t
:
out
:
count
:
END_STRUCT;
END_TYPE;
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BOOL;
TIME;
BOOL;
INT;

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Variable Declarations

Local variable:
VAR
I,j,k :
v
:
END_VAR

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INT;
REAL;

Use VAR, VAR_INPUT,

VAR_OUTPUT, VAR_IN_OUT,
VAR_GLOBAL,
VAR_EXTERNAL for different
variable types.

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Operators and Expressions

( )

parenthesized expression

function( )

function

**

exponentiation

negation

NOT

Boolean complement

+-*/

math operators

MOD

modulus operation

< > <= >=

comparison operators

equal

<>

not equal

AND, &

Boolean AND

XOR

Boolean XOR

OR

Boolean OR

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Y := X+1.0;
y := a AND b;
v := (v1 + v2 + v3)/3
output := (light = open) OR
(door = shut);

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Condition Statements
IF a > 100 THEN
redlight := on;
ELSEIF a > 50 THEN
yellowlight := on;
ELSE
greenlight := on;
END_IF;

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CASE dial_setting OF
1:
x := 10;
2:
x := 15;
3:
x := 18;
4,5: x := 20; (* 4 or 5 *)
ELSE
x := 30;
END_CASE

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Iteration Statements
FOR I:= 0 to 100 BY 1 DO
light[I] := ON;
END_FOR
I := 0;
WHILE I < 100 DO

I := 0;
REPEAT
I := I + 1;
light[I] := on;
UNTIL I > 100;
END_REPEAT

I := I + 1;
light[I] := on;
END_WHILE

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Functions
FUNCTION add_num : REAL
VAR_INPUT
I,J

REAL

END_VAR
add_num := I + J;
END_FUNCTION
Call a function:
x:= add_num(1.2, 5.6);
Built-in Functions:

ABS, SQRT, LN, LOG, EXP, SIN, COS, TAN, ASIn, ACOS,
ATAN, ADD, MUL, SUB, DIV, MOD, EXPT, MOVE), logic
functions (AND, OR, XOR, NOT), bit string functions (SHL,
SHR shift bit string left and right , ROR, ROL rotate bit
string), etc.
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Programs
PROGRAM example7.1
VAR_INPUT

R1 := MS1 AND (NOT R4);

MSI :

BOOL;

R2 := R4 AND (NOT C3) AND (NOT C2);

C1 :

BOOL;

R3 := C4 AND (NOT C3);

C2 :

BOOL;

C3 :

BOOL;

C4 :

BOOL;

R4 := C1;
END_PROGRAM

END_VAR
VAR_OUTPUT
R1 :

BOOL : FALSE;

R2 :

BOOL : FALSE;

R3 :

BOOL : FALSE;

R4 :

BOOL : FALSE;

END_VAR

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Functional Block Programming

Functional block (FB) is a well packaged element of
software that can be re-used in different parts of an
application or even in different projects. Functional
blocks are the basic building blocks of a control system
and can have algorithms written in any of the IEC
languages.

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An Up Counter Function Block

The algorithm in Structured Text:
FUNCTION BLOCK CTU
VAR_INPUT
CU : BOOL;
R : BOOL;
PV : INT;
END_VAR
VAR_OUTPUT
Q : BOOL;
CV : INT;
END_VAR
IF R THEN
CV := 0;

CU
R
PV
Q
CV

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: input to be counted
: reset
: preset value
: contact output
: counter value.

ELSEIF CU
AND (CV < PV) THEN
CV := CV + 1;
END_IF;
Q := (CV >= PV);
END_FUNCTION_BLOCK

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A PID Control Function Block

block diagram

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SP

set point

PV

sensor feedback

KP

proportional error gain

TR

integral gain

TD

derivative gain

AUTO

calculate

XOUT

output to process

XO

manual output adjustment

cycle

time between execution

Vout K p E Tr Edt Td

dE
dt

control algorithm

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Instruction List Programming

A low level language which has a structure similar to an
assembly language. Since it is simple, it is easy to learn and
ideally for small hand-held programming devices. Each line of
code can be divided into four fields: label, operator, operand,
and comment.
e.g.

loop

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LD
ST
ANDN

MS1
R1
C3

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Operator Modifiers Description

LD N
into register

Operator
s

load operand

ST N
store register
value into operand
S

set operand true

reset operand false

AND N, (

Boolean AND

&

N, (

Boolean AND

OR

N, (

Boolean OR

XOR N, (
XOR

Boolean

ADD (

addition

SUB (

subtraction

MUL (
multiplication
DIV (

division

GT
(
greater than
GE
(
greater than and equal
to
EQ
equal

NE
not equal

LE
(
less than and equal to
LT(

less than

JMP
C, N
jump to label
CAL

C, N

Modifier N means negate. ( defers the

call function
block
operator. C is a condition
modifier,
the
operation is executed if the register value is true.
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RET
C, N
return from function or7- 53

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Instruction List for Example 1

PROGRAM example7.1
VAR_INPUT

MS1

ANDN

R4

ST

R1

LD

R4

MSI

C1 :

BOOL;

C2 :

BOOL;

C3 :

BOOL;

ANDN

C3

C4 :

BOOL;

ANDN

C2

END_VAR

ST

R2

VAR_OUTPUT

LD

C4

R1 :

BOOL : FALSE;

ANDN

C3

R2 :

BOOL : FALSE;

ST

R3

R3 :

BOOL : FALSE;

R4 :

BOOL : FALSE;

LD

C1

ST

R4

END_VAR

BOOL;

LD

END_PROGRAM

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Sequential Function Chart

(SFC)
A graphics language used for depicting sequential
behavior. The IEC standard grew out of the French
standard Grafcet which in turn is based on Petri-net. A
SFC is depicted as a series of steps shown as rectangular
boxes connected by vertical lines. Each step represent a
state of the system being controlled. The horizontal bar
indicates a condition. It can be a switch state, a timer, etc.
A condition statement is associated with each condition
bar. Each step can also have a set of actions. Action
qualifier causes the action to behave in certain ways. The
indicator variable is optional. It is for annotation
purposes.
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SFC
Action Qualifiers:
N

non-stored, executes while the

step is active

resets a store action

sets an action active

time limited action, terminates

after a given period

time delayed action.

a pulse action, executes once in

a step

SD stored and time delayed

DS time delayed and stored
SL stored and time limited
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SFC for Example 1

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