450200

Intro to PLCs 200
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Class Outline
Objectives
What Is a PLC?
History of PLCs
PLC Components
How a PLC Works
The Structure of PLC Applications
Principles of Logic
Logic Symbols
CPU
Input Devices
Output Devices
Internal Relays
Counters
Timers
Sequencers
PLC Standardization
Summary
Lesson: 1/17
Objectives
Define PLCs.
Describe the history of PLCs.
Identify the main components of a PLC
system.
Describe how a PLC works.
Describe how a PLC is structured.
Identify basic PLC logic functions.
Identify the most common PLC logic
symbols.
Describe the role of PLC central
processing units.
Identify common input devices.
Identify common output devices.
Identify common internal relays.
Describe how counters work in a PLC.
Describe how timers work in a PLC.
Describe how sequencers work in a PLC.
Describe PLC standardization.
Figure 1. The CPU is the engine that drives the PLC.
Figure 2. A software program is used to create instructions that a PLC
can follow.
Lesson: 2/17
What Is a PLC?
Consider the typical shop floor. Most shop floors contain dozens or
even hundreds of machines, from the very simple to the complex.
Some are still operated and controlled solely by skilled workers.
However, most complex machines, especially large assembly lines
requiring automation, rely on programmable logic controllers,
or PLCs for short. A PLC is a solid-state device invented to
provide electrical control to machines.
The area of PLCs is growing rapidly. PLCs have replaced traditional
relay circuits that were formerly used in machines. Figure 1
shows the older relay circuits that were hard wired. Instead, a PLC
contains a CPU to store the desired functions in memory and uses
software that is programmed to execute those functions. This
offers greater flexibility and allows the same PLC to be used for a
range of applications. Today, PLCs are used to run almost any
application requiring electrical functions that turn on and off when
predetermined conditions are met. Even a simple device such as
the traffic light in Figure 2 uses a PLC.
Almost every new machine that comes into a factory has a PLC
controlling it. Consequently, almost every industrial maintenance
job demands knowledge of PLCs. This class provides an
introduction to the parts and operation of programmable logic
controllers. It describes the basic functions and familiarizes you
with programming language that you will find on most, if not all, of
the popular brands of PLCs.
Figure 1. A PLC can replace this hard-wired relay
circuitry.
Figure 2. Traffic lights use PLCs to operate.
Lesson: 3/17
History of PLCs
The very first PLCs were designed by engineers in the
automotive industry. The automation of the auto
assembly line was relatively advanced, but the
methods used for electrical control were not. Every
year, as design changes were made to different car
models, the relay circuits, the timers, and their
controllers had to be rewired.
Rewiring circuits is a skilled and time-consuming task.
Only trained electricians or engineers could do the
work, making it expensive as well. Also, while the
relays did the job well, all those physical contacts led
Figure 1. A small PLC can control large automated processes that
to wear and costly maintenance. As the manufacturing
required numerous relay circuits.
processes became more and more complicated, more
relay circuits were needed. Size became a big issue
when thousands of circuits were involved. A small
PLC, such as the one in Figure 1, replaces all those
circuits.
The original PLC designs made use of computer
programming languages. The problem with this
design was that most electricians and factory
maintenance people did not know computer
programming languages, as it was outside of their
daily duties. The solution was to use ladder logic.
Ladder logic for a PLC is a programming language that
simulates both the functionality of relay circuits and
uses diagrams that look the same to the plant
electrician as the hard-wired ladder logic diagrams.
Nowadays, electrical maintenance personnel who
work with the machines controlled by PLCs must be
relatively familiar with this ladder logic.
Figure 2. PLC ladder logic is based on electrical ladder diagrams.
Lesson: 4/17
PLC Components
Depending on the brand and model, the PLCs you
use may look slightly different. Smaller types are
block I/O and resemble a box, as you can see in
Figure 1. Larger industrial types take the form of
rack I/O, as shown in Figure 2. A rack holds
multiple circuit board I/O cards. Each I/O
module has a unique address used to locate it in
the program code. Figure 3 shows types of
addresses.
No matter the size or manufacturer, the internal
makeup of all PLCs is similar:
A CPU is the central processing unit of the
Figure 1. A block I/O PLC.
PLC. The CPU is the most important part
because it runs the entire process.
The input modules and output modules
are where electrical signals enter and exit
the PLC. Sensors are physically connected to
the input modules, and the output modules
are hooked to various loads that the PLC
must trigger.
A power supply (Figure 4) is needed for the
CPU and I/O modules. The power supply
Figure 2. A rack I/O PLC.
must convert the standard 120VAC to the
low voltage DC that the CPU requires, usually
around 5V. Input and output devices have
their own power supplies.
An internal relay performs the function of
transferring data from inputs to outputs.
They are software simulated relays that do
not physically exist, but within the PLC
program mimic small control relays, timers,
and counters.
A programming device is used to enter the
program into the PLC memory so that the
correct steps may be executed. A PC is
almost always the PLC programming device
and is interfaced with the PLC.
Figure 3. Addresses generally follow the pattern DEVICE TYPE:
LOCATION/MODULE NUMBER, but smaller block I/O PLCs just have
device type and module number.
Figure 4. A PLC power supply.
Lesson: 5/17
How a PLC Works
Because PLCs replace hard wired relay circuits, many people assume
that logic controllers work the same way. In a regular electrical circuit,
everything is assumed to be happening instantaneously. With the
speed of electricity and a continuously closed path, that is essentially
the case.
A PLC has physical inputs and outputs, but it uses software to simulate
the electrical relays. While the CPU processes information very quickly,
often within fractions of a second, it is not instantaneous. Figure 1 lists
the steps that the CPU continuously repeats.
First, the PLC checks all inputs and outputs to see if they are on or off.
When the inputs and outputs are checked, the PLC stores the data in its
memory. Next, the PLC logically executes your program one step at a
time. If your program contains instructions to turn the first output on, if
inputs one and two are on, it follows that instruction. The PLC follows
all your instructions and stores the results in memory.
The final step is to update the status of the outputs. The PLC looks at
all input and output conditions stored in memory. It reads the data
Figure 1. Each PLC scan consists of these steps.
from step two. Now it turns on the appropriate outputs. The completion
of these steps is known as one scan. After a full scan is complete, the
PLC repeats these steps over and over again, constantly checking and
updating inputs and outputs based on your programmed instructions.
Lesson: 6/17
The Structure of PLC Applications
Without a doubt, there is an incredible range of applications
for PLCs. PLCs can be used to automate the movements of a
robot, the pattern of signals for a traffic light, the steps to
filling and bottling soda, even the cycles of some washer and
dryers, such as the one in Figure 1. Despite the wide range
of applications, all PLCs share a similar structure.
Information signals are sent to the PLC by input devices
that are connected to input modules. These signals are
stored in memory and then processed through ladder logic
software. The memory is updated, and outputs are updated.
The resulting information is sent through the output
modules to the output devices that perform the desired
actions. This pattern of input to software to output provides
the basic setup for any PLC application.
An important point to remember is that input and output
Figure 1. The cycles of some washers and dryers are
devices are actual, physical, machine-mounted devices. Input
controlled by a PLC.
devices are usually some sort of sensor that detect change.
Input devices are plugged into the input modules. Output
devices do action, such as start a motor or turn lights on or
off when told to do so through the output modules. On the
other hand, the PLC software and the program that processes
this information are substitutes for the actual devices. A
ladder logic program, shown in Figure 2, is simply a series of
programming symbols that determine what is done with the
information sent to and from the input and output devices.
Figure 2. A PLC executes the instructions in a ladder logic
program.
Lesson: 7/17
Principles of Logic
If you want to begin programming logic controllers, you must
understand the logic that they use. PLCs rely on Boolean algebra.
Although this term may sound a bit intimidating, it simply means
that PLC programming involves binary numbers to produce "yes" or
"no" responses. This yes or no system fits well with the ladder logic
that was already used in electrical work.
Logic programs reflect basic speech. The best way to begin
understanding PLC logic is to learn the symbols PLCs use to
represent the following basic logic gates:
The AND function works much like a series circuit. Figure 1
shows both the graphic symbol for AND and how it is
represented in a PLC program. To trigger the output, both
inputs must be "on" to close the circuit. Figure 1. An AND function is similar to a series
The OR function (Figure 2) works much like a parallel circuit. If circuit.
you have multiple inputs and want the output to be triggered if
any of the inputs are on, you would use OR logic.
The NOT function (Figure 3) works by allowing one condition to
be on, but will not trigger the output if a second input is
present.
The NAND and NOR functions (Figure 4) work by combining a
NOT gate with an AND or an OR gate. NAND is the opposite of
AND. The only time the output is not on is when both inputs
are on. NOR triggers the output only when no inputs are
present.
Figure 2. An OR function is similar to a parallel
circuit.
Figure 3. The NOT function inverts a gate.
Figure 4. The NAND and NOR functions.
Lesson: 8/17
Logic Symbols
Once you understand basic PLC logic, you can begin to learn how that
logic is used in programs. Because of the limited display space,
symbols are also used to represent PLC logic commands. The two
most basic commands are examine on (EON) and examine off
(EOF). Figure 1 lists the common PLC logic symbols.
Examine on is true if the addressed bit is ON (1) and false if the bit
is OFF (0). The PLC examines the address and looks for an ON
condition (1). If it is ON (1) then the instruction is true. If it is OFF
(0) the instruction is false. So if the condition exists, the output is
triggered. If the bit is OFF, the PLC does not trigger the output.
Examine off is true if the opposite conditions exist.
It is important not to confuse examine on and examine off with the
hard-wired logic symbols normally open contact and normally
Figure 1. Symbols for common PLC logic
closed contact. While it is tempting to do so, and a PLC seems to be
commands.
mimicking these functions, they are not the same and can lead to
error.
Both examine on and examine off are inputs. The most common
output symbol is output energize (OUT). This symbol simply means
to energize the output. Every program line must have at least one
output instruction.
Lesson: 9/17
CPU
A CPU, or central processing unit, is the engine that drives the
operation of a PLC. Figure 1 illustrates how the CPU controls the rest
of the parts of a PLC. The software that makes up the internal relays
simulates the connections that trigger inputs and outputs, but the
CPU is what runs the software.
The processor of a logic controller, shown in Figure 2, is similar to one
you might find in a typical computer with regards to speed and size. It
can process hundreds of lines of program code in a fraction of a
second and can be made very small. However, there are some key
differences that allow a PLC CPU to function well in an industrial
environment.
A traditional PC processor does not do well in extreme conditions. A
PLC model is much more rugged. It can deal with extreme
temperature changes that can occur in many industrial operations.
Also, noise and vibration can interfere with a computers performance,
but the PLC units are designed to withstand the electrical noise.
Figure 1. The CPU is the engine that drives the
PLC.
Figure 2. The CPU of a PLC.
Lesson: 10/17
Input Devices
You can think of input modules as the "wick" to the
PLCs loaded "cannon." The software is ready to ignite
inside, and the ball is ready to be output, but something
must trigger it. Some action must occur, and that action
must be detected to send that information input into the
PLC. The input modules, shown in Figure 1, are where
those different sensors are physically connected to the
PLC.
Input devices send electrical signals to the modules.
Some input devices include: a pushbutton (PB), shown
Figure 1. AC and DC PLC input modules.
in Figure 2, which is manually depressed to close a circuit
and let the PLC know to begin a desired function, such as
starting a motor. A photo eye (PE) (Figure 3) detects
motion, such as a part passing on an assembly line. A
limit switch (LS) is used to cut power when a machine
reaches the end of its safe motion. Figure 4 shows the
symbols for these input devices.
Figure 2. These pushbuttons are input devices that send
signals to the PLC software.
Figure 3. Photo eyes send electrical signals to the PLC when
they sense motion.
Figure 4. Some common input device symbols.
Lesson: 11/17
Output Devices
For any PLC application, the information processed by the PLC
ultimately leads to a signal sent to output devices. The output
module is where the PLC sends the signals it has processed. The
output relays are hooked to various devices that the PLC triggers.
Essentially, the purpose of a PLC is the controlled functioning of
whatever outputs are connected to the output modules.
A PLC controls mechanical devices such as motors, but very rarely
will a PLC directly drive a motor. Output modules do not have
enough current-carrying capacity to do so. Instead, a motor
starter (MS), shown in Figure 1, is connected to the PLC output
modules. This way, the PLC triggers a coil on the motor starter,
which then drives the motor.
Some examples of other devices that connect to the output relays
include a solenoid (SOL) or pilot light (PL). The symbols for these
output devices are shown in Figure 2. A solenoid is an
electromagnetic coil that converts electric energy into mechanical
motion. A pilot light is used to indicate whether power is on to a
particular system.
Figure 1. Motor starters carry more current than a
PLC.
Figure 2. Some common output symbols.
Lesson: 12/17
Internal Relays
The internal relays are the software simulated relays that
allow a relatively small PLC to replicate hundreds to
thousands of physical, external relay circuits. Figure 1
shows PLC software simulated relays. The number of
internal relays that a particular PLC model is able to
replicate is usually dependent on its memory capacity.
There are many different types of internal relays, but some
are more common for factory use.
A counter is a device that opens or closes contacts
when a predetermined count is reached. Many
assembly line processes use a counter to package
products.
Figure 1. A software program can simulate an almost
A timer is simply a software process that waits a set
limitless number of relays.
amount of time after the input to update the output.
Sometimes, you want a delay between an input or
removing an input and the output.
A sequencer is one way internal relays are able to
replicate and replace so many physical relays. A
sequencer can greatly simplify processes that need to
be repeated over and over again, as is often the case
in a manufacturing setting.
Lesson: 13/17
Counters
Many industrial PLC applications require the system to
keep counts, especially with assembly or similar
processes. A brewery would place 12 or 24 cans in a
package before closing it and starting a new one. For
purposes like this, PLCs make use of count up
counters (CTU) and count down counters (CTD).
For most applications, the CTU will work, and they are
easier to use for most people since they count up.
To use a counter with a PLC, you must set them up in
the program. To do this, you need to set a preset
value. The preset is how many items you want the PLC
to count. Each counter also has a reset that's value is
usually zero. The reset is the number it will begin
counting from, and when you count anything, you
almost always start from zero. The third value on a
counter is the accumulator. The accumulator is also
usually set to zero, as it measures what you have
when you start counting. Figure 1 shows a basic
counter box.
Figure 1. A counter box like this one is displayed on a
programming line that requires counting.
Lesson: 14/17
Timers
Another common type of function used by the
internal relays of a PLC is a timer. Older timers, such
as the ones in Figure 1, are physical devices.
However, PLC timers are not solid devices. Rather,
they are simply internal instructions for the PLC
program to wait a certain amount of time before
executing its output. In industry, timing devices are
very useful to synchronize different machining
processes. For example, a timer could instruct a PLC
to wait a few seconds to energize a motor starter to
ensure that a safety door has completely closed.
Figure 1. PLC timers replace these physical devices.
The most common type of PLC timer is a timer on
delay (TON). This function delays activating the
output for a preset amount of time after receiving the
input signal. This delay can be as short as a
millisecond or much longer. Figure 2 shows a basic
TON circuit program.
The opposite of the timer on delay is the timer off
delay (TOF). As you might imagine, this function
waits to relay the signal to shut off an output for a
preset amount of time after receiving the input signal
to do so. An example is how car headlights (an
output) delay turning off after the ignition (an input)
is shut off.
Remember, timers are not physical devices in PLCs.
They are designed much like counters, with a preset,
a reset, and an accumulated value. Instead of
counting something physical, they count units of
time.
Figure 2. When the input is triggered, the timer delays turning on
the output for the preset time.
Lesson: 15/17
Sequencers
Many large-scale production facilities require identical,
repetitive tasks that must be completed many times over
during the course of a day. A PLC can easily automate
many of these processes through the use of a sequencer
(SQO). A sequencer is a logic device that takes a set of
inputs coming into a PLC and goes through a sequence of
steps leading eventually to a set of outputs.
The main benefit of using a sequencer is that it can
greatly simplify what could be a complex process. Rather
than write more lines for the program, you have a SQO
Figure 1. Sequencers allow you to write shorter programs for
symbol on your PLC that lets you repeat a function over
repeatable processes.
and over rather quickly. Figure 1 shows a one-line
program that uses a sequencer.
In order for the sequencer to start the function again,
something must trigger it. There are two main ways to do
this. An event-driven trigger is set off when something
hits a switch or crosses a photo eye. Once a part crosses
the end of an assembly line, or one process in that line, it
triggers the PLC sequencer to do it again for the next
part.
The other way a sequencer can be triggered is with a
time-driven trigger. If everything is working correctly, a
machine will make a part in exactly the same amount of
time every time. The sequencer is on a clock, and as soon
as all the steps have been completed in that set amount
of time, it begins the same steps again.
Lesson: 16/17
PLC Standardization
As PLCs were developed, users began to face a problem
that is common with many new technologies. Many
different companies started to produce their own PLCs,
and all used their own interfaces and protocols. These
differences in protocols lead to PLCs that cannot work
with each other. PLCs communicate through cables,
such as the one shown in Figure 1, or through Ethernet
. Even worse, switching from one PLC system to another
became difficult because users would have to learn a
new set of commands.
While it is natural that improvements to technology
yield some changes, a push was made to reduce the
Figure 1. To communicate with each other, PLCs can be
number of new languages for PLCs. The International
physically connected through cables.
Electrotechnical Commission (IEC) publishes
standards that govern the safe and effective use of
electrical devices. They introduced IEC 61131-3 to
help standardize PLC programming languages. This was
the first international standard to address PLC systems.
The IEC standard supports two graphical languages,
including the common ladder logic and two textual
programming languages. Different brands of PLC may
not necessarily use all the languages. For example,
Allen Bradley PLCs use only ladder logic.
Lesson: 17/17
Summary
A PLC is a solid-state device invented to provide electrical control to
machines. As manufacturing processes became more complicated, more
relay circuits were needed. A small PLC replaces all those circuits. An
internal relay performs the function of transferring data from inputs to
outputs. First, the PLC checks all inputs and outputs to see if they are
on or off. Next, the PLC logically executes your program one step at a
time. The final step is to update the status of the outputs. This pattern
of input to software to output provides the basic setup for any PLC
application.
PLCs rely on Boolean algebra. Symbols are also used to represent PLC
logic commands. The two most basic commands are examine on (EON)
and examine off (EOF). A central processing unit (CPU) is the engine
that drives the operation of a PLC. Input devices send electrical signals
Figure 1. A block I/O PLC.
to the modules. An example of an input device is a pushbutton (PB).
The information processed by the PLC ultimately leads to a signal sent
to an output device, such as a solenoid. Many industrial PLC
applications require the system to keep counts with a counter device.
PLCs use timers that are programmed to wait a certain amount of time
before executing commands. The most common type of PLC timer is a
timer on delay (TON). A sequencer is a logic device that takes a set of
inputs coming into a PLC and goes through a sequence of steps leading
eventually to a set of outputs. The International Electrotechnical
Commission (IEC) publishes standards that govern the safe and
effective use of electrical devices, including PLCs.
Figure 2. The steps in a PLC scan.
Class Vocabulary
Term Definition
A register in PLC memory that stores the results of counting functions. accumulator
The unique location assigned to each I/O module so that it may be correctly referenced and address
signaled by the PLC program.
A logic function where both A and B must be true to trigger C. AND works similar to a series AND
circuit.
Self-regulated machines that meet predetermined requirements in a continuous process automation
without the need for direct human intervention.
A number system used for PLCs that has either 0 or 1 as a value. Using binary, a function is binary
either on or off.
A smaller type of PLC that is a self-contained box. A block I/O has fewer input and output block I/O
modules.
A branch of mathematics that deals with the use of logical operators OR, AND, and NOT. Boolean algebra
A type of PLC software counter that counts down from the reset value. Count down counters count down counter
are less popular because they may use negative numbers.
A type of PLC software counter that counts up from the reset value, usually 0. count up counter
An internal relay program that counts items to a preset number before starting the process counter
over again.
The main processor of information in a PLC that performs all logic and math operations. CPU
A common method used to link computers or PLCs together through a local area network. Ethernet
A sequencer trigger actuated by some type of mechanical motion that is sensed by an input. event-driven trigger
A basic PLC logic instruction symbol. Also referred to as Examine If Open. examine off
A basic PLC logic instruction symbol. Also referred to as Examine If Closed. examine on
Abbreviation for input/output device. I/O
The IEC standard that seeks to limit the number of PLC protocols in use. IEC 61131-3
A type of device, usually a sensor, that sends information into a PLC. Inputs are connected to input device
the PLC by input modules.
The jack where an input device is physically connected to a PLC. The input modules transfer input module
signals to the internal relays.
The part of a PLC that simulates the physical connections of relay circuits by using processor internal relay
driven software.
International
An organization that provides conformity assessment for government, business, and society
Electrotechnical
for all electrical, electronic, and related technologies.
Commission
A method for drawing electrical logic schematics. Ladder logic is now most often used to ladder logic
program PLCs.
A protective device used to open or close electrical circuits when temperature or pressure limit switch
limits are reached.
The sequence of instructions performed by a PLC program. logic
A circuit with several inputs but only one output that can be activated by particular logic gate
combinations of inputs. Logic gates are used to calculate operations in Boolean algebra.
The physical connection on a PLC where an input or output is plugged in. module
A type of PLC output device that starts a motor when triggered. PLCs do not have the current motor starter
capacity to start a motor on their own.
A logic function where both A and B must be false to trigger C. If one input is present, the NAND
output will not be turned on.
A logic function where C will be triggered if neither A nor B are present. NOR
An electrical contact that regularly allows electricity to flow. normally closed contact
An electrical contact that rarely allows electricity to flow. normally open contact
A logic function where the output will not be triggered if a specified input is present. NOT
A logic function where C is triggered if either A or B are true. OR works similar to a parallel OR
circuit.
A device that performs a mechanical action after receiving the electrical signal to do so from output device
the PLC output modules.
The most common PLC output symbol. Using this means to energize, or turn on, the output. output energize
The jack where an output device is physically connected to a PLC. The output modules output module
transfer signals from the internal relays.
A personal computer. PCs are processor driven and are now used to do most PLC PC
programming.
A type of PLC input that senses motion. Once the motion is detected, the photo eye sends a photo eye
signal to begin an output.
A light that indicates whether power is on or a motor is in operation. pilot light
The device that provides power to a PLC CPU and I/O modules. The power supply must power supply
convert the line voltage to around 5VDC for the PLC to use.
A value that is programmed into a PLC counter. The preset is the target number you want the preset
system to reach.
A processor driven device that uses logic-based software to provide electrical control to programmable logic
machines. controller
The physical device used to enter a program into PLC memory. PCs are the most common programming device
programming devices.
The language spoken between computers to help them exchange information. protocol
A type of PLC input that when manually depressed lets the system know the circuit has been pushbutton
closed and a process should begin. Pushbuttons are commonly used as machine start buttons.
A larger type of PLC that is a collection of I/O cards that are linked together and stored in a rack I/O
rack. A rack I/O can handle thousands of inputs and outputs.
Hard-wired physical devices that transfer electrical signals from input devices to output relay circuit
devices. PLCs use software to digitally simulate these connections.
A value that is programmed into a PLC counter. The reset is the number at which the counter reset
begins counting, usually zero.
One complete cycle of a PLC checking inputs, executing its programs, and updating the status scan
of its outputs.
A device that detects a change in a physical stimulus and turns it into a signal that can be sensor
measured or recorded.
A logic device that takes a set of inputs coming into the PLC and orders the steps that lead to sequencer
a series of outputs.
Written operating instructions for a processor to carry out. software
A type of output device coil that utilizes voltage to convert electrical energy to mechanical solenoid
energy via magnetic fields.
A type of circuit used in digital equipment that replaced physical connections. solid-state device
A sequencer trigger actuated by an internal clock. time-driven trigger
An internal relay program that delays sending input data to the outputs for a preset amount timer
of time.
A timer that waits to turn off the output after receiving an off signal from the input. timer off delay
A timer that waits to turn on the output after receiving an on signal from the input. timer on delay

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Intro to PLCs 200

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