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INTRODUCTION TO PLC
LADDER LOGIC PROGRAMMING

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Coverage
PART-1: Introduction to PLC
• What is Programmable Logic Controller?
• Components of PLC
• How does a PLC function?
• Programming methods for PLCs – Ladder, SL,
FB,..
• PLC communications.
• Applications of PLCs
PART-2: Programming the PLC.
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WHAT IS PLC?
• Acronym for PROGRAMMABLE LOGIC CONTROLLER.
• Digital computer used in automation of electro-
mechanical processes.
• uses programmable memory for internal storage of
instructions
• implementing specific functions such as logic,
sequencing, timing, counting and arithmetic
• controls through digital or analog inputs and outputs
• A replacement for hard-wired complex relay logic.
• Earliest PLCs: Year 1960
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Differences
Wired Logic Panel & PLC Based Panel

1. Too much work required in 1. Number of connecting wires

connecting wires.
2. Consumes more space.
3. Difficulty in finding errors;
requires skilled work force.
4. Change in operating sequence or
an application is very difficult.
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reduced by 80%.
2. Consumes very less space.
3. Diagnostic functions of a PLC
allows faster & easier error-
detection.
4. Change in operating sequence
or an application can be done
very easily.
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Differences
Wired Logic Panel & PLC Based Panel

5. In case of automation 5. In case of automation

of complex systems, of complex systems,
cost is very high. cost is very less.
6. Reliability is less. 6. Reliability is high.
7. More spare parts are 7. Less spare parts are
required. required.
8. Lesser computational 8. Greater computational
abilities. abilities.

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PLC sizes
SMALL upto 128 IOs, memory upto 2 Kbytes.
Rs:20000 Modicon m340
MEDIUM upto 2048 IOs, memory upto 32 Kbytes.
Rs: Modicon premium
LARGE typically 8192 IOs, memory 750 Kbytes;
can control individual production
processes or entire plant.
Quantum

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COMPONENTS OF A PLC
POWER
SUPPLY

I M O M
N O PROCESSOR U O
P D + T D
U U P U
T L Registers / U L
From E T E
SENSORS
Memory To
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

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COMPONENTS OF A PLC
• Processor: Provides intelligence to command and govern the
activities of the entire PLC systems.

• I/O modules: Provides signal conversion and isolation between the

internal logic-level signals inside the PLC and the field’s high level
signal.

• Programming Device: used to enter the desired program that will

determine the sequence of operation and control of process
equipment

• Power Supply: Provides the 24V dc voltage needed to run the primary
PLC components or driven machine.

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I/O MODULES

• Input modules converts signals from discrete

or analog input devices to logic levels
acceptable to PLC’s processor.

Flow rate
Float level

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I/O MODULES
DC INPUT MODULE

IS NEEDED TO:
USE TO • Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL •Helps reduce the
effects of electrical
noise

Current Buffer,
FROM Limiting OPTO-
Filter,
TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits

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I/O MODULES
AC INPUT MODULE

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

Rectifier, Buffer,
FROM Resistor OPTO-
Filter,
TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits

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I/O MODULES

• Output modules converts signal from the

processor to levels capable of driving the
connected discrete or analog output devices.

pump
valve

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I/O MODULES
DC / AC OUTPUT MODULE
IS NEEDED TO:
• Prevent voltage
transients from
damaging the
processor.
•Helps reduce the
effects of electrical
noise

Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

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TYPES OF I/O CIRCUITS

• Pilot Duty Outputs – to drive high current electromagnetic
loads such as solenoids, relays, valves & motor starters.
• General-Purpose Outputs – to drive low-voltage low-current
loads such as indicating lights.
• Digital Inputs – to sense the status of limit switches, push
buttons.
• Analog I/O – to sense or drive analog signals. (4-20mA, 0-5V)

Analog i/ps – from thermocouples, pressure transducers.

Analog o/ps – to X-Y recorders, valves.
• Special Purpose I/O – to sense or to drive servomotors, high
speed pulse counting, multiplexed displays.

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INPUTS OUTPUTS

MOTOR

VFD

LAMP
PUSHBUTTONS
PLC

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Level Transmitter IN

PLC
Analog
Tank Input
Module

ANALOG OUTPUT

ANALOG INPUT
Electric to pneumatic transducer

OUT
E Supply air
PLC 0 to 10V P

Analog
Output
Module
Pneumatic control valve
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DIGITAL INPUT DIGITAL OUTPUT

IN

OFF PLC
Logic 0
Input OUT
Module
PLC
24 V dc
Lamp
Digital
IN
Output
Module
ON PLC
Logic 1
Input
Module
24 V dc

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PROCESSOR
• 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.

• The memory system in the processor module

has two parts: a system memory and an
application memory.

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•System memory includes an area called the EXECUTIVE,

composed of permanently-stored programs that direct all system
activities, such as execution of the users control program,
communication with peripheral devices, and other system
activities.
SYSTEM •The system memory also contains the routines that implement the
PLC’s instruction set, which is composed of specific control
functions such as logic, sequencing, timing, counting, and
arithmetic.
•System memory is generally built from read-only memory devices.

APPLICATION
(data table + •The application memory is divided into the data table area and
user program ) user program area.
•The data table stores any data associated with the user’s control
program, such as system input and output status data, and any
stored constants, variables, or preset values. The data table is
where data is monitored, manipulated, and changed for control
purposes.
•The user program area is where the programmed instructions
entered by the user are stored as an application control program.

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OPERATION: PLC Scan Cycle

PHASE 1
Self test

PHASE 2
Input scan

PHASE 3
Logic scan

PHASE 4
Output Scan

Repeats 10 to 100 times per second

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OPERATION SEQUENCE
• Self test: it will check it's own hardware and
software for faults.
• Input scan: it will copy all the input values
into memory
• Logic scan: based on input , program is
executed .
• Output scan : It copies output values from
memory to output devices

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OPERATION: PLC Scan Cycle

• Scan Time: The time PLC takes to implement a
scan cycle.
• SCAN TIME = PROGRAM SCAN TIME + I/O
UPDATE TIME
• Program Scan Time: The time required to
solve the control program.
• I/O Update Time: The time required to read
inputs & update outputs.

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A HAND HELD PROGRAMMER

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PLC COMMUNICATIONS

• Communication to remote equipment (drives,

PC/SCADA)
serial RS232C point to point
Serial RS485 (multidrop) with MODBUS
Ethernet with MODBUS / TCP

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RS 232

• Short distance communication.

• Maximum distance of 30metres @ 9600 baud.
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RS 485

• Long distance communication.

• Maximum distance of 1000metres.
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Communication network options

Network option Transfer rate (max) Distance

RS-485 19,200 bits/s 1.2 km

RS-232 19,200 bits/s 15 m
DH+ 230.4 kbits/s 3 km
Ethernet 100 Mbits/s 150 m
Control Net 5 Mbit/s 30 km
Device Net 500 kbit/s 487 m

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OTHER COMMUNICATION STANDARDS

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Classification based on size

RACK

MINI

MICRO

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SELECTING A PLC
1. Number of logical inputs and outputs.
2. Memory.
3. Number of special I/O modules.
4. Scan Time.
5. Communications.
6. Software.

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LEADING BRANDS OF PLC

AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cuttler Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

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LEADING BRANDS OF PLC

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

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LIST OF ITEMS REQUIRED WHEN

WORKING WITH PLC’S
1. Programming Terminal - laptop or desktop PC.
2. PLC Software. PLC manufacturers have their
own specific software and license key.
3. Communication cable for connection from Laptop
to PLC.
4. Backup copy of the ladder program (on diskette,
CDROM, hard disk, flash memory). If none,
upload it from the PLC.
5. Documentation - (PLC manual, Software manual,
drawings, ladder program printout, and Seq. of
Operations manual.)
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AREAS OF APPLICATION
 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical

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Programming PLCs

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IEC61131-3

• International standard for programmable

controller programming languages.

• It specifies syntax, semantics & display for the

following PLC programming languages:

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IEC61131-3
1. Ladder Diagram (LD).

GRAPHICAL
2. Sequential Function Chart (SFC).

3. Function Block Diagram (FBD).

4. Structured Text (ST).

TEXTUAL

5. Instruction List (IL).

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FBD

LD

SFC

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IL

ST

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ALLEN BRADLEY PLC I/O ADDRESSING

INPUTS: OUTPUTS:
FUNCTION

RACK SLOT No.

I:1/5 O:3/1
CHANNEL No.

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LADDER PROGRAMMING
Ladder Rung

E
Left Power Rail Right Power Rail

G
Branch
H
I J
S
K
R

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LADDER DIAGRAM SYMBOLS

Relay contact Relay contact

Normally Open Normally Closed
(NO) (NC)

Condition State of NO State of NC

OFF 0 1

ON 1 0

BOX
Relay coil

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AND OPERATION

A B C

Rung

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OR OPERATION

C
A
Rung

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NOT OPERATION

A C

Rung

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LADDER PROGRAMMING EXAMPLE

Scan 1 Scan 2-100

Scan 1001 Scan 1002 Scan 1050

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• Initially the tank is empty. Therefore, input 0000 is TRUE and input 0001 is also
TRUE.
• Gradually the tank fills because 500(fill motor) is on.
• After 100 scans the oil level rises above the low level sensor and it becomes open
(i.e. FALSE).
• Notice that even when the low level sensor is false there is still a path of true logic
from left to right. This is why we used an internal relay. Relay 1000 is latching the
output (500) on. It will stay this way until there is no true logic path from left to
right (i.e. when 0001 becomes false).
• After 1000 scans the oil level rises above the high level sensor at it also becomes
open (i.e. false).
• Since there is no more true logic path, output 500 is no longer energized (true) and
therefore the motor turns off.
• After 1050 scans the oil level falls below the high level sensor and it will become
true again.
• Notice that even though the high level sensor became true there still is NO
continuous true logic path and therefore coil 1000 remains false!
• After 2000 scans the oil level falls below the low level sensor and it will also
become true again. At this point the logic will appear the same as SCAN 1 above
and the logic will repeat.
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COUNTERS & TIMERS

COUNTERS TIMERS

SYMBOL SYMBOL

LADDER DIAGRAM LADDER DIAGRAM

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COMMONLY USED PLC PROGRAMMING SOFTWARES

1. Allen-Bradley – Rockwell
Software RSLogix500
2. Modicon - Modsoft
3. Omron – Syswin
4. GE-Fanuc Series 6 –
LogicMaster6
5. Square D- PowerLogic
6 . Te x a s I n s t r u m e n t s – S i m a t i c
7 . Te l e m e c a n i q u e – M o d i c o n T S X
Micro

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SPECIFICATIONS OF PLC IN FCRI

• Make : Allen-Bradley
• Model : MicroLogixTM 1100
• No. of I/O modules : 5
• From L to R : 1-DC Input, 2-Isolated Relay o/p,
3-Analog o/p, 4-Analog i/p, 5-Isolated Relay
o/p.
• Communication Method : RS232, Ethernet.

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REFERENCE

http://www.google.co.in/
http://www.scribd.com/

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THANK YOU

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PLC
Environment The PLC was specifically
designed for harsh
conditions with electrical
noise, magnetic fields,
vibration, extreme
temperatures or humidity
Programming Languages are typically
languages fixed to ladder logic,
function block or
structured text.
Flexibility PLCs in rack form are
easy to exchange and add
parts. They are designed
for modularity and
expansion.
PLC
PLCs execute a single
Speed
program in sequential
order. The have better
ability to handle events in
real time
Reliability A PLC never crashes over
long periods of time.
("Never" may not be the
right word but its close
enough to be true.)
Data Memory is limited in its
management ability to store a lot of
data.
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PC
Common PCs are not
designed for harsh
environments.
Industrial PCs are
available but cost
more
A PC is very flexible
and powerful in what
to use for
programming
Typical PCs are limited
by the number of
cards they can
accommodate and are
not easily expandable
PC
PCs, by design, are
meant to handle
simultaneous tasks.
They have difficulty
handling real time
events
A PC locking up and
crashing is frequent.
This is where the PC
excels because of it's
hard drive. Any long
term data storage,
history and trending is
best done on a PC.
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