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INTRODUCTION TO PLCs
(PROGRAMMABLE LOGIC CONTROLLERS)
• A special computer designed to control hundreds of digital and
analogue input and output signals with a very fast response time;
• Used for real time control in factories, particularly for robot work
cells or automated machinery;
• Uses stored instructions in its programmable memory to
implement logic, sequencing, timing, counting and arithmetic
control functions for controlling machines and processes.
• Connected to computer systems easily using one of many widely
used communications protocols (e.g. RS-232 serial ports), which
they normally have to enable communication with many systems
and devices

Thursday, 24th February 2011 IENG3006 Automation Lecture 5 1

INTRODUCTION TO PLCs (Cont’d)

Schematic diagram showing components of a PLC
External Source
of power

Power
Supply

Inputs

Programming Input/ Output

Processor
Device Module

Outputs

Memory Unit

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INTRODUCTION TO PLCs (Cont’d)

PLCs are either fixed or modular
INPUT UNIT OUTPUT UNIT
I:1/0 O:2/0
I:1/1 O:2/1
INPUT OUTPUT
TERMINALS TERMINALS
Sketch of
CPU structure of a
I:1/15 O:2/15 fixed PLC

O O O
I I I U U U
Sketch of Power C N N N T T T
structure of a Supply P
U
P
U
P
U
P
U
P
U
P
U
P
U
modular PLC T T T T T T

SLOT 0 1 2 3 4 5 6
NUMBER

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INTRODUCTION TO PLCs (Cont’d)

Modular PLCs are mounted on normally numbered racks that are
enclosed in cabinets. Smaller systems use a more integrated
configuration.
SCADA - Supervisory Control And Data Acquisition:
– Traditionally used for data collection from PLCs and plant floor controllers.
– SCADA systems are also used for monitoring and supervisory control of processes. SCADA
systems also form a vital part of many manufacturers’ information systems. They provide
manufacturing data to many other software systems in the typical manufacturing enterprise.

START INPUT UNIT

I:1/0 INPUTS
Feed devices are actually hardwired to PLC thus
I:1/0 transmitting current signals.
I:1/1 I:1/1
STOP Types of inputs:
Analogue only –5-24 V DC; 110/120 V AC
INPUT Discrete – 24 V DC; 20-40 mA
TERMINALS Combo
OUTPUTS
Similar to inputs

I:1/15
Common
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INTRODUCTION TO PLCs (Cont’d)

CPU – Microprocessor (Industrially Hardened)
A manufacturer cannot tolerate control systems that lock up.
– PLCs are designed to be very rugged in an industrial environment. They
are very noise immune. They can operate in extremes of temperature,
shock, vibration and dirty environments.
PLCs use Hard real-time control, in which the real-time operating system is loaded first. The
control engine runs as the highest priority task. All Windows functions run as the lowest
priority task within the operating system. The logic control engine always has priority and is
completely protected from Windows, which is not allowed to pre-empt real-time control.
Surface Mount: - plug chip on female mount (on board)
Alternatively, can also drill holes and attach chips by using pins to keep pins in place – solder
onto board. (There is a tendency for solder to undergo thermal fatigue with time, hence
reliability of connections is key – Military Specs). With Modular Systems, highest degree of
failure occurs due to corrosion where the racks fit into the slots.
Lithium cadmium batteries are used (7 years life span) to ensure no data loss
should power fail. If battery fails, need to replace the PLC.

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INTRODUCTION TO PLCs (Cont’d)

PROGRAMMING PLCs
Ladder Diagrams Switch Coil

INPUT UNIT OUTPUT UNIT

I:1/0 O:2/0
I:1/1 O:2/1

INPUT OUTPUT
TERMINALS TERMINALS
CPU

I:1/15 O:2/15

• The basic ladder diagram looks similar to a stepladder. Two uprights hold the rungs that
make up the PLC ladder. The left and right uprights (called power rails) represent power. If
we connect the left and right uprights, power can flow through the rung from the left
upright to the right.
• The PLC would then run the ladder, continually monitoring inputs and controlling outputs
by a process called scanning.

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INTRODUCTION TO PLCs (Cont’d)

PLC SCANNING AND SCAN TIME
Most people would like to believe that a ladder provides a sequential process:
That the first rung is evaluated and then acted upon before the next rung and so on. That the CPU on
looking at the first rung, goes out and checks the actual inputs for their present state, comes back,
immediately turns on or off the actual output for that rung, and then evaluates the next rung.
In fact, scan time divided into two components: the I/O scan & program scan.
The I/O scan can be divided into the output step and the input step. During these two steps, the CPU
transfers data from the output image table to the output modules (i.e. output step) and then from the
input modules to the input image table (i.e. input step).
The Program scan (logic evaluation) uses the conditions from the image table to evaluate the ladder logic.
If a rung is true/false, then the CPU writes a 1/0 into the corresponding bit in the output image table.
Note that nothing concerning the real world I/O is occurring during the evaluation phase.
Factors affecting scan time:
1.No. of inputs
2.No. of outputs
3.No. of I/O modules
4.Length (No. of rungs) of program and their states.

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INTRODUCTION TO PLCs (Cont’d)

ADDRESSING AND INSTRUCTIONS (Rockwell Automation)
Rockwell Automation divides its memory system into two types: program and data.
Program File Memory – The 256 files in program memory (files 0 through 255) contain controller
information, the main ladder program and any subroutines.
File 0 - contains various system-related information & user-programmed information such as
processor type, I/O configuration, processor file name & password.
File 1 - is reserved
File 2 - contains the main ladder diagram
Files 3 through 255 - for subroutines
Data Memory – Also has 256 files.
File 0 - PLC output status storage
File 1 - PLC input status storage
File 2 - Reserved for PLC status information (troubleshooting)
File 3 - Storage of bit information about conditions or as contacts for non-real-world I/O
File 4 - Timer Information
File 5 - Reserved for Counter Information
File 6 - Reserved for control with shift registers and sequencers
File 7 - Integer Storage
File 8 - Floating point number storage
Files 9 through 255 - User configurable

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INTRODUCTION TO PLCs (Cont’d)

ADDRESSING AND INSTRUCTIONS (Rockwell Automation)
Rockwell Automation – Memory Addressing.
File Slot File Slot Bit
Bit Number Number
Number Number Number
Number
Output
Input

I1:1/3 O0:2/3
Slot Bit Slot Bit
Delimiter Delimiter Delimiter Delimiter

Examine if Closed
Sensor Status Signal State
Activated 1
Not Activated 0
Output Energize
Examine if Opened
Instruction
Sensor Status Signal State
Activated 0
Not Activated 1
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E.g. 1 - CONSIDER LAST DAY’S EXAMPLE:

F = (A  B  C) + D

Where F is an alarm system and A, B, C & D are sensor inputs

Function is an expression of Combinational Logic.

E.g. if used for monitoring a compressor, the alarm F will activate where:
A – Oil Level
B – Oil Pressure
C – Oil Temperature
D – Vibration Level
Assignment: Prepare the truth table for the circuit

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E.g. 1 - continued:

Ladder for Alarm F

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E.g. 2 - ROBOT-CNC-CONVEYOR PROBLEM:

A = I0I1I2I3I4I5I6I7

For NOT alarm condition (i.e. alarm NOT on or in other words for machine
operating condition i.e. machines functioning) the sensors one to four must
be active functioning signals (i.e. I0 AND I1 AND I2 AND I3) AND there must
be no intrusion signals (i.e. I4 AND I5 AND I6 AND I7)
Thus for machines to halt (i.e. for alarm to sound)
A = A = I0I1I2I3I4I5I6I7
By De Morgan’s theorem
A = I0+ I1+ I2+ I3+ I4+ I5+ I6+ I7

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INTRODUCTION TO PLCs (Cont’d)

Robot-CNC-conveyor Workcell Example

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INTRODUCTION TO PLCs (Cont’d)

Robot-CNC-conveyor Workcell Example – cont’d

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INTRODUCTION TO PLCs (Cont’d)

Express the following expressions in Ladder Logic on the Ladder
Logic Simulator LOGIXPRO:

F = AB + CD + E

G = (A + B'C)(A'B + D') + C'D

H = (x'y + z')w + w'x'(y' + z)

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HAZARDS
Static and Dynamic Hazards
Should a discrete control system/circuit fail, the equipment it services will malfunction with
varying consequences: from loss of time; loss of materials; loss of equipment; and may be
even loss of life. Precisely because of the consequences of circuit failure, the term hazard
has been used to denote those circumstances that give rise to the system/circuit failure.
Static Hazard, is a situation in which the output of a given combinational circuit may
momentarily change output “a glitch” where the function governing the circuit
dictates its output to remain constant. It can happen that in the process of function
simplification, consensus terms are left out. Depending on the application, such
absence may give rise to glitches in the state transitions of the system.
In Dynamic Hazards, an output may change several times for a single change in input.
This is caused by the occurrence of three or more paths from an input to the output,
each path having a different delay. Such hazards affect asynchronous circuits and as
in the case of combinational circuits, can be eliminated by simply rearranging the
form of the equation or by adding consensus terms.

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E.g. 3 - Tank Problem – “Latching”:

When HLS is true (i.e. 1) then V1 = 0 i.e. false
V1
When LLS is true (i.e. 1) then V1 = 1 i.e.true
LLS HLS V1
HLS
0 0 0
V2 0 1 0
LLS
1 0 1
1 1 x

State to be true = enter hold exit

Entry Holding Exiting
Conditions Conditions Conditions
V1 = LLSHLS + V1HLS
I:1/0 I:1/1 O:2/0
LLS = input 0
HLS = input 1
V1 = output 0
O:2/0 I:1/1

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Latching (Continued):
• Latching uses past events to regulate present
behaviour by establishing the conditions
under which a system: enters into; is held
within; and leaves a particular ‘state’.

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EXERCISE
Using the Ladder Logic Simulator LOGIXPRO,
programme the Garage Door so that :

• Door movement will halt immediately when the Stop Switch is initially pressed, and will remain halted if
the switch is released.
• Pressing the Open Switch will cause the door to Open if not already fully open. The opening operation
will continue to completion even if the switch is released.
• Pressing the Close Switch will cause the door to Close if not already fully shut. The closing operation will
continue to completion even if the Switch is released.
• If the Door is already fully opened, Pressing the Open Switch will Not energize the motor.
• If the Door is already fully closed, Pressing the Close Switch will Not energize the motor.
• Under no circumstance will both motor windings be energized at the same time.
• The Ajar Lamp will be illuminated if the door is NOT in either the fully closed or fully opened position.
• The Open Lamp will be illuminated if the door is in the Fully Open position.
• The Shut Lamp will be illuminated if the door is in the Fully Closed position.

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