Programmable Logic Controllers

Anil Markana
PDPU.
1

Programmable Logic
Controller

PLC is a general purpose control system that accepts input from

such sources as push buttons, limit switches, temperature,
pressure, and flow sensors. It is capable of generating outputs to
such devices as load relays, motor starters, stepping motors,
solenoid valves and even servo drives.
A programmable logic controller (PLC) is a solid- state device
designed to perform logic functions previously accomplished by
electromechanical relays .
The PLC is an assembly of solid-state digital logic elements
designed to make logical decisions and provide outputs.
It used for control and operation of manufacturing process
equipment and machinery

Programmable Logic
Controller

It has been designed to operate in the industrial

environment and is equipped with special
input/output interfaces and a control programming
language
It is capable not only performing relay switching
tasks, but also counting, calculating, comparing and
the processing the analog signals.

Advantages of PLC compared

with
Relay much of the hand wiring associated with
Its eliminated

conventional relay control circuit.

Its small and inexpensive compared to equivalent relaybased process control systems.
Capable of simulating a hundred relay, timers and
counters.
Easy to program and install
Hardware features such as keylocks can restrict the
access to PLC, and software features such as passwords.
It does can be designed with communications
capabilities that allow them to converse with other
computer systems or to provide human interfaces.
4

PLC Block Diagram

PLC Diagram

Parts of PLC (cont.)

PLC can be divided into parts:

The central processing unit (CPU)

The input/out (I/O) section
The power supply
The programming device.

Parts of PLC (cont.)

CPU - is the brain of the PLC.

It consists of a microprocessor for implementing the

logic and controlling the communications among the
modules.
Required memory for storing the results of the logical
operation performed by the microprocessor.
The CPU is designed so that the user can enter the
desired circuit in ladder logic.

Power Supply used to supplies dc power to other

modules that plug in rack and other field devices
7

Parts of PLC (cont.)

Memory Module used to control input and output

of the process.
IO Modules
Programming Device - are used to enter the desired
program into the memory of the processor.

This program is entered using relay ladder logic. The

program determines the sequence of operation and
ultimate control of the equipment or machinery.

How it Works?

The program for a process is stored in the solid state

memory, As a rule, a program is not changed (except for
the corrections) while the controller is dedicated to a
particular process. Program controls the PLC in a way
that any 1 (ON signal, TRUE pulse) coming from input
unit, it performs the necessary process. This process
usually the controls of an output.

PLC is cyclic controller in that it goes through all the

inputs analysis and outputs on a repetitive basis. The
length of time for a cycle is a function of the number of
rungs in a ladder diagram
9

How it Works?

10

Scan Time

Program controls the output with respect to the

state of inputs, continuously it must control the
status. One pass of the program is one operating
cycle. During each cycle, all inputs to the
controller are sampled, logic evaluated and
outputs are set accordingly. Such a cycle is often
referred as a scan, and the time required for one
cycle is called the scan time.

11

The Four Stages of a PLC

Scan
PLC program changes outputs
by examining inputs
THE
CONTROL
LOOP
Read inputs

Set new outputs

Power turned on
Process changes and PLC pauses
while it checks its own operation
12

Inputs to PLC

The inputs to PLC come from the process

connected devices or sensors such as
Limit switches
Thumb wheels,
Push buttons
Thermocouple
RTD
Transmitters like 4 to 20 ma current source
P to E converters
13

Output from the PLC

Outputs from PLC are given to the devices and

final control elements such as
Lamps,
Indicators,
Relays,
Solenoids,
Motor contactors
4 - 20 mA signals to operate control valves
14

PLC Programming
PLC programming language refers to the method by
which user communicates information to the PLC.
There are three most common languages:

Ladder diagram language

The most common used by PLC language.
Boolean language
The statements refers to the basic AND, OR and NOT
logic gate function.
Function chart system (Function blocks)
It is a method of programming a control system that uses
a more structured approach.
15

Ladder Diagrams
A

Ladder Diagram is one of the simplest methods used to

program a PLC.
It is a graphical programming language evolved from
electrical relay circuits.
Each program statement is represented with a line, called the
rung, that has all relevant inputs to the left and the output to
the right.

16

Ladder Diagrams

The output device of a rung is energized if electric

power can conceptually flow from the left side of the
rung to the right side. Input devices are assumed to
block the flow of power if they are not activated.

During the execution of a ladder diagram, the PLC reads

the states of all inputs, then determines the states of all
outputs starting from the rung at the top side, going
down to the last rung, and finally updates the state of the
output devices.

17

PLC Programming
Inputs
I1:00

Rung 1

I1:04

I1:03

O1:00

Rung 2

I1:02

Outputs

I1:01
L

18

PLC Programming

During the development of a PLC program, we must use

specific names to identify the inputs, outputs, memory
flags, timers and counters.
PLC manufactures use a variety of approaches in naming
the inputs, outputs and other resources.
A typical naming convention is to identify inputs with the
letter I and outputs with the letter O, followed be a 1digit number that identifies the slot number and a 2-digit
number that identifies the position of the input or output in
the slot.
For example:

I1:00 refers to the first input of slot 1

O2:00 refers to the first output of slot 2.

19

PLC Programming

Some manufactures number the inputs or outputs starting

from 00, while others use the number 01 to identify the
first input or output.
The state of an output can be also used as an input in a
ladder diagram. In such a case the PLC uses the state of
the specific output device that is stored in the output
image memory

20

Relay Logic Instructions (NO-NC contacts)

I1:00

O1:00

Examine if Closed (XIC)

If the input device is ON or Closed, then the
corresponding bit in the data memory (input
image) is set to true, thus allowing
(conceptually) the energy to flow from its
left side to its right hand side. Otherwise it
is set to false, thus blocking the energy.

Input is ON or Closed

Examine if Open (XIO)

If the input device is OFF or Open, then the
corresponding bit in the data memory (input
image) is set to true, thus allowing
(conceptually) the energy to flow from its
left side to its right hand side. Otherwise it
is set to false, thus blocking the energy.

Input is OFF or Open

I1:00
Energy Flow
Input is OFF or Open
I1:00
Energy is Blocked

O1:00
Energy Flow
Input is ON or Closed
O1:00
Energy is Blocked

21

Basic Logic Functions (OR, AND)

Two Input OR Function

The output is ON if any of the two inputs is ON.
Wiring Diagram
Vdc

Ladder Diagram

Vac

I1:00

O1:00

I1:01

Truth Table
O1:00

PLC
I1:00
I1:01

I1:00 I1:01 O1:00

OFF OFF OFF
OFF ON ON
ON OFF ON
ON ON ON

Two Input AND Function

The output is ON if both of the two inputs are ON.
Wiring Diagram
Vdc

Vac
PLC

I1:00
I1:01

O1:00

Ladder Diagram
I1:00

I1:01

Truth Table
O1:00

I1:00 I1:01 O1:00

OFF OFF OFF
OFF ON OFF
ON OFF OFF
ON ON ON

22

Basic Logic Functions (NAND,NOR)

Two Input NAND Function

The output is ON if any of the two inputs is OFF.
Wiring Diagram
Vdc

Ladder Diagram

Vac

I1:00

O1:00

I1:01

Truth Table
O1:00

PLC
I1:00
I1:01

I1:00 I1:01 O1:00

OFF OFF ON
OFF ON ON
ON OFF ON
ON ON OFF

Two Input NOR Function

The output is ON if both of the two inputs are OFF.
Wiring Diagram
Vdc

Vac
PLC

I1:00
I1:01

O1:00

Ladder Diagram
I1:00

I1:01

Truth Table
O1:00

I1:00 I1:01 O1:00

OFF OFF ON
OFF ON OFF
ON OFF OFF
ON ON OFF

23

Timer On-Delay (TON) Instruction

The TON instruction begins count when its input rung conditions are
true. The accumulated value is reset when the input rung conditions
become false.
Timer ladder diagram example:

I1:01

TON
AC
PR

07
O1:01

T1:Dn

T1
0

Typical timing diagram (Assume that Preset = 07)

I1:01

T1:En

T1:Acc

00

00

01

02

03

00

00

00

01

02

03

04

05

06

07

07

00

T1:Dn
1s

2s

3s

4s

5s

6s

7s

8s

9s

10 s

11 s

12 s

13 s

14 s

15 s

16 s (Time)

24

25

Classification of PLC

Hardware based:
Modular
Non modular (Integrated)
I/O handling capacity
Micro <=32
Small 32< <256
Medium 256<= <1024
Large 1024 < <2048
Very Large >=2048
26

PLC Applications
There are three major types of PLC applications:

Single-ended: It involves one PLC controlling one process.

This would be a stand-alone unit and would not be used for
communicating with other computers or PLCs.
Multitask: It usually calls for a medium size PLC and involves
one PLC controlling several processes. It can be a subsystem
for larger processes and communicating with a central PLC.
Control management: It involves one PLC controlling several
others. It requires a large PLC processor designed to
communicate with other PLCs and possibly with a computer.
The control management PLC supervises several PLCs by
downloading programs that tell the other PLCs what has to be
done.

27

Manufacturers of PLCs:

GE- Fanuc
Siemens
Allen Bradley
Honeywell
Mitsubishi
Omron
Micro logic.
28