Workshop

on PLC
Programme Logic Controller
Presented By :
Rahul Kumar Gupta
Instructor-IC
Contents
What is PLC?
History of PLC
Major components of PLC
Operational sequence of PLC
Ladder logic
Exampleof starting and stopping of a motor
Advantages
Disadvantages
Application
What is PLC?
PLC is a digital computer designed for
multiple inputs and output
arrangements, extended temperature
ranges, immunity to electrical noise, and
resistance to vibration and impact. A
PLC is an example of a real time system.
PLC was introduced in late 1960s
First commercial & successful Programmable Logic
Controllers was designed and developed by Modicon as a
relay replacer for General Motors.
Earlier, it was a machine with thousands of electronic parts.
Later ,in late 1970s,the microprocessor became reality &
greatly enhanced the role of PLC permitting it to evolve form
simply relay to the sophisticated system as it is today.
Major Components of a Common PLC

POWER
SUPPLY

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

5
Major Components of a Common PLC

POWER SUPPLY
Provides the voltage needed to run the primary PLC components

I/O MODULES
Provides signal conversion and isolation between the internal logic-
level signals inside the PLC and the fields high level signal.
PROCESSOR
Provides intelligence to command and govern the activities of the entire
PLC systems.

PROGRAMMING DEVICE
Used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.

6
PLC operation sequence
1) Self test: Testing of its own hardware and
software for faults.
2) Input scan: If there are no problems, PLC Self test
will copy all the inputs and copy their values
into memory.
Input scan
3) Logic solve/scan: Using inputs, the ladder
logic program is solved once and outputs are
updated. Logic scan
4) Output scan: While solving logic the output
values are updated only in memory when Output
ladder scan is done, the outputs will be scan
updated using temporary values in memory.
Programming Languages of PLC
Most common languages encountered in PLC
programming are:
1) Ladder Logic
2) Functional Block Diagram
3) Sequential Function Chart
4) Boolean mnemonics
 PLC Specifications:

Make: LGIS PLC

Model: K7M-DR30UE, MASTER K120S Series
18 Digital Inputs
12 Digital Outputs
2 Analog Inputs
24 V DC Power Supply
Ladder Logic
The ladder logic is the oldestprogramming
language for PLC.
It is well suited to expressCombinational
logic.
The main ladder logic symbols represent
the elements :

make contact

break contact

relay coil
 AND Gate OR Gate

A B Logic(Y) A B Logic(Y)
OFF OFF OFF
OFF OFF OFF
OFF ON ON
OFF ON OFF
ON OFF ON
ON OFF OFF
ON ON ON
ON ON ON

Y
A B Y
B
 NOR Gate NAND Gate

A B Logic(Y) A B Logic(Y)
OFF OFF ON OFF OFF ON
OFF ON OFF OFF ON ON
ON OFF OFF ON OFF ON
ON ON OFF ON ON OFF

A B Y Y

B
Block diagram of a PLC
Outputs
LEDs

Inputs
Ladder Logic Program for Start/Stop of Motor :

X1 X2 Y1

Y1
Programming PLC:
Starting of Motor:
Continuous Running of motor when Start Button is
released:
To Stop the Motor :
PLC Examples [Lunch Bell]

Regular output coils are of course an essential part of our programs but we
must remember that they are only TRUE when ALL INSTRUCTIONS
before them on the rung are also TRUE.

Please think back about the lunch bell

example. We would've had to keep
pressing the button for as long as we
wanted the bell to sound. (A momentary
switch) The latching instructions let us use
momentary switches and program the plc
so that when we push one the output turns
on and when we push another the output
turns off.
Example Continued

Here we are using 2 momentary push

button switches. One is physically
connected to input 0000 while the other is
physically connected to input 0001. When
the operator pushes switch 0000 the
instruction "set 0500" will become true
and output 0500 physically turns on.
Even after the operator stops pushing the
switch, the output (0500) will remain on.
It is latched on. The only way to turn off
output 0500 is turn on input 0001. This
will cause the instruction "res 0500" to
become true thereby unlatching or
resetting output 0500.
Example Continued
Lunch Bell with Counter
Here we want to count 5 widgets from input 0001 before turning on output
0500. Sensor 0002 will reset the counter.
Example Continued
Example Continued
 Lubricating Oil Controller:
We are controlling lubricating oil
being dispensed from a tank. This
is possible by using two sensors.
We put one near the bottom and
one near the top, as shown in the
picture below

Here, we want the fill motor to

pump lubricating oil into the tank
until the high level sensor turns
on. At that point we want to turn
off the motor until the level falls
below the low level sensor. Then
we should turn on the fill motor
and repeat the process.
Examples continued:

Inputs Address
Low level sensor 0000
High level Sensor 0001

Output Address
Motor 0500

Internal Utility Relay

1000
Examples continued:

The Ladder Diagram

Examples continued:

Scan 1 Scan 2 Scan 3

Initially the tank is The internal After scan 2 the

empty. Therefore, relay is turned oil level rises
input 0000 is TRUE on as the water above the low
and input 0001 is level rises. level sensor and it
also TRUE becomes open.
(i.e. FALSE)
Examples continued:

Scan 5 Scan 6
Scan 4
After scan 4 the oil Since there is no more After scan 6 the oil
level rises above the true logic path, output level falls below
high level sensor at it 500 is no longer the high level
also becomes open (i.e. energized (true) and sensor and it will
false) therefore the motor become true again.
turns off.
Level Indicator:
 Reliability.
Flexibility in programming and reprogramming.
Cost effective for controlling complex systems.
Small physical size, shorter project time.
High speed of operation.
Ability to communicate with computer systems inthe
plant.
Ease of maintenance /troubleshooting.
Reducedspace.
Energy saving.
Disadvantages of PLCs
PLC devices are proprietary it means that part or
software of one manufacturer cant be used in
combination with parts of anothermanufacturer.
Limited design and costoption
Fixed Circuit Operations.
PLCs manufacturers offer only closed architectures.
 Wherever automation is desired the PLCs arebest
suited to meet the task.

Few examples of industrieswhere PLCs are used :

1)Robots manufacturing and control
2) Car park control
3) Train control station system
4) Food processing
5)Materials handling
6)Machine tools
7)Conveyer systemetc.
Thank You!!!