Programmable Logic Controller(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.
 Advantages of PLC
• 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 in the
plant.
• Ease of maintenance /troubleshooting.
• Reduced space.
• Energy saving.
Geometric base types of PLC
 Rack: A rack is often large (up to 18” by 30” by 10”) and
can hold multiple cards. When necessary, multiple racks
can be connected together.

 Mini: these are similar in function to PLC racks, but

about half the size.

 Micro: these units can be as small as a deck of cards.

They tend to have fixed quantities of I/O and abilities,
but cost will be the lowest.
 SIMATIC Controller (PLC)

S7-300 Rack type

S7-200

S7-1200 S7-400
Micro PLC s7-200
 Processor used in S7-200
CPU 221
CPU 222
CPU 224
CPU 224xp
CPU 226
Features of CPU used S7-200
Technical Data CPU 221 CPU 222 CPU 224 CPU 224xp CPU 226
Digital input 6 8 14 14 24
Digital output 4 6 10 10 16
Analog input No No No 2 No
Analog output No No No 1 No
Program Memory 4 KB 4 KB 8/12KB 12/16KB 16/24KB
Data Memory 2 KB 2 KB 8 KB 10 KB 10 KB
High speed Counter 4 4 6 6 6
Timer 256 256 256 256 256
RS-485 1 1 1 2 2
Expansion module 0 2 7 7 7
 224XP Built-in Features
Internal:
- Power Supply
I/O Point - Super Capacitor
Overview - Clock (for 224,224XP,226)
Status
LEDs

CPU Status Mounting

LEDs Holes for
Panel
Installatio
Removable n
Analogue
Terminals
Removable
Terminal
Cartridge Blocks
Slot (224,226)

Snap-On Clip
Communication 24V Sensor for DIN Rail
Ports Power Mounting
Output
Expansion I/O Modules
• Up to 2 Modules (EM) for 222 CPUs
….up to 7 EMs for 224/226 CPUs
• Removable Terminals on digital I/O Modules
• Module Connection via I/O Expansion Ribbon Cable
CPU-Basic Device + Expansion Module
S7 200 PLC Wiring Diagram
SIMATIC S7-300 within the system family

High-end range/
Medium range
S7-400

Mid- and low-end The universal PLC

Performance range for system solutions
S7-300 with production
engineering as focal
point
Micro PLCs
S7-200

+ Programming devices
+ STEP 7 software
+ Communication
+ Human Machine Interface
Integrated Automation
S7-300 – The best-selling controller from
Totally Integrated Automation
S7-300 – The automation platform for production
engineering
Modular PLC S7-300 Module
S7 – 300 CPU
Mode Selector
MRES = Memory reset function
STOP= Stop mode, program not executed
RUN = Program execution
RUNP = Program execution, read/write access

Status Indicator
SF = Group error, internal CPU or fault in module
BATF = Battery fault
DC5V= Internal 5 VDC voltage indicator
FRCE = FORCE
RUN = Flashes when the CPU is starting up,
then steady light in Run mode
STOP= Show steady light in Stop mode
SF DP = Physical bus fault
BUSF = No configuration or incorrect configuration
 Processor used in S7-300
CPU 312
CPU 314
CPU 315-2DP
CPU 317-2DP
CPU 318
Features of CPU used S7-300
Technical Data CPU 312 CPU 314 CPU 315- CPU 317- CPU 318
2DP 2DP
Digital input 256 1024 1024 1024 1024
Digital output 256 1024 1024 1024 1024
Analog input 64 256 256 256 256
Analog output 64 256 256 256 256
Program Memory 16KB 48KB 128KB 512KB 512KB
Data Memory 5 KB 16 KB 42 KB 170 KB 170 KB
High speed Counter 128 256 256 512 512
Timer 128 256 256 512 512
Ethernet 1 1 1 1 1
Expansion module 6 12 16 32 32
Micro PLC s7-1200
 Processor used in S7-1200
CPU 1211
CPU 1212
CPU 1214
CPU 1215
CPU 1217
 Features of CPU used S7-1200
Technical Data CPU 1211C CPU 1212C CPU 1214C CPU1215C CPU 1217C

Digital input 6 8 14 14 14
Digital output 4 6 10 10 10
Analog input 2 2 2 2 2
Analog output No No No 2 2
Program Memory 25 KB 25 KB 50KB 125KB 150KB
Data Memory 2 KB 2 KB 2 KB 2KB 2KB
High speed Counter 3 4 6 6 6
Timer 4 4 4 4 4
Ethernet 1 1 1 1 1
Expansion module 4 6 12 12 12
Basic PLC Components
CPU
Power Supply
Memory
Input Blocks
Output Blocks
Communications
Expansion
Connections
Most important PLC producers
Siemens - Germany
AB (Allen Bradley) – US
Schneider Electric (Modicon) – France
Mitsubishi – Japan
ABB - Germany
SAIA – Switzerland
GE Fanuc - US
B&R (Bernecker + Reiner) – Austria
Teco – Czech Republic
Global Players in PLC

Source: ARC Research, 2005-10

PLC Communication with PC
General PLC architecture
RS 232 Ethernet

Real-Time RAM/flash serial port ethernet

CPU ROM
Clock EPROM controller controller
extension
bus
Parallel bus buffers

fieldbus analog- digital- external

Digital
controller digital analog Digital Output I/Os
Input
converters converters

signal power signal

relays
conditioning amplifiers conditioning

field bus direct Inputs and Outputs

General PLC Architecture
Inputs
Inputs
and Outputs Devices
Outputs

Push Buttons • Motors

Proximity switches • Solenoids
Photoelectric sensors • Indicator lamps
Temperature sensors • Resistive loads
Pressure sensors
• Contactors

Push button Photo Sensor Pressure Motor

Sensor
Overview: Supporting Technologies

Sensors, Switches
PLC Software
Light Curtains / Safety Devices

Digital / Analog I-O Blocks Encoders, Actuators, Contacts

Network
PLC Hardware
 Input/output Circuits

Pilot Duty Outputs

Outputs of this type typically are used to drive high-
current electromagnetic loads such as solenoids,
relays, valves, and motor starters.
These loads are highly inductive and exhibit a large
inrush current.
Pilot duty outputs should be capable of withstanding
an inrush current of 10 times the rated load for a short
period of time without failure.
 Input/output Circuits

General - Purpose Outputs

These are usually low- voltage and low-current and are used
to drive indicating lights and other non-inductive loads.
Noise suppression may or may not be included on this types
of modules.

Discrete Inputs
Circuits of this type are used to sense the status of limit
switches, push buttons, and other discrete sensors. Noise
suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.
 Input/output Circuits

Analog I/O
Circuits of this type sense or drive analog signals.

Analog inputs come from devices, such as thermocouples,

strain gauges, or pressure sensors, that provide a signal voltage
or current that is derived from the process variable.
Standard Analog Input signals: 4-20mA; 0-10V
Analog outputs can be used to drive devices such as voltmeters,
X-Y recorders, servomotor drives, and valves through the use of
transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V
 Analogue Cards
Typical Analogue Input Analogue Output signals
signals are: control:
 Analogue Valves
 Flow sensors
 Actuators
 Humidity sensors
 Chart Resorders
 Potentiometers  Variable Speed Drives
 Pressure sensors  Analogue Meters
 Temperature sensors
 Vibration Typical Analogue Signal
Levels
 4-20mA
 1-5 Vdc
 0-10 Vdc
 -10 – 10Vdc
 Input/output Circuits

Special - Purpose I/O

Circuits of this type are used to interface PLCs to
very specific types of circuits such as servomotors,
stepping motors PID (proportional plus integral
plus derivative) loops, high-speed pulse counting,
resolver and decoder inputs, multiplexed displays,
and keyboards.
This module allows for limited access to timer and
counter presets and other PLC variables without
requiring a program loader.
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

33
Example of Output Card
PLC wiring
PLC Wiring

PLC I/O ports:

Typically rated for low amperage.
Ordinarily connected to I/O devices through American
Wire Gauge size fourteen (AWG 14).
AWG 14 wire has more than sufficient ampere rating
for carrying current for the PLC I/O ports.
PLC Wiring
In most applications, the output devices require
larger voltage and current ratings.
A magnetic relay should be used to connect larger
voltage and current equipment to the output
device.
PLC output port provides voltage and current to
the input coil of the magnetic relay.
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards
RS 232
• Used in short-distance computer communications,
with the majority of computer hardware and
peripherals.
• Has a maximum effective distance of approx. 30 m at
9600 baud. The data rate of RS 232 is 20kbits/sec.

38
PLC Communications
RS 422 / RS 485

• Used for longer-distance links, often between several

PCs in a distributed system. RS 485 can have a
maximum distance of about 1000 meters. The data
rate of RS 485 is 10Mbits/sec.

39
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN

Mitsubishi Melsec-NET
Siemens SINEC
Texas Instruments TIWAY

40
Examples of PLC Programming Software:
1. Allen-Bradley – Rockwell Software RSLogix500
2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Siemens – Simatic
6. Telemecanique – Modicon TSX Micro
Overview: Cost per license
Software Manufacturer Cost (Low) Cost (High)
TwinCat3 Beckhoff $0.00 $700
Rslogix 500 Allen-Bradley $500.00 $2,800.00
GX Developer Mitsubishi $600.00
Simatic Step 7 Siemens $750.00 $5,500.00
Rslogix 5000 Allen-Bradley $800.00 $7,000.00
CX-Programmer Omron $2,500.00 $4,000.00
Unity Modicon $5,000.00

*The five basic PLC programming languages outlined in Standard IEC 61131 are
available in any of the above mention software packages. Namely: IL, ST, FBD, LD,
SFC.
 Selecting a PLC
Criteria
Number of logical inputs and outputs
Memory
Number of special I/O modules
Expansion Capabilities
Scan Time
Communication
Software
Support
Dollars
Programming and configuring - Made easy with
STEP 7
• Easy to use
• Object-oriented, intuitive
user interface
• Configuring instead of
programming
• Standard function blocks
parameterizing instead of
programming
• Uniformity across the family –
common database
• Powerful functions -
e.g. module parameters set by software
• Offline simulation
• We work according to standard!
• Programming languages in
conformity with IEC 61131-3
• Windows 95/98/NT/2000/XP Professional
operating system
 PLC PROGRAMMING
LADDER LOGIC:
PLC programs are typically written in a special application on a
personal computer, then downloaded by a direct-connection
cable or over a network to the PLC. The program is stored in
the PLC either in battery-backed-up RAM or some other non-
volatile flash memory. Often, a single PLC can be programmed
to replace thousands of relays.
ELEMENTS OF LADDER LOGIC

NORMALLY OPEN NORMALLY CLOSED

(CONTACT) (CONTACT)

Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
ELEMENTS OF LADDER LOGIC

COILS

Coils represent relays that are energized when power flows to

them. When a coil is energized it causes a corresponding
output to turn on by changing the state of the status bit
controlling the output to 1. That same output status bit maybe
used to control normally open or normally closed contact
anywhere in the program.
LADDER LOGIC EXAMPLE
OR OPERATION
C
A

In the above, it can be seen that either input A or B is

be true (1), or both are true, then the output C is true
(1).
 Ladder Logic Execution
Rungs of Ladder diagram are solved from Left to right
and top to bottom
Branches within rungs are solved top left to bottom
right
Ladder Rung

A D E
Left Power Rail Right Power Rail
B
Branch
F G H
P S
I J K
R
Timer Parameter in PLC
 Timer number: This number come from timer file. For
example, the timer number is T4:0,which represent
the timer file 4,timer 0 in that file.
Time base: The Timer are typically programmed with
several different time base. The value of Time base will
be 1,0.1,0.01,0.001 second. Suppose Time base is set to
o.1 sec,The Delay Time = Preset valve in second.
 Preset Time: The Preset time will show the time delay
length which programmer want to set the value.
Timer Types
On Delay Timer
Retentive On Delay Timer
Off Delay Timer
The on Delay Timer is used to delay an output on for a
fixed period of time after the input turn on. The
difference between delay on time and retentive on delay
time is that retentive on delay timer keep the input on
for specific time period . The off Delay Timer is used to
delay an output off for a fixed period of time after the
input turn off.
 On-Delay Timer Circuit
L1 S1
L2 Sequence of operation
S1 open, TD de-energized,
TD1 open, L1 is off.
L1
S1 closes, TD energizes,
timing period starts,
10 s
TD1 still open, L1 is still off.

10 s After 10 s, TD1 closes, L1 is

switched on.
Input
ON
S1 is opened, TD de-
OFF
Output energizes, TD1 opens
Timing Diagram instantly, L1 is switched off.
 Off-Delay Timer Circuit
L1 L2
S1 Sequence of operation
S1 open, TD de-energized,
TD1 open, L1 is off.
L1
S1 closes, TD energizes,
TD1 closes instantly,
10 s L1 is switched on.
S1 is opened, TD de-energizes,
10 s
timing period starts, TD1 is
still closed, L1 is still on.
Input
On
Off After 10 s, TD1 opens, L1 is
Output
switched off.
Timing Diagram
Timers in S7-200
ON delay timer

T38 is timer number, PT is preset timing value

OFF delay timer:

RETENTIVE timer:

When PLC is on When PLC is stopped

Timer Examples
Industrial application require that an output come on
6.5 sec after the system start up, remain on for 4.5 sec
and turn off after 5.5 sec of system shut down.In such
application, On delay timer,Off delay timer and
Retentive timer will be used.
Control of Traffic Lights in One Direction

A typical application for PLC timers is the control of

traffic lights.

Control of Traffic in One Direction

Sequence of Operation

Red Green Amber

30 s 25 s 5s
Control of Traffic in one direction
The input to timer T4:0 is controlled by T4:2 done
bit(DN).
The input to timer T4:1 is controlled by T4:0 done bit.
The input to timer T4:2 is controlled by T4:1 done bit.
The Enable bit (EN) of Timer T4:0 is on after T4:2
done bit. The Timer T4:0 start and red light is on for
30 sec, As it reach 30 sec the done bit of Timer T4:o is
turn on(normally Off ) and Timer T4:1 start.
Control of Traffic Lights in One Direction

30

25

5
Program for switching motor off at 5 sec Interval
Bearing Lubrication Program

Sequence Of Operation

• To start the machine, the operator turns SW on.

• Before the motor shaft starts to turn, the bearings are supplied
with oil by the pump for 10 s.
• The bearings also receive oil when the machine is running.
• When the operator turns SW off to stop the machine, the oil
pump continues to supply oil for 15 s.
• A retentive timer is used to track the total running time of the
pump. When the total running time is 3 h, the motor is shut down
and a pilot light is turned on to indicate that the filter and oil
need to be changed.
• A reset button is provided to reset the process after the filter and
oil have been changed.
Bearing Lubrication Program

10
0

0
Counter Parameter in PLC
The counter used in PLC perform same function as
mechanical counter.
Counter Number: This number come from counter file.
Suppose counter number is C5:0,which represent counter
file 5,counter o in that file.
Preset value:This is value specified by programmer which
counter must reach before the controller set the done bit.
Accumulated value:The counter output instruction will
increment/decrement (depend upon counter type) its
accumulated value by 1 each time the counted event occurs.
Counter Types
Counter up
Counter down
Counter up/down
Counter up
The counter up instruction counts up from current
value each time the input makes the transition from
off to on. When the current value is equal to preset
value, the counter output pin turn on. The counter is
reset when the Reset input R is turn on, when reset
instruction is executed.
Counter down
The counter down instruction counts down from
current value each time input makes the transition
from off to on. The counter stop upon reaching zero,
and the counter output bit turn on. The counter reset
the counter output bit and load the current value with
the preset value PV when load input LD turn on.
R input for CTU and LD input for CTD are reset inputs
of counter .The counter are reset by using this inputs.
COUNTERS in S7-200

UP Counter

Down counter, loading contact Down counter, counting reverse

UP-DOWN Counter:

UP counter is active DOWN counter is active

Simple Up-counter Program

0
Up-counter Program Timing Diagram
 Parts Counting Program
Counter C5:2 counts the total
number of parts coming off an
assembly line for final
packaging

Each package must contain 10 parts

When 10 parts are detected, counter C5:1 sets bit B3/1 to initiate
the box closing sequence

Counter C5:3 counts the total number of packages filled per day

A pushbutton is used to restart the total part and package count from
zero daily
Parts Counting Program

010
9

10
09

0
Up/down-counter program
Simulated up/down-counter program
Program that provides continuous
monitoring of items in process.

The accumulated count of

the counter continuously
indicates the number of
in-process parts.
Program that provides continuous
monitoring of items in process
 Simulated program that provides
continuous monitoring of items in process.
24-hour clock
program
Simulated 24-hour clock
program.
 Counter uses
• Count the number of items being produced or
tested
• Maintain the level in a tank by counting the
number of gallons in and drained
• Keeping track of very long duration time periods
by combining a timer and counter
• Counting frequency, encoder, tachometer (pulses)
 Counter Examples
• Straight counting in a process
• Sum of two counts
• Difference of two counts
• Timed interval starts when count reaches
preset value
• Count of events after fixed interval
• Rate is determined by dividing count by
time interval
Disadvantages of PLCs
• PLC devices are proprietary it means that part or
software of one manufacturer can’t be used in
combination with parts of another manufacturer.
• Limited design and cost option
• Fixed Circuit Operations.
• PLCs manufacturers offer only closed architectures.
Application of PLC
Wherever automation is desired the PLCs are best
 suited to meet the task.
Few examples of industries where 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 system etc.