PLC Features

Programmable Logic Controller (PLC) Rugged design; suitable for harsh industrial environments against
high temperature variations, dust, and vibrations.
Industry standard I/O interfaces; capable of communicating with
Prof. Dr. M. Zahurul Haq other PLCs, computers and intelligent devices.
[email protected] Industry standard programming languages; easily learned and
http://teacher.buet.ac.bd/zahurul/ understood. Programming is primarily concerned with logic,
timing, counting and switching operations.
Department of Mechanical Engineering
Bangladesh University of Engineering & Technology Field programmable.
Reduces hard wiring and wiring cost.
ME 475: Mechatronics Monitoring, error checking and diagnostics capability.
Competitive in both cost and space requirements.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 1 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 2 / 44

PLC & Related Components Basic Components

PLC is essentially a microcomputer, tailored specifically for certain

control tasks.
Hardware: consists of the actual device technology, i.e. the PCBs,
integrated modules, wires, battery, housing etc.
Firmware: is the software part, known as executive software, that
is permanently installed and supplied by the the PLC
manufacturer. Programs are usually stored in ROM or EPROM.
Software: is the user program. User programs are usually stored
in the RAM.

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 3 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 4 / 44
Firmware Multitasking Capability

Some PLCs are capable of executing multiple tasks with a single

PLC hardware does not differ significantly from computers. What processor. User program assigns I/O for each task separately.
makes the PLC special is the executive software. It is the internal Multitasking may take several forms:
program, provided by the manufacturer,which executes the user’s Time driven - it is possible to configure the processor to run each
program. task on periodic time intervals. Hence, the time-critical job, such
The executive software determines as the portion of that controls high-speed motions or machine fault
- what functions are available to the user’s program, detection, to run faster than the noncritical portions, such as
- how the program is solved, servicing indicator lights.
- how the I/O is serviced, Event driven or Interrupt driven - user defines a particular
- what the PLC does during power up and down and fault conditions.
event, such as an input changing state or an output turning off,
that causes each tasks to run.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 5 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 6 / 44

PLC Packaging Considerations in Choosing PLC

The manner in which a PLC & its I/O are packaged is critical in
determining its suitability for an application. Number and Types of input & output points required
Heat Removal - appropriate means must be provided for Size and type of memory required
generated heat removal to ensure low internal temperature.
Speed and power required of CPU and instruction set
Commonly used methods include air venting, forced air circulation
& heat sinking. Manufacturer’s support and backup
Mounting - to be mounted inside NEMA rated enclosure.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 7 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 8 / 44
 PLC Hardware PLC Hardware

Basic Hardware

Sensor Input Logic Solver Output

Power Supply- PLCs are generally powered from AC mains and
Actuator
power supply system converts ac voltages to required dc voltages.
Memory - Program memory receives and holds program
instructions. Data memory is used to temporarily hold data
Program Loader Memory
generated from processes or acquired through I/O devices.
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Processor is a micro-processor based CPU and is the part of
PLC consists of five major sections: PLC that is capable of reading and executing program instructions
and data.
1 Power Supply
Program loader is used to enter/change the user program into
2 Memory
the memory and to monitor the program execution.
3 Central Processing Unit (CPU)/ Logic Solver
4 I/O Interface
5 Programming Section

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 9 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 10 / 44

PLC Hardware PLC Hardware

Detailed Block Diagram Power Supply

Executive Internal User I/O image Provides voltage levels required for internal operations (typically
memory RAM memory memory
+5 V dc or ± 12 V dc).
Provides power for I/O modules.
I/O bus
address bus I/O Provides constant voltages.
CPU interface
data bus
Packaged properly to prevent overheat.
Separate or built into the processing unit.
Power
Communication
It is one of the most critical components of a PLC -
interface
supply 1 It is typically non-redundant. Hence a failure of the power supply
Watchdog can cause the control system to fail.
timer 2 It usually contains high-voltage components. Hence, an isolation
failure can create the potential for serious injury and fire.
field power to/from program loader

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 11 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 12 / 44
 PLC Hardware PLC Hardware

Memory Central Processing Unit (CPU)

CPU executes a program stored in the executive memory which is

The memory function of the CPU stores programs and data that the set by the manufacturer.
CPU needs to perform various operations. The memory is organized
into several sections according to the functions they perform. It organizes all control activity by receiving inputs, performing
logical decisions according to the program, and control the
Executive Memory - collection of system programs stored in outputs.
ROM.
CPU does not operate on the I/O directly. Rather, it works with the
Scratch Pad - is the work area used to temporarily store the I/O image stored in the I/O image memory. The I/O interface is
binary information used by the processor. These are volatile responsible for transferring the image outputs to the I/O system,
memory as RAM-type chips are usually used. Battery backed-up reading the inputs from the I/O system, and writing them into I/O
CMOS RAM are also used which may last up to 10 years. image memory.
Processor File - the memory block in which programmer stores A ‘watchdog’ timer is provided to time the CPU to execute the
and manipulates the software. The processor file is made up of user’s program. If this time exceeds a predetermined value,
program files, and data files. watchdog timer will indicate fault and execute subsequent
predefined procedure.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 13 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 14 / 44

PLC Hardware PLC Hardware

Input/Output (I/O) Systems I/O Systems . . .

I/O system acts as the eyes, ears and hands of PLCs.
Discrete I/O - signal is discrete, such as ON/OFF, OPEN/CLOSE, Discrete I/O Inputs - push-buttons, selector switches, joy sticks,
energized/de-energized etc. relay contacts, pressure switches, level switches, starter contacts,
Data I/O - complex system needs data, requires ADC/DAC. temperature switches, flow switches, limit switches, photo-electric
switches, and proximity switches.
Input Module functions:
Reliable signal detection Discrete I/O Outputs - light, relays, solenoids, starters, alarms,
Voltage adjustment of control voltage to logic voltage valves, heating elements, and motors.
Protection of sensitive electronics from external voltages Data I/O Inputs - potentiometers, temperature transducers, level
Screening of signals. transducers, pressure transducers, humidity transducers,
Output Modules functions: encoders, bar code readers, wind speed transducers.
Voltage adjustment of logic voltages to control voltage Data I/O Outputs - analog meters, digital meters, stepper motors
Protection of sensitive electronics from spurious voltages from the
(signals), variable voltage outputs, and variable current outputs.
controller
Power amplification for actuation of control elements
Short-circuit and overload protection of output modules
Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 15 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 16 / 44
 PLC Hardware PLC Operation & Programming PLC Operation

I/O Capacity PLC Operation Review

A factor that determines the size of a programmable controller is the

controller’s I/O and capacity.
1 Mini-Micro – usually 32 or less I/O, but may have up to 64.
2 Small – usually 64 to 128 I/O, but may have up to 256.
3 Medium – usually 256 to 512 I/O, but may have up to 1024.
4 Large – usually 1024 to 2048 I/O, but may have many thousands
more on very large units.
The I/Os may be directly connected to the PLC or may be in a remote
location. I/Os in a remote location from the processor section can be e194.eps
hard wired back to the controller, multiplexed over a pair of wires, or
sent by a fiber optic cable. 2 switches (SW-0 & SW-1) are connected via terminal IN-0 and IN-1 of
input module. 2 terminals of output module (OUT-0 & OUT-1) drive 2
indicator lamps (Lamp-0 & Lamp-1)
Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 17 / 44 . Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 18 / 44

PLC Operation & Programming PLC Operation PLC Operation & Programming PLC Operation

...

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The ladder diagram (LD) has two rungs. The top rung will light Lamp-0
& if both SW-0 and SW-1 are closed. The bottom rung will light
Lamp-1 if either SW-0 or OUT-0 are closed.
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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 19 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 20 / 44
 PLC Operation & Programming PLC Operation PLC Operation & Programming PLC Programming

... Programming Devices

Programming a PLC involves 3 categories:

If the self diagnostic check determine that the system is operating
1 Handheld Programmers - are small inexpensive devices. These
properly, PLC start scanning operation.
typically have membrane keys for entering data and LCD displays
1 Update the Input Image Table to show one line of a ladder program.
2 Scan Program Instructions 2 Dedicated Terminals - are designed for one particular brand of
3 Update Output Terminals PLC. These provides troubleshooting operation while the PLC is
running.
Three-step scanning process is continuous and is repeated many
times each second. The time it takes to complete one scan depends
3 Micro-Computers / PCs - are widely used to program and
on the size of the program and the microprocessor clock speed. simulate the program. Tested programs are downloaded to the
PLC using serial communications.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 21 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 22 / 44

PLC Operation & Programming PLC Programming PLC Operation & Programming PLC Programming

Program Loader Program Loader

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 23 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 24 / 44
 PLC Operation & Programming PLC Programming PLC Operation & Programming PLC Programming

PLC Programming Languages Ladder Diagram (LD):

EN 61131-3 defines five PLC programming languages:

1 Ladder Diagram (LD): graphic language derived from circuit e107.eps

diagram of directly wired relay controls. Function Block Diagram (FBD):

2 Function Block Diagram (FBD): functions & function blocks are
represented graphically and interconnected into networks.
3 Instruction List (IL): textual assembler-type language consisting
of an operator and an operand. e108.eps

4 Structured Text (ST): high level language based on Pascal. Instruction List (IL):
LD Part-TypeA
5 Sequential Function Chart (SFC): a language resource for the OR Part-TypeB
AND Part-present
structuring of sequence-oriented control programs. AND Drill-ok
ST Sleeve-in

Structured Text (ST):

Sleeve-in : = (Part-TypeA OR Part-TypeB) AND Part-present AND Drill-ok;

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 25 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 26 / 44

PLC Operation & Programming PLC Programming PLC Operation & Programming LD Programming

Instruction List (IL) Mnemonics Ladder Diagram (LD)

IEC1131 Mitsubishi OMRON AB1 CH2 Siemens

LD LD LD X10 STR/AND A The use of ladder programming involves writing a program in a
LDN LDI LD NOT XIC STN/ANN AN manner to drawing a switching circuit. The ladder diagram
ST OUT OUT OTE OUT = consists of two vertical lines representing the power rails, and
AND AND AND AND A circuits are connected as horizontal lines.
O OR OR OR O Advantages of Ladder Language -
It is readily understood and maintained.
IL Codes used differ to some extent from manufacturer to It provides graphic display of program flow.
manufacturer, and IEC 1131-3 is the proposed standard to unify IL Programming is fast.
codes. Generates more readable programs for sequence control.

1 Allen-Bradley
2 Cutler-Hammer

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 27 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 28 / 44
 PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

PLC Ladder Programming Conventions Elements of Ladder Diagram

1 The vertical lines of the diagram represent the power rails

between which the circuits are constructed.
2 Each rung on the ladder defines one operation in the control
process.
3 A LD is read from left to right and from top to bottom.
4 Each rung must start with an input or inputs and must end with at
least one output.
5 Electrical devices are shown in their normal conditions, e.g. a
normally closed switch is shown closed.
6 A device can appear in more than one rung of a ladder.
7 The inputs and outputs are all identified by their addresses, the
notation used depending on the PLC manufacturers.

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 29 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 30 / 44

PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Logical Function: AND Logical Function: OR

IN 1 IN 2 OUT
IN 1 IN 2 OUT LD IN 1
0 0 0
0 0 0 LD IN 1 IN 1
IN 1 0 1 1 OR IN 2
AND IN 2 OUT
OUT 0 1 0 IN 2 = OUT
1 0 1
IN 2 1 0 0 = OUT END
END 1 1 1
1 1 1

OUT IN 1
IN 1 IN 2

OUT
Solenoid

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IN 2
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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 31 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 32 / 44
 PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Logical Function: NAND Logical Function: NOR

IN 1 IN 2 OUT
LD NOT IN 1 IN 1 IN 2 OUT
0 0 1
IN 1 0 0 1 LD NOT IN 1
0 1 1 OR NOT IN 2 IN 1
OUT AND NOT IN 2
IN 2 = OUT OUT 0 1 0
1 0 1 IN 2
END 1 0 0 = OUT
1 1 0 END
1 1 0

IN 1 OUT
IN 1 IN 2

OUT

IN 2 x023.eps

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 33 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 34 / 44

PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Logical Function: XOR (Mitsubishi Example) Latch Circuit

After being energized, latch circuit maintains that state.
IN 1 IN 2 OUT LD X400 If power fails, latch rung will be de-energized. When power is
0 0 0 AND NOT X401 restored, machine will not automatically restarted, it can be
IN 1
0 1 1 LD NOT X400 manually restarted by pressing START switch.
OUT
IN 2 AND X401
1 0 1
ORB
1 1 0 OUT Y430
END
X400 X401

Y430

X400 X401

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ORB: OR branches/block together.

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 35 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 36 / 44
 PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Timers/Counters Timers

Timers are output instructions that are internal to the PLC. These
Timers/counters instructions results in internal outputs that are capable of providing timed control of devices that they activate
provides the same functions as hardware timers/counters. or deactivate.
These are used to activate or deactivate a device after an expired EN 61131-3 defines 3 types of timer function blocks:
intervals/counts. 1 TP: Pulse Timing
2 TON: On-delay timing
Both of these require an accumulator resistor to store the elapsed 3 TOF: Off-delay timing
count/time and a register to store the preset value.
The length of the time delay is determined by specifying a Preset
Timers can be linked together, the term is cascade, to give larger
value. Timer is enabled when the rung conditions become TRUE.
delay times than is possible with just one timer.
Once enabled, it automatically counts up until it reaches the
preset value and then goes TRUE.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 37 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 38 / 44

PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Timer Instruction Parameters Timer Example

A batch process– which involves filling a container with a liquid, mixing

the liquid, and draining the container – is automated with a PLC. The
sequence of events is as follows:
1 a fill valve opens and lets the liquid into the container until it is full.
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2 liquid in the container is mixed for 3 minutes.
T : 1 - timer address, where 1st address hods the status bits EN, 3 a drain valve opens and drains the tank.
TT, & DN; 2nd address holds preset value and the 3rd address
holds accumulator to hold the current value.
EN - bit is TRUE as long as the timer rung is TRUE.
TT - bit is TRUE as long as the timer is counting
DN - bit is TRUE when the timer is done.
Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 39 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 40 / 44
 PLC Operation & Programming LD Programming PLC Operation & Programming LD Programming

Counters

Counters are used to detect and count piece members and

events. Counter instruction is placed in a rung and will increment
(or decrement) every time the rung makes a FALSE-to-TRUE
transition. The count is retained until a RESET instruction is
enabled. The counter has a preset value associated with it. When
the count gets up to the preset value, the output goes TRUE.
EN 61131-3 differentiates 3 different counter modules:
1 CTU: Incremental counter
2 CTD: Decremental counter
3 CTUD: Incremental/Decremental counter

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Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 41 / 44 Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 42 / 44

PLC Operation & Programming LD Programming

e187.eps

C : 1 - counter address where 1st address hods the status bits

EN, & DN; 2nd address holds preset value and the 3rd address
holds accumulator to hold the current value.
EN - bit is TRUE as long as the counter rung is TRUE.
DN - bit is TRUE when the counting is done.
RESET - when this bit goes TRUE, it resets the counter.

Prof. Dr. M. Zahurul Haq (BUET) PLC ME 475 43 / 44