International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

Programmable Logic Controllers (PLC) and its Programming

Mukul Pathade and Gaurav Yeole

Sardar Patel College of Engineering, Andheri (W), Mumbai- 400 058.

Abstract: - This paper describes the important personal computers (PC) PLCs are designed such that
concepts of PLC and its applications. The main they can withstand different physical conditions such
difference between PC and PLC is that latter is as temperatures, electrical noises according to
capable of functioning in severe conditions (such as requirements in industry. The development of PLC
dust, moisture, heat, cold, etc.) and have the facility has brought a revolution in seventies [2].
for input/output (I/O) arrangements. PLC is highly
customized system so the cost of package PLC is low II. WHAT IS PLC?
as compared to other control systems. A PLC is an A PLC (Programmable Logic Controller) is a
example of a hard real time system since output small computer with a built in operating system. A
results must be produced in response to input PLC has input lines where sensors are placed to
conditions within a bounded time, otherwise notify upon incoming event (e. g., temperature level,
unintended operation will result. In industrial liquid level) and output lines to signal any reaction to
sector PLCs offers several advantages over other incoming events. These are real time devices. It was
control systems, hence it is widely used. designed to replace relay logic systems as the
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technicians needed to rewire the relays to change the
Keywords: - Automation, PLC, Ladder logic.
logic. But with PLC, logic can be changed by making
I. INTRODUCTION changes in program. PLC has a programmable
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memory to store and implement instructions which

A utomation means using automatic methods in

factories, offices, farms, labs, houses, space
vehicles, atomic power station, shops, schools
PLC receives as an input from field which can be
either current or voltage depending on the type of
sensors.
anywhere they are possible. It means giving
machines the power to control work in their places, to There are two types of PLC viz., Modular
do jobs without the help of man’s skills and PLC and Compact PLC. Compact PLC has inbuilt
experience. ‘Automaton’ is the word and idea from I/O (Input-Output) modules, while modular has
which automation sprang, is a mechanical man, separate I/O modules. Fig.1 shows Siemens S7-300
robot. Automatic processes are not new they have modular PLC.
been developing from centuries. A new word,
‘Automation’ was introduced to cover them. These
machines have served the purpose to work for long
hours and relieve the pain of mind as well as body
[5].

Programmable Logic Controller (PLC) is a

digital computer used for automation of
electromechanical processes. The first PLC was Fig. 1- Siemens S7-300 PLC.
manufactured by Bedford Associates and it was
1- Power Supply; 2- CPU; 3,4 – Digital I/O;
designated as 084 in seventies [3]. One of the people
5,6 – Analog I/O.
who worked on that project was Dick Morley and he
is considered to be the “Father” of PLC [1]. Unlike

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

Fig. 2 illustrates the basic working of PLC. PLC. Fig.3 shows the front panel of 2A power
Irrespective of the manufacturer of the PLC this supply module. Power supply modules are available
block diagram remains the same. for different current ratings ranging from 2A to 10A
[6].

① "24 VDC output

voltage present" display
② 24 VDC On/Off switch
③ Mains and protective
conductor terminals
④ Terminals for 24 VDC
output voltage
Fig 2- Block Diagram of PLC ⑤ Strain-relief

III. Why PLC? 4.2) Central Processing

Unit (CPU) of PLC: It is most important module of
Originally PLCs were designed to replace relay
the PLC. CPU consists of microprocessor and
control logic. The cost savings using PLCs have been
memory. Its processor talks to the periphery (i.e., DI,
so significant that relay control is becoming rare,
DQ, AI, AQ) and function modules via P-bus. The
except for power applications. PLC eliminates much
communication to CPU to outside devices is through
of the hard wiring that was associated with
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K-bus. The P-bus and K-bus are handled by separate
conventional relay control circuits. Once the program
processor inside CPU. There are varies ports on CPU
using software has been written on PG and tested it
such as RS232, Ethernet port for the communication
can be downloaded to other PLCs too. PLCs have
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purpose. There are different registers inside CPU for

resident diagnostic and override functions allowing
data handling, address handling and for control
user to trace and correct software and hardware
functions. In Siemens S7-300 PLC there are two 32
problems. When running a PLC program a visual
bits registers are available for performing logical and
operation can be seen on the screen. Hence
troubleshooting a circuit is really quick, easy and
arithmetic operations. They are known as
simple. One single PLC can easily run many machines. accumulators. Number of accumulator varies with
CPU.
IV. COMPONENTS OF PLC
CPU memory is mainly divided into work
A basic PLC has following components: memory, load memory and system memory. Load
memory is used to store the program. It may be
 Power Supply Module RAM, ROM or EPROM depending on the
 CPU programmable controller. Programmer may use a
 Signal Modules (Digital I/O and Analog I/O) memory card (RAM or EEPROM) to extend the load
 Interface Module memory. The work memory which is an integrated
 Function Module RAM used to store the parts of user program required
 Communication Module for program processing.
 Memory Unit
And the third is system memory which
4.1) Power Supply Module: It converts the supply consists of PII (Process Image Input), PIQ (Process
voltage (AC 120/230 V, DC 24 to 110V) to the Image Output), bit memories (M), Timers/Counters
operating voltage 24V. This converted voltage is (T)/(C) and Local stack (L) areas. These memory
further supplied to all various modules connected to areas are updated cyclically by the operating system.
At the beginning of the cyclic scan signal states are

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

transferred from input modules to PII region; at the 4.5) Rack: All above mentioned modules along with
end of the each program scan signal states are interface module are placed on the rectangular
transferred from the PIQ region to output modules. support known as Rack. Number of modules on a
The size of each timer and counter is 16 bit (word). particular rack are fixed and decided by the
They can be accessed by user program by means of manufacturer.
instruction. Their number depends on CPU. Bit
memory is used to store the intermediate results. Bit 4.6) Interface Module: This module is used for
memory is accessible everywhere in program. Unlike interfacing the racks. It allows number of PLCs and
bit memory system memory also has local stack other intelligent device to communicate and pass
which is valid for particular part of the program only. PLC data over high speed local area communication
network. Any device may interface with the network,
To ensure the fast execution of the user because the network is not restricted to the product
program and to avoid the unnecessary load on the designed by the network’s manufacturer. The
work memory, only parts of the program relevant for receiving network interface accepts the transmission,
program execution are loaded in the work memory. passes the information to the CPU and if necessary
The parts of the block which are not required for the sends a command to the intended field device.
executing the program are retained in the load
memory. V. P ROGRAMMING ON PLC

The front panel of CPU has status and line As the name suggests PLC is a
indicator LEDs, Slot for MMC, Operating Mode programmable device, programming is mainly done
switch, MAC Address and 2D barcode, connection on Programming device (PG). Different softwares are
for voltage supply and various interface ports for available for programming depending on the
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MPI(multi point interface), PPI(point to point manufacturer of PLC (e. g., Software SIMATIC
interface), PROFInet Industrial Ethernet etc. These Manager STEP 7 is used to program the Siemens
PLC).
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interfaces are used to connect the CPU with the

Programming device (PG) and other PLC CPUs if Generally in SIMATIC Manager
required in large plants. Status LEDs may flash programming can be done in following three
yellow, red, green and orange to indicate various languages [7]:
states of the PLC. Mode switch is a mechanical
switch to put PLC in STOP, RUN and memory reset 1. Ladder (LAD)
mode (MRES). MRES is often used by programmer 2. Statement List (STL)
to clear the work memory area. When one resets the 3. Function Block Diagram (FBD)
CPU memory, programs stored in RAM are lost
while programs in EPROM are retained. Fig. 4 shows the Graphical User Interface (GUI) of
the SIMATIC Manager STEP 7. From here one can
4.3) Signal Modules: These are status indicators of access all the functions installed for standard
the incoming and outgoing signals of PLC [6]. The packages and any optional packages. Programmer
status of the field input is stored in this module. can work with this software in one of two ways:
These modules may be digital or analog depending
on the peripheries. The communication between CPU 1. Offline, without PLC connection
and these modules is done via P-bus. 2. Online, with the PLC connection

4.4) Memory Unit: It is mainly used to expand the

load memory. It may be a RAM or an EPROM
memory card. EPROM memory cards are mostly
preferred as these are non-volatile. The supportable
size of MMC depends on the CPU. The maximum
available size of MMC is 8 MB.

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

The left half of the fig. 4 shows the directory the entire program can be stored in OB1 that is
structure of the folders and files and it is an example cyclically called by operating system. The OBs such
of object hierarchy. The above directory has a project as OB100, OB101 and OB102, have startup program
name CPU314C_2DP which can be changed. stored in them and is executed only once when CPU
Programmer needs to install a station (mentioned on is turned ON. Fig. 5 shows cyclic program execution.
CPU) on which he is working; station can be installed
by clicking on + box next to project name. The ii) Functions (FC):
SIMATIC Manager displays the hardware object in A function contains the partial functionality of
the right half of the window. Programmer needs to the program. It is a logic block “without memory”.
configure hardware network. Configuring means Temporary variables belonging to FC are saved in the
inserting the configuration of the actual hardware Local data stack (L-Stack). Temporary variables are
modules that programmer has used in PLC on the deleted after the associated block is executed. An FC
software. Hardware configuration table gives the is always executed by calling it in another block.
information about MLFB (Machine Readable Product Number of FCs applicable will be CPU specific. FC
Designation) number, MPI address of CPU, can be used to return a value to calling block (for
addresses of analog and digital I/O modules. System example, mathematical functions signal control with
data in fig. 4 saves the hardware configuration. binary logic operations). There are different types of
The programming software provides various functions used in programming they are,
types of blocks in which the user program and the
 User Functions (User needs to insert)
related data can be stored. Depending on the
 Standard Functions (User needs to import it
requirement of the process, program can be
from std. library of software)
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structured in different blocks. Different blocks
 System Functions (It is an integrated part of
available for programming in PLC are as follows:
the CPU user needs to call it in logic blocks,
abbreviated as SFC) such as Timer and
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i) Organization Blocks (OB):

Counter Functions to implement timing and
They form the interface between the counting sequences respectively.
operating system and the user program. They are iii) Data Blocks (DB):
named as OB followed by integer number from 1 to
127 (e.g., OB1). Similarly there are different types of These blocks are used by the logic blocks of the
OBs which can be used for different purposes. OBs user program for storing values. Unlike the
cannot be called by programmer they are implicitly temporary data, the data in data blocks is not
called by operating system.OB1 is a cyclic OB and overwritten when execution of the logic blocks is
completed. DBs are of two types Shared (Global) DB
and Instance DB. The information stored in global
DB can be accessed by all the logic blocks in user
program, while it is not the case with instance as they
are always assigned to a particular Function Block
(FB). Data is stored in variables of the user program
which are uniquely identified by:

a) Storage location: Addressing of variable

follows the format of identifier followed by
byte.bit address e.g., I124.2 (I-Identifier,
124-byte no, 2-bit no), M20. This format is
applicable for PII, PIQ and bit memory.
b) Data types: All data stored in the user data
block must be identified by the data type.

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

Elementary, Complex and User defined data In this process PLC is the Controller, which
types (UDT) are the available data types. The decides controlling action. PLC receives number of
data types determine the amount of memory inputs from different devices located at different parts
space required. Elementary data types are of the plants. PLC then decides controlling action on
never more than 32bits long (BOOL, byte, the basis of status of inputs & logic written in its
word, etc.); while complex can be longer memory. According to the controlling action the
than 32bits (array, structure, date & time). output device operates. As it uses programming logic
UDT are special data structures user creates to control the process, called as Programmable Logic
that can be used in the program once defined. Controller. PLC takes decisions without interference
of man; hence it is used for automation.
iv) Function Blocks (FB):
VI. WORKING OF PLC
They belong to the blocks that need to be
programmed by the user. A FB is block “with According to the requirements on the field,
memory”. It is assigned a data block as its memory programmer designs the logic in the software. The
(instance DB). A FB contains a program that is designed programme needs to be downloaded on the
always executed when a different logic block calls load memory of the PLC. Load memory may be
the FB. FB makes it much easier to program RAM or EPROM. Now, as the program is loaded in
frequently occurring complex functions. They can be CPU of PLC it can be executed by processor of the
called by OBs, FCs and FBs. Unlike FCs, FBs are CPU. The sensors present at the field sense the
initialised i.e., a FB is assigned its own private data incoming signal and converts into electrical signal
area in which FB can remember process states. FBs and this signal is further sent to input modules of the
PLC. Corresponding data of input signal is stored in
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can have static as well as temporary variables. Static
variable are retained even after the block is executed PII region of system memory. This data is further
and is accessible throughout the programme. processed in work memory according to the logic
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developed by the programmer. After processing the

Elements used in programming the PLC: The input data the outcome of operation is stored in PIQ
elements used in PLC programming depend on the region of system memory. The data in the region can
programming language. In LAD language some of be read on output modules which controls the
the elements used in logic are: actuators on the field. If mechanism of plant is to be
altered, then same PLC can be used by just changing
 -| |- Normally Open (NO) contacts the logic of the program in PG, while it’s not the case
 -|/|- Normally Closed (NC) contacts with relay logic where the technician needs to change
 -( )- regular coil. the whole wiring.

The fig. 6 shows an example of a small control VII. COMPARISONS OF PLC WITH OTHER
system. A tank is to be filled with water it also has a CONTROL SYSTEMS
lamp connected to it. Owner of the plant has
demanded that lamp should be on if water level is PLCs are well-adapted to a range of automation
within limits. tasks. This industrial process is mainly used where
changes to the system would be expected during its
operational life. PLC applications are typically highly
customized systems so the cost of a packaged PLC is
low compared to the cost of a specific custom-built
controller design. Very complex process control,
such as used in the chemical industry, may require
algorithms and performance beyond the capability of
even high-performance PLCs. Very high-speed or
precision controls may also require customized

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 1, January - 2014

solutions. PLC and other control devices such as method, the amount of retraining needed for
Remote Terminal Units (RTU) and distributed engineers and trades people was greatly reduced.
control system (DCS) are increasingly beginning to Modern control systems still include relays, but these
overlap in responsibilities [4]. The above figure are rarely used for logic.
shows the comparison of PLC with other control
systems. References
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[1] D. Morley, looks back on the 40 th anniversary of the
VII. APPLICATIONS OF PLC
PLC Manufacturing Automation, 12 September, 2008.
Depending on the type of technology used,
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[2] E. A. Parr, Industrial Control Handbook, Industrial

controllers can be divided into pneumatic, hydraulic, Press Inc., 1999.
electrical and electronic controllers. The fig. 8 shows
gives some of the applications of PLC. [3] M. A. Laughton, D. J. Warne, Electrical Engineer's
Reference book, 16 th Edition, Newnes, 2003.

[4] Richa Natto, Aditya Bagri, International Journal of

Computer Applications, Vol 77, No. 11, September 2013.

[5] Eric Bruton, Automation, English Language Book

Society.

[6] Siemens, SIMATIC S7-300 Module data Manual,

February 2013.
VIII. CONCLUSION
[7] Siemens, SIMATIC Programming with STEP 7
PLC was invented in response to the needs of the Manual, March 2006.
American automotive manufacturing industry.
Programmable logic controllers were initially
adopted by the automotive industry where software
revision replaced the re-wiring of relay control panels
when production models changed. Ladder logic is the
main programming method used for PLCs. It has
been developed to mimic relay logic. The decision to
use the relay logic diagrams was a strategic one. By
selecting ladder logic as the main programming

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