Enriching Skills

INDUSTRIAL
AUTOMATION ENGINEER
TRAINING

PLC
(PROGRAMMABLE LOGIC CONTROLLER)

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 Contents
Enriching Skills

• Introduction of PLC
• Block Diagram of PLC and Role of each module
• Types of I/O Modules
• I/O configuration types
• Scan Cycle of PLC
• PLC Wiring
• PLC Programming Software Introduction
• Basic Instructions

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 Enriching Skills

Introduction of PLC

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 COMPARISON Enriching Skills

MICROPROCESSOR MICROCONTROLLER PLC

• A multipurpose, • Microcontroller has • A PLC is a special
programmable device a microprocessor, microcontroller
that accepts digital in addition with a designed for industrial
data as input, fixed amount of use, that is for
processes it according RAM, ROM and controlling machinery
to instructions stored other peripherals or processes.
in its memory, and all embedded on a • A PLC is a system that
provides results as single chip. uses a microprocessor
output. • A microcontroller is or microcontroller as
• It is only one a specialized form one of the components
component of an of microprocessor
electronic device and that is designed to
requires additional be self-sufficient
circuits, memory and and cost-effective.
firmware or software
before it can function.
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Transition from Relays to Bits
EM Contact Relay and its schematic Enriching Skills

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Transition from Relays to Bits
Application of Relay to a circuit Enriching Skills

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Transition from Relays to Bits
Application of Relay Enriching Skills

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Transition from Relays to Bits
Application of Relay Enriching Skills

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 Transition from Relays to Bits
Illustration of relay Enriching Skills

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Transition from Relays to Bits
NC contact & NO contacts: True or False Enriching Skills

Coil: On or Off

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 Transition from Relays to Bits
Bar Type Contact Relay Enriching Skills

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 PROGRAMMABLE LOGIC Enriching Skills

CONTROLLER
• A PLC is a microprocessor based, mini-computer
specifically tailored specifically for certain control
tasks
• It uses programmable memory to store instructions
and specific functions that include On/Off control,
timing, counting, sequencing, arithmetic and data
handling to control machines and processes

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•
Enriching Skills

It is an industrial computer which is used to

replace mechanical timers, counters and
mechanical relays into the software logic
instruction.

• In plc we can program with the help of logic and it

provides us controlling of any process as per our
requirements

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 PROGRAMMABLE LOGIC Enriching Skills

CONTROLLER
• Extensive use of PLCs because of:
Flexible
Faster Response time
Less and simpler wiring
Modular design – easy to repair and troubleshoot
Rugged – can withstand harsh industrial
surroundings

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 HISTORY OF PLC Enriching Skills

• The first PLC systems evolved from conventional computers in

the late 1960s and early 1970s.
• Programmable logic controllers were initially adopted by the
automotive industry where software revision replaced the re-
wiring of hard-wired control panels when production models
changed.
• The plants had to be shutdown for up to a month at model
changeover time but the early PLCs when used along with
other new automation techniques shortened the changeover
time.

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 HISTORY OF PLC Enriching Skills

• The earliest PLCs were developed to offer the same

functionality as the existing relay logic systems.
• The PLCs:
Could start in seconds
Could bear tough plant environment
Had battery backup

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GENERAL FEATURES OF A
PLC Enriching Skills

General characteristics of a programmable controller include:

• Withstands rugged industrial environment, such as
temperature and humidity
• Easily installed and maintained
• Reusable (i.e., can be moved and reprogrammed)
• Modular (i.e., parts can be replaced easily for maintenance or
repair)
• Easy transition for people who worked with relays

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TYPICAL PLC APPLICATION Enriching Skills

Here we can see an example of a typical PLC (Programmable Logic

Controller) application. This application could be production of any
liquid product, such as the brewing of a batch of beer. What we see
are several devices that can detect information about the beer. The
sensors are an example of this-- they can detect whether the tank is
filled too much, or too little. We call these devices “Input Devices”.

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TYPICAL PLC APPLICATION Enriching Skills

We can also see devices that can create actions to the batch of beer,
such as the motor, that can turn on and mix the beer, or the valves
that can open or close, to either allow beer ingredients to fill the tank,
or to allow the batch of beer out of the tank to the next stage of the
system. We call these devices “Output Devices”.

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TYPICAL PLC APPLICATION Enriching Skills

The instructions that tell the output devices what to do based on

the conditions returned by the input devices are written in
programs that are stored and run by the PLC (Programmable
Logic Controller).

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 ADVANTAGES OF PLCs Enriching Skills

FLEXIBILITY
It is easier to create and change a
program in a PLC than to wire and
rewire a circuit.
The program can be modified by
the end-user on field.
Moreover, one model of a PLC can
be used to run numerous
machines with distinct program
for each machine.

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 ADVANTAGES OF PLCs Enriching Skills

LOWER COST
With day-by-day improving
technology, it is possible to
get more functions (relays,
timers, counters, sequencers)
into smaller and less
expensive packages.

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 ADVANTAGES OF PLCs Enriching Skills

CAPABILITY OF
COMMUNICATION
PLCs can be communicated to
perform functions such as:
supervisory control, data
gathering, monitoring devices
and process parameters, and
downloading and uploading of
programs.

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 ADVANTAGES OF PLCs Enriching Skills

QUICK RESPONSE TIME

PLCs have real-time operation
which implies that they react
immediately on the input they
obtain.
Real-time operation is a relative
concept that means any task is
guaranteed to be handled within a
certain time.

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 Enriching Skills

Block Diagram of PLC &

Role of each Module

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 COMPONENTS OF PLC Enriching Skills

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 COMPONENTS OF PLC Enriching Skills

There are five basic components in a PLC system:

• The PLC processor, or controller
• I/O (Input /Output) modules
• Chassis or backplane
• Power supply
• Programming software that runs in a PC
In addition to these 5, most PLCs also have:
• A network interface

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PROCESSOR, Enriching Skills

CONTROLLER, OR CPU
• Stores the control program and
data in its memory
• Reads the status of connected
input devices
• Executes the control program
• Commands connected outputs to
change state based on program
execution
 For example: Turn a light on,
start a fan, adjust a speed, or
temperature
• Comes in various physical forms

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PROCESSOR, Enriching Skills

CONTROLLER, OR CPU

Comes in various physical forms:

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 Enriching Skills

Type of i/o modules

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 I/O MODULES Enriching Skills

• Physically connect to field devices

• Input modules convert electrical signals coming in from
input field devices such as pushbuttons, to electrical
signals that the PLC can understand.
• Output modules take information coming from the PLC
and convert it to electrical signals the output field
devices can understand, such as a motor starter, or a
hydraulic solenoid valve.
• I/O modules form the interface by which input field devices
are connected to the controller.

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 I/O MODULES Enriching Skills

I/O comes in various forms:

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 TYPES OF I/O MODULES Enriching Skills

The following table illustrates four different I/O module types

and their specific functions:

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 Enriching Skills

I/O Configuration types

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 I/O CONFIGURATION:
TYPES
Enriching Skills

• Local, Extended-local, and Remote I/O are terms used for

different types of I/O configurations. I/O configurations are
differentiated by the following:
• The number and type of modules present in the chassis
• The distance of each chassis and module from the processor
• The required speed of communications

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 LOCAL I/O Enriching Skills

• Local I/O: I/O modules

connected to a processor
across a backplane, thus
limiting their distance from
the processor.
• Resident I/O Chassis:
Chassis that houses the
processor.

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 INPUT MODULES Enriching Skills

• Input modules interface directly to devices such as switches

and temperature sensors.
• Input modules convert many different types of electrical
signals such as 120VAC, 24VDC, or 4-20mA, to signals which
the controller can understand.

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 INPUT MODULES Enriching Skills

• Input modules convert real world voltage and currents to

signals the PLC can understand.
• Since there are different types of input devices, there is a
wide variety of input modules available, including both digital
and analog modules.

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 OUTPUT MODULES Enriching Skills

• Output modules interface directly to devices such as motor

starters and lights
• Output modules take digital signals from the PLC and convert
them to electrical signals such as 24VDC and 4 mA that field
devices can understand.

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 OUTPUT MODULES Enriching Skills

Output modules take a signal from a PLC and convert it to a

signal that a field device needs to operate.
• Since there are different types of output devices, there is a
wide variety of output cards available, including both digital
and analog cards.

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 EXTENDED-LOCAL I/O Enriching Skills

Extended-Local I/O: I/O modules connected to a processor

across a parallel link, thus limiting the distance from the
processor.
Parallel Link: A communication link that allows information to
transfer simultaneously.
Adapter Module: A module in an I/O chassis that provides a
communication interface between the I/O modules in that I/O
chassis and the processor.

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 REMOTE I/O Enriching Skills

Remote I/O: I/O modules connected to a processor across a serial

link.
Serial Link: A communication link that allows information to
transfer sequentially.

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 REMOTE I/O Enriching Skills

• Remote I/O configuration:

• I/O modules reside in separate chassis from the processor.
• A remote I/O adapter module is needed to communicate.
• The chassis generally can be located farther from the
processor than with extended-local configuration.
• Serial link gives a slightly slower data transfer than extended-
local configuration.
• The distance from the processor (cable length) depends on
the type of programmable controller and the communication
rate.

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 Enriching Skills

CHASSIS/BACKPLANE

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 CHASSIS/BACKPLANE Enriching Skills

All PLCs need some method of communicating between the

controller, I/O and communications modules.
A chassis provides the following:
• Communication pathways between I/O modules and
processor (or other communications adapter) via a circuit
board called the backplane
• Power supply connections

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CHASSIS AND BACKPLANE Enriching Skills

EXAMPLES

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 Enriching Skills

POWER SUPPLY

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 POWER SUPPLY Enriching Skills

A power supply is needed to provide power to the PLC and any

other modules.
• The Power Supply also furnishes the following:
 Conditions voltage and current so that they are compatible with
processor and I/O components
 Provides over and under voltage protection
 Provides over current protection

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 FORMS OF POWER
SUPPLIES
Enriching Skills

Power supplies come in various forms:

• Power supply modules that fit into one of the slots in a chassis
• External power supplies that mount to the outside of a chassis
• Stand alone power supplies that connect to the PLC or I/O through
a power cable
• Embedded power supplies that come as part of the PLC block.

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 AREAS OF APPLICATION Enriching Skills

Manufacturing / Machining

Food / Beverage

Metals

Power

Mining

Petrochemical / Chemical

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 CONTACTOR
Enriching Skills

OUTPUTS
INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

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 APPLICATION OF
PLC Enriching Skills

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 TYPES OF PLC Enriching Skills

PLC

Modular Non- modular

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 TYPES OF SIGNALS Enriching Skills

S/G

DIGITAL ANALOG
24V DC C-4ma to20ma
0V DC V-0v to 10v

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 DIGITAL INPUTS
Enriching Skills

Pushbuttons
Toggle Switch
Proximity Sensor
ON/OFF Switch
Relay
Level Switch
Pressure Switch

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 DIGITAL OUTPUTS
Enriching Skills

Contactor
Solenoid Valve
LED
Motor
Bulb
Indicators
Relay

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 ANALOG IN/OUTs
Enriching Skills

Temp Sensor
Flow Sensor
Level Sensor
Pressure Sensor
Speedometer
Control Valve
Drive
Encoder

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57
 Enriching Skills

SCAN CYCLE OF PLC

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SCAN CYCLE OF PLC – PLC
OPERATION
Enriching Skills

A PLC works by continually scanning a program. We can think of

this scan cycle as consisting of 3 important steps.

The Scan Time, the time required for one full cycle, provides a
measure of the speed of response of the PLC.
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 BASIC TERMINOLOGY
• Scan Time: The time required for the controller to read all inputs, Enriching Skills

execute the program, and update all outputs.

• Program Scan Time: The time required for the controller to
execute the instructions in the program.
• I/O Scan Time: The time required for the processor to scan all I/O
modules, writing output data and reading input data.
• The following graphic shows both the program and I/O scan time:

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 SCAN RATE/SCAN TIME Enriching Skills

 The completion of one cycle of the sequence is called- SCAN

 Time required for one cycle is called SCAN TIME Or speed of

response of PLC

 Scan time in normal applications is 1 ms to 2 ms & in bigger

applications 100 ms to 200 ms

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VARIOUS BRANDS OF PLC Enriching Skills

 Allen Bradley USA

 Siemens Germany
 Modicon France
 Mitsubishi Japan
 GE Fanuc USA
 Omron Japan
 Hollysys China

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 PROGRAMMING
LANGUAGES IN PLC
Enriching Skills

 Ladder Logic ( LAD/LD )

 Structured Text ( ST)

 Instruction List ( IL )

 Sequential Function Chart ( SFC )

 Function Block Diagram ( FBD )

 Continuous function chart (CFC)

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 PLC SELECTION CRITERIA Enriching Skills

Types of Plc.
Types of I/Os.
Number of I/Os.
Scan Time.
Number of communication port.
Sinking and Sourcing Concepts.
Memory Size.
Bit Resolution of plc for analog.
Types of Protocols
Baud rate of plc.
User friendly
Compact in size
Cost Effective
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 Enriching Skills

Available PLCs of Allen Bradley

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Available PLCs of Allen Bradley
Enriching Skills

PICO
Micrologix
SLC
PLC
Compact logix
Flex logix
Control logix
Drive logix
Soft logix
Guard logix
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 CONFIGURATION OF PLC
ALLEN BRADLEY Enriching Skills

PLC MEMORY I/O’S CAPACITY

MICROLOGIX 1000 IK 32

MICROLOGIX 1100 8K 144

MICROLOGIX 1200 4K 136

MICROLOGIX 1500 14K 512

MICROLOGIX 1400 10K 256

SLC 5/01,02,04,05 1 K TO 16K 4096

COMPACT LOGIX 126 K 4096 to 8024

SLC 5/03 8K 4096

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 Allen Bradley : PICO Enriching Skills

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 Allen Bradley : Micrologix Enriching Skills

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 Allen Bradley : SLC
Enriching Skills

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 Allen Bradley : PLC
Enriching Skills

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Allen Bradley : Compact Logix
Enriching Skills

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Allen Bradley : FlexLogix
Enriching Skills

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Allen Bradley : Control Logix
Enriching Skills

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 Enriching Skills

Wiring of plc- SINK & SOURCE

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 SINKING / SOURCING Enriching Skills

 The concept of sinking & sourcing is depend upon the

direction of current.

 When the direction of current is inward the PLC then it is

known as SINKING

 When the direction of current is outward the PLC then it is

known as SOURCING

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 Wiring of plc
Enriching Skills

It is method of connecting two different polarity signal to a common terminal.

It may be of two type
1. Input wiring
a. sinking configuration
b. sourcing configuration
2. Output wiring
a. sinking configuration
b. sourcing configuration

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 SINKING(PNP) Enriching Skills

PNP

Direction of
PLC
current is
inward to the PLC

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 SINKING(NPN) Enriching Skills

NPN

NO NC Direction of
PLC
current is
inward to the PLC

common

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 SOURCING(NPN) Enriching Skills

NPN
Direction of
current is
PLC
Outward from the PLC

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 SOURCING(PNP) Enriching Skills

PNP
NO
NC Direction of
PLC
current is
Outward from the PLC

common

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 Opto -coupler
Enriching Skills

When diode conducts, infra red light falls on the base of 5v dc

the transistor, which conducts and inverter makes O/P high.
Inverter

Current limiting O/P high

Start resister

Stop
Opto coupler
S/W

Com
Diode transistor pair is called optical isolation (produces 1.5kv
isolation).
In case one diode is parallel to another diode in
opposite polarity. It can act as source or sink both

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 Input wiring of plc as
sinking input Enriching Skills

Opto-coupler

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 Input wiring of plc as
sourcing input Enriching Skills

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 output wiring of plc as
sourcing output Enriching Skills

Ac mains

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 output wiring of plc as
sinking output Enriching Skills

Ac mains

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 Enriching Skills

PLC programming S/W

introduction

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 RSLogix 500 Overview
Enriching Skills

• The RSLogix™ family of IEC-1131-compliant

ladder logic programming packages helps to
maximize performance, save project
development time, and improve productivity
• This family of products has been developed to
operate on Microsoft® Windows® operating
systems and it supports the Allen-Bradley SLC™
500 and MicroLogix™ families of processors,
RSLogix™ 500 was the first PLC®

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 RSLogix 500 Overview Enriching Skills

• Main Features of RSLogix 500 software:

-Flexible, easy-to-use editors
-Common look-and-feel
-Diagnostics and troubleshooting tools
-Powerful, time-saving features and
functionality

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 Difference B/W RS Logix
Series
Enriching Skills

RSLogix 5 RSLogix 500 RSLogix 5000

Compatible with programs Compatible with programs Compatible with Control

created with Rockwell created with Rockwell Logix Series of processors
Software’s DOS-based Software’s DOS-based
programming packages for programming packages for
the PLC-5 processors the SLC 500 and
MicroLogix families of
processors

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 Enriching Skills

Data files and addressing

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CATELOGUE OF MICROLOGIX
PLC Enriching Skills

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DATA FILES IN MICROLOGIX Enriching Skills

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Data files in AllenBradely
Enriching Skills

Data File File Name

output File O

Input File I

Status File S2

Binary File B3

Timer File T4

Counter File C5

Control File R6

Integer File N7

Float File F8

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 I/O Addressing
Enriching Skills

File Name: Slot no. Word/Bit no.

For Example:
What would be the address of this bit

For this just make a copy

File name I

Slot No. 0

Word No. 0

Bit No. 2
So, The address of this bit will be

I:0.0/2
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 RSLinx Overview Enriching Skills

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 Enriching Skills

Basic Instructions

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 BASIC INSTRUCTIONS Enriching Skills

• One organizes ladder logic as rungs on a ladder and put

instructions on each rung. There are two basic types of
instructions:
• Input instruction: An instruction that checks, compares, or
examines specific conditions in the machine or process.
• Output instruction: An instruction that takes some action,
such as turn on a device, turn off a device, copy data, or
calculate a value.

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 BASIC INSTRUCTIONS Enriching Skills

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 PLC PROGRAMMING LADDER
LOGIC Enriching Skills

Each line of code is known as a “rung”. In this example there are 4 rungs,
numbered 0, 1 and 2, and the end rung marking the end of the program.
 The PLC executes the program 1 rung at a time, starting with the first rung and
then working down.
 Ladder logic rungs are basically IF-THEN statements. Each individual rung is
executed from the left to the right

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 REALIZATION OF BASIC GATES
USING BASIC Enriching Skills

PLC INSTRUCTIONS
• The logical AND function is constructed by series combinations of
digital (discrete) inputs
– Two (or more) series components
• The logical OR function is constructed by parallel combinations of
digital (discrete) inputs
– Two (or more) parallel components
• The logical NOT function is constructed by referencing the input
signal with a normally closed contact (XIO instruction)
• More complex Boolean expressions can be formulated with various
serial-parallel combinations of XIC and XIO instructions
– NAND, NOR, XOR, XNOR
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EQUIVALENT LADDER LOGIC
DIAGRAM
Enriching Skills

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 Enriching Skills

Any Queries?

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