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Programmable Logic Controllers

GNB

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Course Content
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• Introduction to Controllers

• Architecture of PLC

• Details Component Study of PLC

• Programming Methods of PLC

• Selection of PLC

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Introduction
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Controllers
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• Due to the rapid advances in technology, all industrial processing

systems, factories, machinery, test facilities, etc. turned from
mechanization to automation.

• As new and efficient control technologies evolved, computerized

automation control is being driven by the need for high accuracy,
quality, precision and performance of industrial processes.

• Industrial automation is the use of control devices such as

PC/PLCs etc. to control industrial processes and machinery by
removing as much labor intervention as possible, and replacing
dangerous assembly operations with automated ones.

• Industrial automation is closely linked to control engineering.

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 Supervisory Control and Data Acquisition
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“
Distributed Control System

Programmable Logic Controller

Relay Logic

Microcontroller

Microprocessor

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Introduction
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• A programmable logic controller (PLC) is an industrial grade computer capable of being

programmed to perform control functions.
• The PLC is designed for multiple I/O arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
• It has been designed to operate in the industrial environment and is equipped with
special I/O interfaces and a control programming language.
• The structure of a PLC is based on the computer architecture.
• It is capable of performing relay switching tasks, timing, counting, calculating,
comparing, and the processing of analog signals.
• Programs for the control and operation of manufacturing process equipment and
machinery are typically stored in battery-backed or nonvolatile memory.
• IN PLC Scan time refers to the entire time to execute.
• The difference b/w Online and Off-line PLC is where the edited program resides.

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 Advantages
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• Increased Flexibility
• Fast response
• Easy programming and installation
• High control speed
• Network compatibility
• Troubleshooting and testing convenience
• High reliability
• Low Cost.

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ClickComparison
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Table
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Characteristic Relay Systems Digital Logic PLC Systems

Price Comparatively Costly Low Low

Size Bulky Compact Compact

Operating Speed Slow Very Fast Fast

Maintenance Poor Poor (if Soldered) Good

Time Consuming to Design, Test and fine Simple to program and

Installation
design and Install tuning is time consuming Install

Noise Immunity Excellent Good Good

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“
Richard E Dick Morley, An American
Mechanical Engineer considered as the
father of PLC.

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Architecture of PLC
GNB

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Definition
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• A PLC is a Specialized Computer used to control

machines and Process.
• It uses programmable memory to store
instructions and execute specific functions that
include on/off control, timing, counting,
sequencing, arithmetic and data handling.
• It is an assembly of Solid State logic elements
designed to make logical decisions and provide
outputs.
• It is basically a computer designed for use in
machine control.

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 Architecture of
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• PLC Architecture is Proprietary ( Closed Architecture).
• Central Processing Unit, I/O Section, Power Supply and
Programming Devices.
• PLC programs cannot be interchanged among different
PLC manufacturers.
• PLC I/O – Fixed and Modular Types.
• The power supply supplies DC power to other modules
that plug into the rack. power to field devices is
provided by external alternating current (AC) or direct
current (DC) supplies. For some small micro PLC
systems, the power supply may be used to power field
devices.
• The processor consists of a microprocessor for
implementing the logic and controlling the
communications among the modules

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 Architecture of
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• Input devices such as pushbuttons, limit switches, and

sensors are hardwired to the input terminals.
• Output devices such as small motors, motor starters,
solenoid valves, and indicator lights are hardwired to
the output terminals.
• To electrically isolate the internal components from the
input and output terminals, PLCs commonly employ an
optical isolator, which uses light to couple the circuits
together.
• The external devices are also referred to as “field” or
“real-world” inputs and outputs.
• A programming device is used to enter the desired
program into the memory of the processor. A personal
computer (PC) is the most commonly used
programming device.

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 Architecture of
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• A program is a user-developed series of instructions that directs the PLC to execute

actions. A retentive function is not to reset after power cycle.
• A programming language provides rules for combining the instructions so that they
produce the desired actions.
• Relay ladder logic (RLL) is the standard programming language used with PLCs.
• PLC software – to write a PLC program using ladder logic or another programming
language and document it. PLC S/w is used to write a PLC Program
• PLC software that allows the user to monitor and control the process is also called a
human machine interface (HMI).

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 Size
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• Nano is the smallest size with less than 15 I/O points.
• Micro type PLC 15 to 128 I/O points
• Medium type PLC 128 to 512 I/O points
• Large type PLC over 512 I/O points.
• In general it is not advisable to buy a PLC system that is larger than current needs dictate.
• There are three types of PLC application: Single-Ended, Multitask & Control Management.
• A single-ended or stand-alone PLC application involves one PLC controlling one process.
• A multitask PLC application involves one PLC controlling several processes.
• A control management PLC application involves one PLC controlling several other PLC’s.
• The largest integer number that a PLC counter function can reach is 65535

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 Memory
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• Memory is the part of a PLC that stores data, instructions, and the control program. Memory size is
usually expressed in K values: 1 K, 6 K, 12 K, and so on(1 K means 1024).

• Modern computers usually have a word size of 16, 32, or 64 bits.

• PLC that uses 8-bit words has 49,152 bits of storage with 6 K word capacity(8 x 6 x 1024 = 49,152).

• PLC using 32-bit words has 196,608 bits of storage with the 6 K memory(32 x 6 x 1024 = 1,96,608).

• Factors affecting the memory size needed for a particular PLC installation include:
1. Number of I/O points used
2. Size of control program
3. Data-collecting requirements
4. Supervisory functions required
5. Future expansion

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I/O SECTION (PLC)

GNB

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 I/O
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• The input/output (I/O) section of a PLC is the

section to which all field devices are connected
and provides the interface between them and the
CPU.
• The input interface allows status information
regarding processes to be communicated to the
CPU.
• The CPU communicates the operating signals
through the output interface to the process
devices under its control.
• Combination I/O modules can have both input
and output connections in the same physical
module.
• Its function is to Accept signals from field devices
and convert them into signals that can be used by
the processor

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 I/O
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• A module is made up of a PCB and a terminal

assembly. The PCB contains the electronic
circuitry used to interface the circuit of the
processor with that of the I/O device.
• Modules are designed to plug into a slot or
connector in the I/O rack or directly into the
processor.
• Modules contain terminals, status lights, and
connections to the power supply for each and
every inputs and outputs. Terminal and
status light arrangements vary with different
manufacturers.

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 I/O
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• I/O modules can be 8, 16, 32, or 64

point cards.
• The number refers to the number of
inputs or outputs available.
• The standard I/O module has eight
inputs or outputs. A high-density
module may have up to 64 inputs or
outputs.
• Basically, I/O section of PLC is
classified into two types, Discrete and
Analog Type.
• Points per module defines the no. of field
I/O connected in single module.

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• This type of interface connects field input devices

of the ON/OFF nature such as selector switches,
pushbuttons, and limit switches.
• Output control is limited to devices such as lights,
relays, solenoids, and motor starters that require
simple ON/OFF switching.
• The classification of discrete I/O covers bit
oriented inputs and outputs.

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• The input circuit is composed of two basic sections: the power section and the logic section.
• An optical isolator is used to provide electrical isolation between the field wiring and the PLC
backplane internal circuitry.

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• If the module is a current-sourcing module,

then the input or output device must be a
current-sinking device.
• Conversely, if the module is specified as
current sinking, then the connected device
must be current sourcing.
• If a device provides current when it is ON, it
is said to be sourcing current.
• Conversely, if a device receives current when
it is ON, it is said to be sinking current.

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• Analog devices represent physical quantities

that can have an infinite number of values.
• Typical analog inputs and outputs vary from
0 to 20 mA, 4 to 20 mA, or 0 to 10 V.
• Analog input modules normally have
multiple input channels that allow 4, 8, or
16 devices to be interface to the PLC.
• The two basic types of analog input modules
are Voltage Sensing & Current Sensing.
• Analog Parameters : temperature, speed,
level, flow, weight, pressure, and position.
• Analog voltage input modules are available
in two types: Unipolar & Bipolar.

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• High Speed Counter Module
• Thumbwheel Module
• TTL Module
• Encoder Counter Module
• BASIC or ASCII Module
• Stepper Motor Module
• BCD Output Module
• PID Module
• Motion and Position Control Module
• Communication Module

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• Nominal Input Voltage • Channels per module
• Input Threshold Voltage • Input Current Voltage Range
• Nominal Current Per Input • Output Current Voltage Range
• Ambient Temperature Rating • Input Protection
• Input ON/OFF Delay
• Resolution
• Output Voltage
• Input Impedance and Capacitance
• Output Current
• Common Mode Rejection
• Inrush Current
• Short Circuit Protection
• Leakage Current
• Electrical Isolation
• Points per Module
• Backplane Current Draw

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• A processor module is divided into two
sections: the CPU section and the
memory section.
• The CPU section executes the program
and makes the decisions needed by the
PLC to operate and communicate with
other modules.
• The memory section electronically stores
the PLC program along with other
retrievable digital information.
• PLC power supplies are normally
designed to withstand momentary
losses of power without affecting the
operation of the PLC.
• Hold-up time, which is the length of
time a PLC can tolerate a power loss,
typically ranges from 10 ms to 3 s.

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• The difference is that the program used

with the microprocessor is designed to
facilitate industrial control rather than
provide general-purpose computing.
• The CPU executes the operating system,
manages memory, monitors inputs,
evaluates the user logic (ladder
program), and turns on the appropriate
outputs.
• The CPU of a PLC system may contain
more than one processor.
• One advantage of using multiprocessing
is that the overall operating speed is
improved.

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• Memory is the element that stores • A programming terminal device is needed

information, programs, and data in a to enter, modify, and troubleshoot the PLC
PLC. program.
• Data are stored in memory locations by • The most popular method of PLC
a process called writing. programming is to use a personal
computer (PC) in conjunction with the
• Data are retrieved from memory by what
manufacturer’s programming software.
is referred to as reading.
• The functions of programming device is to
• The complexity of the program
change, monitor and enter the user
determines the amount of memory
program.
required.
• A closed contact would have a binary 1
stored in its respective location in the
input table, whereas an open contact
would have a 0 stored.
• Memory Types : Volatile & Non-Volatile

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• At start, PLC scans the status of all inputs are read.

• The control plan stored in the PLC is called Program.
• Optical isolator circuit cannot rectify AC signal
• The main difference between a plc and control system is that it uses hardwired relay
control logic and the other uses programmed instructions.
• The IO system provides interface between CPU and field equipment
• The function of PLC is to make logical decisions and control outputs based on them
• BCD output module is a special type of IO module

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Switches Relays
GNB

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Switches
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• Switches are used for operator input • The momentary pushbutton switch is
to send instructions to the control activated when the button is pressed,
circuit. and deactivated when the button is
• Switches are installed on the released.
moving parts of a machine to • The deactivation is done using an
provide automatic feedback to the internal spring
control system.
• The maintained pushbutton activates
• The most common switch is the when pressed, but remains activated
pushbutton. when it is released.
• There are two types of pushbutton, • Then to deactivate it, it must be
the momentary and maintained. pressed a second time.

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Switches
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• The contacts on switches can be of

two types. These are normally open
(N/O) and normally closed (N/C).
• Whenever a switch is in deactivated
position, the N/O contacts will be
open (non-conducting) and the N/C
contacts will be closed (conducting).
• Mushroom Head switches are used
for emergency stop/run.
• Other types include, Rotary switch,
Limit switch.

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Relays
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• Early electrical control systems were composed of

mainly relays and switches.
• A relay, or contactor, is an electromagnetic device
composed of a frame with an electromagnet coil and
contacts.
• It is possible to construct a relay with a built-in time
delay device that causes the relay to either switch on
after a time delay, or to switch off after a time delay.
• Few Advantages may be it is available in all different
shapes and sizes; Easy to troubleshoot.
• Few disadvantages may be like, low switching speed;
internal components wear and tear; noise happens
during switching.

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Programming Languages in PLC

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Programming Languages
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style
PLC

The term PLC programming

language refers to the method by
which the user communicates
information to the PLC.
When placed in the program
mode, the processor does not
scan/execute the ladder program

The standard IEC 61131 was

established to standardize the
multiple languages associated
with PLC programming by
defining the following five
standard languages:

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Ladder Diagram
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• Ladder diagram is the universal
programming language of PLC. It has a short
abbreviation as LD and also known as
Ladder Logic. And it is one of the oldest
programming languages for PLC.
• Most popular all over the world. This
language is easy to learn by using a logic
gate and some important programming rules.
• This looks like relay racks, each device in the
relay rack would be represented by a symbol
on the ladder diagram.
• The name ladder diagram is based on the
programming language pattern similar to a
ladder, with two vertical rails that shows
electrical connection among a series of
horizontal rungs between them.
• Ladder Logic consists of virtual relaycontacts
and coils

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Function Block
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• Function block diagram (FBD) is a popular
and easy way to write a program like a
Ladder Diagram.
• FBD is represented like box which consists of
a number of lines of code for putting different
programming functions.
• It is a graphical language for programming
logic controller. So, it makes easy to describe
a system.
• In Function Block Diagram inputs and
outputs are connected in blocks by
connection lines.
• Function blocks are mainly used to do
repetitive tasks like starters, closed-loop
control, PID loops, etc.

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• Structured Text PLC language is shortly

denoted by the ‘ST’ and ‘STX‘.
• It uses high-level programming language
syntax.
• The syntax of ST is similar to the syntax of a
high-level programming language with loops,
variables, conditions, and operators.
• It is a very powerful language that can easily
execute complex mathematical logic.
• The ST consists of various statements with
complex statements and instructions like IF,
WHILE, CASE, RETURN, FOR, REPEAT, etc.

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Instruction List title style
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• Instruction List (IL) is another type of PLC
programming language which uses the
mnemonic code.
• So the syntax of this programming language
is easy to remember.
• In general, AB PLC brand works on the
Instruction List (IL) programming language.
• Instruction List(IL) is one of the PLC
programming languages which is like an
assembly programming language.
• The mnemonic codes like LD, AND, OR, A,
etc. are used in this PLC programming
language.
• Sometimes it is easy to remember the code
while using this programming language.

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Sequential
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• Sequential function charts (SFC) is also a

graphical programming language.
• It has become a popular method of
accurately specifying sequential control
requirements.
• The benefit of SFC is easy to understand
because you can visualize what is happening
and when it is happening in the procedure of
the code.
• The main function of SFC is only the active
parts of the code are executed. Due to this, it
makes easier to troubleshoot and to change
the code if problems occur.

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TIMERS & COUNTERS

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TIMERS
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• Timers are used to provide delay for energizing or de-energizing the output.
• A good application of timed interrupt is PID function block
• There are three types of Timers available in PLC.
1. ON Delay Timer
2. OFF Delay Timer
3. Retentive Timer
• There are few properties associated with timer. They are:
1. Time Base
2. Preset Value
3. Accumulated Value
4. Timer Name
5. Enable Bit
6. Done Bit

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On
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• ON delay Timer is used to provide delay function only after the particular rung becomes true.

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On
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Off
ClickDelay
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• The off-delay timer (TOF) operation will keep the output energized for a time period after the rung
containing the timer has gone false.

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Off
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 Retentive
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• A retentive timer accumulates time

whenever the device receives power, and
it maintains the current time even if
power is removed from the device.
• When the timer accumulates time equal
to its preset value, the contacts of the
device change state.
• Loss of power to the timer after reaching
its preset value does not affect the state
of the contacts.
• The retentive timer must be
intentionally reset with a separate signal
for the accumulated time to be reset and
for the contacts of the device to return
to its non-energized state.

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Counters
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• Electronic counters can count up, count down, or be combined to count up and down.
• Although the majority of counters used in industry are up-counters, numerous applications
require the implementation of down-counters or of combination up/down-counters.
• The attributes used for Counters are:
1. Counter Type
2. Counter Address
3. Counter Preset Value
4. Counter Accumulated Value
5. Counter Enable Bit
6. Done Bit
• Counters are classified into 3 types:
1. Up Counter
2. Down Counter
3. Up/Down Counter
4. High Speed Counter

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Up Counter
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• The up-counter is an output

instruction whose function is
to increment its accumulated
value on false-to-true
transitions of its instruction.

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Down
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• The down-counter instruction will count down or decrement by 1 each time the counted event occurs.
• Each time the down-count event occurs, the accumulated value is decremented.

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Thank You

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