INTRODUCTION TO PLC

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 INTRODUCTION TO PLC
• PLC stands for Programmable Logic Controllers.
• They are basically used to control automated systems in industries.
• They are one of the most advanced and simplest forms of control systems which
are now replacing hard-wired logic relays at a large scale.

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 ADVANTAGES
Before getting into details about PLCs, 3 reasons why PLCs are
being widely used these days

• They are user friendly and easy to operate

• They eliminate the need for hard-wired relay logic
• They are fast
• It is suitable for automation in industries.
• Its input and output modules can be extended depending upon
the requirements

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PLC ARCHITECTURE

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PLC ARCHITECTURE
A basic PLC system consists of the following sections:
Input/ Output Section: The input section or input module consists of devices like
sensors, switches, and many other real-world input sources. The input from the
sources is connected to the PLC through the input connector rails. The output section
or output module can be a motor or a solenoid or a lamp or a heater, whose
functioning is controlled by varying the input signals.

CPU or Central Processing Unit: It is the brain of the PLC. It can be a hexagonal or
an octal microprocessor. It carries out all the processing related to the input signals
in order to control the output signals based on the control program.
Programming Device: It is the platform where the program or the control logic is
written. It can be a handheld device or a laptop or a computer itself.
Power Supply: It generally works on a power supply of about 24 V, used to power
input and output devices.

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PLC ARCHITECTURE
Memory: The memory is divided into two parts- The data memory and the program
memory. The program information or the control logic is stored in the user memory or
the program memory from where the CPU fetches the program instructions. The input
and output signals and the timer and counter signals are stored in the input and
output external image memory respectively.

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WORKING OF PLC

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WORKING OF PLC
• The input sources convert the real-time analog electric signals to suitable digital
electric signals and these signals are applied to the PLC through the connector
rails.
• These input signals are stored in the PLC external image memory in locations
known as bits. This is done by the CPU
• The control logic or the program instructions are written onto the programming
device through symbols or through mnemonics and stored in the user memory.
• The CPU fetches these instructions from the user memory and executes the input
signals by manipulating, computing, processing them to control the output devices.
• The execution results are then stored in the external image memory which controls
the output drives.
• The CPU also keeps a check on the output signals and keeps updating the
contents of the input image memory according to the changes in the output
memory.
• The CPU also performs internal programming functions like setting and resetting
of the timer, checking the user memory.
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OPERATION OF PLC
The Principle of operation of the PLC can be understood with the cyclic scanning
also called as scan cycle, which is given in the below figure.

Operational Sequence
The operational sequence is as follows:
1. Input switch is pressed.
2. Input module places a “1” in the input data table,
3. The ladder logic program sees the “1” and caused a
“1” to be put into the output data table.
4. The output data table causes the output module to
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energize associated point.
5. The output device energizes.
 OPERATION OF PLC
The Scan Cycle
PLCs operate by continually scanning programs and repeat this process many times
per second. When a PLC starts, it runs checks on the hardware and software for
faults, also called a self-test. If there are no problems, then the PLC will start the scan
cycle. The scan cycle consists of three steps: input scan, executing program(s), and
output scan.
Input Scan: The PLC looks at each input card to determine if it is ON or OFF and saves this
information in a data table for use in the next step.
Execute Program (or Logic Execution): The PLC executes a program one instruction at a time
using only the memory copy of the inputs the ladder logic program. For example, the program
has the first input as ON. Since the PLC knows which inputs are ON/OFF from the previous step,
it will be able to decide whether the first output should be turned ON.

Output Scan: When the ladder scan completes, the outputs are updated using the temporary
values in memory. The PLC updates the status of the outputs based on which inputs were ON
during the first step and the results of executing a program during the second step. The PLC
now restarts the process by starting a self-check for faults. www.automationforum.co
APPLICATIONS OF PLC
PLC can be used in three different applications.
1. Stand alone,
2. Multi task and
3. Control management.
Standalone PLC Application
The standalone control system application is very small, there is only one PLC for controlling the
whole process.
In this application, All IO’s are interacting with this master PLC for its control process. These
types of PLC applications will be stand-alone.
Multi-task PLC Application
Multi-task PLC application requires more than one controller for its operation. It controls several
tasks at once.
The number of IOs will be more compared to the stand-alone. Communication will be
happening between PLCs to control the process.
Data transfer can be done by using a server connection between the PLC and computer systems

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Control Management
Control management PLC application using several controlling devices. This application
requires a very large PLC/DCS or computer system.
All the PLCs are connected in the hub with the master PLC, Master PLC will get updates and
respond to the remaining PLCs.

Serial/Ethernet/TCP/IP communication is a must for these types of applications.

The control program, IO address details, Memory coil details, instruction libraries, and data
are stored in memory space in the processor of PLC. It refers to the number of bits it can
store. Values will be stored in the quantity of K, for example, 1 K meant 1024 bits.
PLC memory size can be measured in words.1 word will be of 2 bytes which is 16 bits.
PLC with the 8-bit word has 49,152 bits with 6K memory. PLC with the 32-bit word has
196608 bits of storage with 6K memory. The memory size will get affected by the numbers
of rungs /networks we are using in the PLC program and the Number of IOs.

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PLC types based on Size
Small [PLC]
A small [PLC] computer can control smaller machines such as conveyors and motors. It has less
functionality than the other two classes of PLCs and contains enough memory to store ladder
logic programs for monitoring local I/O devices.
They typically have serial communications ports configured to communicate with field actuators
and sensors over RS-232 or RS-485 links. These devices may be purchased in separate
modules to be fitted into existing control systems easily.

Medium [PLC]
A medium [PLC] is a computer that can control larger machines such as assembly lines and
motors. It has more functionality than the other two classes of PLCs due to its large memory
size, expanded communication ports, higher processing speeds, and additional input/output
devices.
Examples of medium programmable controllers are digital-to-analog converters (DACS), serial
communications ports configured to communicate with field actuators via networks or buses like
Ethernet or DeviceNet, and analog input modules for local sensors configured to monitor
physical parameters like pressure, temperature, and weight.

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Large [PLC]
A large PLC is a computer that can control very large machines such as whole building blocks
or power-producing turbines. It has more functionality than the other two classes of PLCs due to
its high memory size, expanded communication ports, high processing speeds, and additional
input/output devices.

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