Instrumentation and

Programmable Devices

Pr. H. BENTARZI

Chapter V Programmable device PLC

V.1 History
V.2 PLC back ground
V.3 PLC hardware
V.4 PLC Software

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 V.1) Brief history:

The concept of programmable controllers started in 1968, when an initial design

specification for the first PLC was provided a group of engineers from general motors.
For the design, it had to be characterized with the following:
•Cost-competitive with the equivalent relay panels: the need of minimizing the cost was
because of the frequent change in production requirements.
•Smaller than its relay equivalent where many relays are involved.
•Easily maintained and repaired using the modular approach.
•More reliable in plant environment: It had to survive harsh industrial environment with a
long lifetime.
Which were then used, in most industrial control there are two important factors in the
initial design of PLC’s that led to their success.
First factor is their reliability in industry, and the second important factor is that the
programming language that was initially selected was based on standard electrical logic
design.

V.2) PLC back ground:

Programmable logic controllers (PLC) are stand-alone microprocessor based

control systems commonly used by industry and utilities. Typical applications for
PLCs include control of production lines, machining equipment, parts handling,
packaging, conveyors, pump stations, traffic lights, and a multitude of other
applications, PLC controlled system complexity ranges from small dedicated
applications (e.g. controlling the cycling of pumps within a sewage lift stations)
to extremely complex and powerful automated assembly lines (e.g. automobile
manufacturing).
PLCs are manufactured by a multitude of companies such as square D, GE,
Allen Bradley, Texas Instruments/Siemens, Omron etc. most companies have a
full line of products ranging from simple controllers that handle tens of inputs
and outputs (I/O) to PLCs that can be interconnected or networked and handle
thousands of I/Os.

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 V.2) PLC back ground:

Advantages of PLCs:
•Cost-effective for controlling complex systems.
•Flexible and can be reapplied to control other systems quickly
and easily.
•Computational abilities allow more sophisticated control.
•Trouble shooting aids mocks programming and reduces down
time.
•Reliable components make there likely to operate for years
before failure.
•High power driving.
•Low cost.
•Ease of maintenance

V.3) PLC hardware

The actual PLC hardware typically consists of an industrially hardened rack mount
system that contains plug-in modules for various functions; the power supply (commonly
12 to 24 VDC), the main processor module, various input and output modules, and
possibly a communication module for networked systems. Connections between the I/O
and the PLC are typically made via banks of screw terminals on the I/O modules.
Typical inputs to a discrete PLC system include limit switches, photo-detector switches,
pulse encoders, and other ON/OFF buttons, inputs from these different devices are
effectively open or closed switches-regardless of the type sensing being performed.
These inputs are powered by the PLC power supply and feed a voltage signal into the
PLC (e.g. 0VDC = OFF /24 VDC = ON).
Typical outputs from a PLC include contactors, triacs, or open collector transistors. In
many applications, the PLC outputs are connected to larger current handling slaved
devices such as motor starters, contactors, or control relays which in turn control high
voltage/current loads.

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 V.3) PLC hardware

Typical PLC based system with

I/O expansion module

V.3) PLC hardware

The internal structure of a PLC

The structure of a PLC consists of four
basic components:
•An input interface
•An output interface
•The central processing unit (CPU)
•The memory unit.
The below diagram shows the relationship
between each of the components in a
PLC:

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 V.3) PLC hardware

V.3) PLC hardware

Central Processing Unit – CPU

Central Processing Unit (CPU) is the brain of a PLC controller. CPU itself is usually
one of the microcontrollers. A foretime these were 8-bit microcontrollers such as 8051,
and now these are 16- and 32-bit microcontrollers. Unspoken rule is that you'll find
mostly Hitachi and Fuji cu microcontrollers in PLC controllers by Japanese makers,
Siemens in European controllers, and Motorola microcontrollers in American ones. CPU
also takes care of communication, interconnectedness among other parts of PLC
controller, program execution, memory operation, overseeing input and setting up of an
output. PLC controllers have complex routines for memory check up in order to ensure
that PLC memory was not damaged (memory check up is done for safety reasons).
Generally speaking, CPU unit makes a great number of check-ups of the PLC controller
itself so eventual errors would be discovered early. You can simply look at any PLC
controller and see that there are several indicators in the form of light diodes for error
signalization.

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 V.3) PLC hardware

V.3) PLC hardware

. Memory
System memory (today mostly implemented in FLASH technology) is used
by a PLC for an process control system. Aside from this operating system it
also contains a user program translated from a ladder diagram to a binary form.
FLASH memory contents can be changed only in case where user program is
being changed. PLC controllers were used earlier instead of FLASH memory
and have had EPROM memory instead of FLASH memory which had to be
erased with UV lamp and programmed on programmers. With the use of
FLASH technology this process was greatly shortened. Reprogramming a
program memory is done through a serial cable in a program for application
development.

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 V.3) PLC hardware

Memory
User memory is divided into blocks having special functions. Some parts of a
memory are used for storing input and output status. The real status of an input
is stored either as "1" or as "0" in a specific memory bit. Each input or output
has one corresponding bit in memory. Other parts of memory are used to store
variable contents for variables used in user program. For example, timer value,
or counter value would be stored in this part of the memory.

V.3) PLC hardware

Input units
Explanation of PLC controller input and output lines have up to now been
given only theoretically. In order to apply this knowledge, we need to make it a
little more specific. Example can be connection of external device such as
proximity sensor. Sensor outputs can be different depending on a sensor itself
and also on a particular application. Following pictures display some examples
of sensor outputs and their connection with a PLC controller. Sensor output
actually marks the size of a signal given by a sensor at its output when this
sensor is active. In one case this is +V (supply voltage, usually 12 or 24V) and
in other case a GND (0V). Another thing worth mentioning is that sinking-
sourcing and sourcing - sinking pairing is always used, and not sourcing-
sourcing or sinking-sinking pairing.

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 V.3) PLC hardware

Input units

V.3) PLC hardware

Input units

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 V.3) PLC hardware

Output units
PLC controller output lines usually
can be:

-transistors in PNP connection

-transistors in NPN connection
-relays

V.3) PLC hardware

Output units

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 V.4) PLC software:

PLC hardware manufacturers strive to make their hardware as

versatile and adaptable as possible to different control
requirements, but it is the PLC program (software) that gives the
hardware its unique functional personality. To implement a control
strategy, PLC users develop their own PLC software program
which is loaded into the PLC memory, customizing the PLC for
their particular application. In many applications, the cost of the
PLC hardware may be rivaled or exceeded by the labor costs in
developing a particular PLC program for a control system.

V.4) PLC software:

PLC manufacturers provide software packages for use on

personal computers that aid in the development of the PLC
program. Many different methodologies are currently used in
programming PLCs but ladder logic portrayal is currently the most
common relays programming.

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 V.4) PLC software:

Instruction list (IL):

It is an external programming system.

Mnemonic are used to identify the different command.
e.g.: LD X
OUT Y

V.1 PLC

Ladder logic:

Programmable controllers are generally programmed in ladder diagram

(or "relay diagram") which is nothing but a symbolic representation of electric
circuits. Symbols were selected that actually looked similar to schematic
symbols of electric devices, and this has made it much easier for electricians
to switch to programming PLC controllers. Electrician who has never seen a
PLC can understand a ladder diagram.

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 V.4) PLC software:

Ladder diagram:
There are several languages designed for user communication
with a PLC, among which ladder diagram is the most popular.
Ladder diagram consists of one vertical line found on the left hand
side, and lines which branch off to the right. Line on the left is
called a "bus bar", and lines that branch off to the right are
instruction lines. Conditions which lead to instructions positioned
at the right edge of a diagram are stored along instruction lines.
Logical combination of these conditions determines when and in
what way instruction on the right will execute. Basic elements of a
relay diagram can be seen in the following picture.

V.4) PLC software:

Most instructions require at least

one operand, and often more than
one. Operand can be some
memory location, one memory
location bit, or some numeric value
-number. In the example above,
operand is bit 0 of memory location
IR000. In a case when we wish to
proclaim a constant as an
operand, designation # is used
beneath the numeric writing (for a
compiler to know it is a constant
and not an address).

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 V.4) PLC software:

a ladder diagram consists of

two basic parts: left section
also called conditional, and a
right section which has
instructions. When a
condition is fulfilled,
instruction is executed, and
that's all!

V.4) PLC software:

Normally open and normally closed contacts:

Since we frequently meet with concepts "normally open" and "normally closed" in
industrial environment, it's important to know them. Both terms apply to words such as
contacts, input, output, etc. (all combinations have the same meaning whether we are
talking about input, output, contact or something else).

Principle is quite simple, normally open switch won't conduct electricity until it is
pressed down, and normally closed switch will conduct electricity until it is pressed.
Good examples for both situations are the doorbell and a house alarm.

If a normally closed switch is selected, bell will work continually until someone pushes
the switch. By pushing a switch, contacts are opened and the flow of electricity towards
the bell is interrupted. Of course, system so designed would not in any case suit the
owner of the house. A better choice would certainly be a normally open switch. This way
bell wouldn't work until someone pushed the switch button and thus informed of his or
her presence at the entrance.

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 V.4) PLC software:

V.4) PLC software:

The control sequence:

Typically PLCs perform their control function via the
following three step sequence.
•LATCH INPUTS: the PLC latches the status of all of
the inputs entering the PLC via the input modules and
stores them in input status registers.
•EXECUTE THE PROGRAM: the PLC then executes
its user programmed control program analyzing the
latched input information and making control output
decisions.
•CYCLE OUTPUTS: the PLC then writes the scan cycle
appropriate control output logic to output registers.
The states of these output registers are then
simultaneously written to the outputs, cycling them ON
or OFF accordingly. The PLC then returns to step 1
and continually repeats the loop.

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Thank You

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