UNIT IV PROGRAMMABLE LOGIC CONTROLLER 9

Introduction – Architecture – Input / Output Processing – Programming with

Timers, Counters and Internal relays – Data Handling – Selection of PLC.

4.1 INTRODUCTION
DEFINITION OF PLC:
 A programmable logic controller (PLC) Program is a specially designed digital operating
microprocessor-based controller that uses a programmable memory for internal storage of
instructions and for implementing function such as logic, sequencing, timing, counting and
arithmetic in order to control machines and processes.

Need of PLC :

 The programmable logic controller (PLC) device is widely used in industry to automate event
based control, interlocking of operations and sequencing of operations.
 PLC is used in almost all process industries, where there is requirement of process safety and
interlocks e.g. thermal power stations, steel industry, cement industry, pharmaceutical industry,
petrochemical industry, fertilizer industry etc.

Features of PLC

1. Compact and rugged in construction.

2 . PLC can be easily programmed.
3. Reprogramming is very easy.
4. It gives noiseless operation.
5. More reliable, low maintenance cost.
6. Interfacing of computer is possible for further processing and analysis.
7. Controlled outputs are available in different voltages [DC: +5 V, +12 V, +24 V, AC: 9 V, 18 V, 24 V,
110 V]
8. Inbuilt timers, counters and registers.
9. PLCs can store data and programs.
10. I/O channels are isolated hence interfacing with sensors and actuators are easy.

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4.2 ARCHITECTURE OF PLC

Fig.4.2.1 Basic PLC Architecture

Basic components of plc:
The PLC hardware system consists of the basic components are
1. Processor
2. Memory
3. Power Supply
4. Input I Output modules
5. Programming device

1. Processor:
 It is the heart of PLC
 He processor processes the signals from input module and generates controlling
signals for the system
 It also scans and solve the logic of the user program
 It consists of ALU, microprocessor unit, memory unit and system powersupply
2. Memory:
 The memory unit contains the program stored in it
 The programs were written with control actions to be executed by the microprocessor for
the input given.
 RAM is a temporary storage device used to store ladder diagram and for testing and
evaluation

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  Then it is stored in ROM where changes cannot done.

3. Power Supply:
 The purpose of a power supply unit is to convert the main A.C voltage into a low – level D.C
voltage (5V).
 The D.C. voltage is supplied to the processor and the circuits in the input and output
interface modules.
 The power supply should be free from heavy loads, noises and voltage fluctuations.

4. Input / Output Modules:

 The Input module receives information from extended devices and sends to processor and
communicates the processed information to the external devices through output modules.
 The Input devices are mechanical switches, photo sensors, temperature sensors, flow
sensors, other type of sensors keypads etc.,
 The output devices may include solenoid valves, Relays, contactors, lights, Horns,
 Heating elements, fans, Motor starter, signal Amplifiers. Conveyor belt, lift, automatic door
etc.,
 I/O devices are also called peripheral devices.
5. Programming Device:
 It is used to communicate between user and PLC.
 It is used to enter the required program into the memory of the CPU.
 The program is developed in programming device and stored into memory unit

BASIC INTERNAL ARCHITECTURE OF A PLC SYSTEM:

 The CPU consists of the following units. They are ALU, Memory Unit & control unit.
Central Processing Unit:
 The CPU controls and processes all the operations within the PLC.
 It is supplied with a clock with a frequency of typically between 1 to 8 MHz.
 This frequency determines the operating speed of the PLC and provides the timing and
synchronization for all elements in the system.
 The information within the PLC is carried by means of digital signals.
 The processor is a microprocessor that executes a program to perform the operations
specified in a ladder diagram or a set of Boolean equations.
 The CPU consists of the following units. They are ALU, Memory Unit & control unit.

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 Fig.4.2.2 Internal Architecture of a PLC System

i. Arithmetic and Logic Unit (ALU):

 This unit performs data manipulation and arithmetic and logical operations on input I
variable data and determines the proper state of the output variables.
 The arithmetic operation includes addition, subtraction etc., and logic operations include
AND, OR, AND, EXCLUSIVE - OR.
ii. Control Unit:
 A control unit is used to control the timing of operations.
 The processor functions under a permanent supervisory operating system that directs the
overall operations from data input and output to execution of user programs.
 The controller can perform only one operation at a time. So, it scans each of the inputs
sequentially, evaluates the ladder diagram program, provide each output(s), and then
repeat the whole process.
 Hence, the timing control's necessary for a PLC system.
iii. Memory Unit:
 There are several memory elements in a PLC system.
 System Read-only Memory (ROM) gives permanent storage for the operating system and
fixed data by the CPU.

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  RAM for the user to develop program and acts a temporary memory.
 In addition, temporary buffer stores for the I/O channels.
 The sequence of instructions to be executed, programs are stored in the memory unit.
 During entering and editing including Debugging, the program is stored in the temporary
storages called RAM (Random Access memory).
 Once the program is completely finished (free & from errors).
 It may be 'burned' into ROM
 When the ROM is plugged into the PLC, the device is ready to be placed into service in the
industrial environment.
 For network programmed PLCs, the final PLCs program is downloaded into a special
reprogrammable
 ROM (EPROM, PROM, and EEPROM) in the PLC.
 Memory may be either volatile type or Non-volatile type.
Volatile Memory:
 Volatile memory or temporary memory or Application memory is the user memory, where
the user can enter and edit the program.
 Volatile memory will lose all its programmed contents if operating power is removed or
lost.
 here for necessary to provide a battery backup power to all times.
Non Volatile Memory:
 Non-volatile memory or permanent memory or system memory is (used) a system memory
that stores the monitor a booting programs, lookup tables etc.,
 This is usually programmed and supplied by the manufacturer.
 This controls the operation of PLC.
 It does not lose its content during power failure.
 It does not require any battery.
The ROM memory offers the CPU to use only fixed amount of data.

The Different Types of ROMS are

Mask programmed ROM, PROM, EPROM & EEPROM

Mask Programmed ROM:

 It is a special type of ROM which is programmed during manufacturing.
 The programmed content stored by this type of ROM memory cannot be altered.
PROM:
 PROM stands for programmable Read only memory.
 It is a special type of ROM usually programmed by manufacturer during manufacturing.
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  It has the disadvantage of requiring special programming device and once programmed
Cannot be erased or altered.
EPROM:
 EPROM stands for electrically programmable Read only Memory.
 Here, the user programs electrically.
 One can erase the program completely by shining UV light source or quartz window in
package.
 After the program chip is erased completely, program changes can be made.
 When the program developed in RAM, the manufacturers usually load it in EPROM to make
permanent storage.
EEPROM:
 EEPROM - Electrically Erasable programmable Read-only memory.
 Even though, it is a non-volatile memory, it offers some programming flexibility as RAM.
 One can erase the program completely by electrical signals.
 Program changes can be made very easily with the use of a PC with EEPROM software.
 It can be electrically programmable by the user.

Buses:
 A set of parallel lines that provides communication between various devices of a system is
termed as a Bus.
 The bus system carries information and data’s to and from the CPU, Memory and I/O units.
 The information is transmitted in binary form as 0 or 1
 Digital signals or electrical signals are flowing inside the bus.
 It might be tracks on a printed circuit board (PCB) or wires in a ribbon cable.
 The PLC system contains four buses.
 They are namely Data Bus, Address Bus, Control bus and system bus.
Data Bus:
 The data bus contains 8, 16 or 32 parallel signal lines for sending data between the various
devices of a system.
 An 8-bit microprocessor has an internal data bus which can handle 8-bit numbers.
Address Bus:
 The Address bus contains 16, 20, 24 or 32 parallel signal lines to carry the Address of the
memory locations for accessing stored data.
 Every memory location is given a distinct unique address to locate easily and accessed by
the CPU either to read or write data.

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Control Bus:
 The Control bus contains 4 to 10 parallel signal lines to carry the signals used by the
CPU that are related to internal Control actions. Typical control bus signals are Memory
read Memory write, I/O Read and I/O write.
I/O System Bus:
 The I/O system bus provide the communication between the I/O ports and I/O units
Input / Output Unit:
 The I/O units provide the interface between the system and the outside world, allowing for
connections to be made through I/O channels to input / output devices.
 Programs are entered from a program panel through I/O unit.

Advantages of PLC over the Relay System

1. Enhanced reliability.
2. Ease in logic modification.
3. Interactive operator interface.
4. On line repair facility.
5. I / O forcing through software.
6. On line monitoring of user logics.
7. Trouble shooting aids make programming easier and reduce downtime.
8. Computational abilities allow more sophisticated control.

Disadvantages of PLC
1. There's too much work required in connecting wires.
2. There's difficulty with changes or replacements.
3. It's always difficult to find errors; And require skillful work force.
4. When a problem occurs, hold-up time is indefinite, usually long.

Application of PLC
There are many applications that you can find PLCs are use in the various industries.
 Material Handling  Electrical/Electronic Appliance
 Conveyor System  Manufacturing / Packaging Machine
 Pick and Place Robot Control  Disk Drive Manufacturing
 Pump Control  Petrol/Chemical Plant
 Swimming Pool / Water Treatment  Traffic Light System
 Chemical Processing Plant  Plastic Manufacturing Industries
 Paper and Pulp Industries  Train Control Station system
 Power Station Plant  Process Monitoring Control

Page. No: 7
4.3 INPUT / OUTPUT PROCESSING
Input Channel of PLC
 Sensors like proximity sensors, rotary encoders, optical sensors, limit switches are
interfaced to PLC through it's input / output modules.
 The I/O modules provide signal conditioning and isolation so that the sensors can be
connected directly.
 For input channel usually an optocoupler is used for isolation purpose and for protection of
input module voltage divider circuit and a protection diode is used as shown in Fig. 4.3.1.

Fig. 4.3.1. Input Channel Protection

Output channel
 The external device or circuit is connected to PLC through a switching device.
 The output channel is specified by the type of switching element ie. relay type, transistor
type or triac type. The switching device (relay, transistor, triac) isolates the PLC from the
external circuitry.

1) Relay output
 In relay type output the signal from PLC is used to operate a relay. Relay can switch currents
of few milli amperes to few amperes to external circuit.
 Relay can switch both AC and DC signals.
 Relays can withstand high surge currents and voltage transients. Because of mechanical
switching in relays, they are relatively slow to operate.

2) Transistor output
 In transistor type output, a transistor is used to switch current through external circuit.
 Transistors can switch faster than the relay.
 Transistors can be used for switching of DC signals only and can be destroyed by
overcurrent and high reverse voltage.
 Hence proper protection circuits are to be provided.
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  Also for switching higher current higher current capacity of transistor is needed.

3) Triac output
 Triac type outputs are used specially for switching of DC signals.
 Triacs may damage due to overcurrent.
 Hence for protecting triacs optoisolater and fuses are used.

Input/output voltage levels

 A range of inputs are available to a PLC e.g. 5 V, 24 V, 110 V, 240 V, digital/discrete i.e. on-off
signals. Fig. 4.3.2 shows various input levels

Fig. 4.3.2 Input Voltage Levels

 After signal conditioning and processing the output signal might be a 24 V, 100 mA
switching signal, 110 V DC – 1A, 240 V – 1A. The following figure 4.3.3 shows various
output levels.

Fig. 4.3.3 Output Voltage Levels

Output Channel of PLC
 The sourcing and sinking are used to describe the way in which DC devices are connected to
PLC
Current Sourcing:
 If a switch is connected to the positive of the battery and current flows from positive to
negative, it is said to be the sourcing the current. So, the input device receives current from
the input module.
 For the PLC, input unit, hence input module is the source of the current. For the PLC output
unit, output module is the source of current as it supplies current to the output devices.
Sourcing output units for interfacing with solenoids.

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Current Sinking:
 Here, the input device supplies current to the input module. For the PLC input unit, hence
the input module is the sink for the current. Sinking input units are used for interfacing with
electronic equipment.
 So, if a switch is connected to the negative of the battery and current flows from positive to
negative, by conventional current flow direction, it is said to be the sinking for Current. For
the PLC output unit, the current flows from output device to the output module then the
output module is the sink for current.

Steps involved in input / output processing:

The sequence followed by a PLC when carrying out a program can be as follows:
 Scan the inputs associated with one rung of the ladder program
 Solve the logic operation involving those inputs.
 Set / Reset the outputs for that rung
 Move on the next rung and repeat the operations 1, 2, 3

The two methods of Input/ Output processing operations are

 Continuous updating
 Mass Input / Output copying
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Continuous Updating:
The sequence followed thus in continuous updating is as follows:
 Fetch and decode the first program instruction
 Scan there relevant inputs
 Fetch and decode the second program instruction
 Scan the relevant inputs etc. For the remaining program instructions
 Update outputs
 Report the entire sequence.

Mass Input / Output Copying:

The sequence followed in Mass I/O copying is thus:
 Scan all the inputs and copy into RAM
 Fetch and decode and execute all the program instructions in sequence
 Copy all the output instructions to RAM
 Update all outputs.
 Repeat the sequence

4.4 PROGRAMMING WITH TIMERS, COUNTERS AND INTERNAL

RELAYS
PLC PROGRAMMING:
Structure of Rung:

 The following figure 4.4.1 shows a ladder rung, starting with the input, normally open symbol
for input contact is shown by | |.

Fig. 4.4.1 A Ladder Rung

 In drawing ladder diagrams the addresses of each element are appended to its symbol. When
writing up the inputs and outputs to the PLC, relevant input addresses must be connected to the
input and output terminals with its output addresses.
LOGIC Functions:

1. AND Logic Function:

 AND logic circuit represents series circuit

 AND gate is composed with two inputs and one output.
 AND gate produce output when both the inputs are HIGH state.

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 Input(A) Input(B) Output
A.B
0 0 0

0 1 0

1 0 0
1 1 1

Step Instruction Address Parameter Description

0 LD X 400 X 400 Input Start a rung with open contacts

1 AND X401 X401 AND Logic Open contact AND logic function

2 OUT Y 430 Y 430 Output Output or terminate the rung

2. OR Logic Function:
 OR logic circuit represents the parallel circuit.
 OR Gate is composed of two or more inputs and one output.
 OR operation is like addition of binary numbers.
 OR gate produce output when any one input are HIGH state.

Input(A) Input(B) Output

A+B
0 0 0
0 1 1
1 0 1
1 1 1

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 Step Instruction Address Parameter Description

0 LD X 400 X 400 Input Start a rung with open contacts

1 OR X401 X401 OR Logic Open contact OR logic function

2 OUT Y 430 Y 430 Output Output or terminate the rung

3. NOT Logic Function:

 NOT function is also known as Inverter.

 NOT gate is composed of single input and a single output.
 The bubble, or circle, at the output is the standard symbol used to represent inversion.
 In NOT gate, there is an output, when there is no input and no output when there is an input

Input(A) Output
A’
0 1
1 0

4. NAND Logic Function:

 NAND is a combination of AND and NOT gates.

 Arrangement shows AND gate is followed by NOT gate. Hence it is called NOT AND gate.
 Both the inputs A and B have to be at LOW state to get the output at HIGH state.
 NAND Gate is composed of two or more input with a single output.
 Any one input is in LOW state also output will be HIGH state

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 Input(A) Input(B) Output
AB
0 0 1
0 1 1
1 0 1
1 1 0

Step Instruction Address Parameter Description

0 LD X 400 X 400 Input Start a rung with closed contacts

1 ORI X401 X401 NOR Logic Add a closed contact in parallel

2 OUT Y 430 Y 430 Output Terminate the rung

5. NOR Logic Function:

 NOR is a combination of OR and NOT gates.

 Arrangement shows OR gate is followed by NOT gate. Hence it is called NOT OR gate.
 Both the inputs A and B have to be at LOW state to get the output at HIGH state.
 NOR Gate is composed of two or more input with a single output.
 Any one input is in HIGH state also output will be LOW state

Input(A) Input(B) Output

A+B
0 0 1
0 1 0
1 0 0
1 1 0

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 Step Instruction Address Parameter Description

0 LDI X 400 X 400 Input Start a rung with closed contacts

1 ANI X401 X401 NAND Logic Add a closed contact in series

2 OUT Y 430 Y 430 Output Terminate the rung

6. Exclusive OR (XOR) Logic Function:

 When both the inputs are at LOW state the output will be at LOW state
 When both the inputs are at HIGH state the output will be at LOW state
 When any one input is HIGH state the output will be at HIGH state

Input(A) Input(B) Output

A⊕B
0 0 0
0 1 1
1 0 1
1 1 0

Step Instruction Address Parameter Description

0 LD X 400 X 400 Input Start a rung with Open contacts

1 ANI X401 X401 NAND Logic Add a closed contact in series with Input.

2 LDI X 400 X 400 Input Start a new rung with a closed contacts.

3 AND X401 X401 AND Logic Add a open contact in series with input

4 ORB - - Do OR operation between two sub circuits

5 OUT Y 430 Y 430 Output Terminate the rung

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(i). PROGRAMMING WITH TIMERS:
 A timer is a special counter ladder function that allows the PLC to perform timing operations
based on a precise internal clock.
Types of Timers:
1. Delay ON Timers or ON delay timers
2. Delay OFF Timers or OFF delay timers
3. Pulse Timers
4. Cascaded Timers
5. ON-OFF Cycle Timers
6. One Shot Timers

1. Delay ON Timers:

 The term delay is used to indicate that this timer burns on, after waiting for a fixed time delay
period.
 When there is an input, the timer is energized and starts timing, after some pre-set value, the
timer contacts are closed to output.
 TON is used to denote ON-delay.

2. Delay OFF Timers:

 OFF delay timers are maintained as ON for a fixed time of delay period before turning off.
 TOF is used to denote OFF-delay.

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3. Pulse Timers:
 Pulse timer switches is another type of Timer which comes either ON or OFF for a fixed period of
time as a function of pulses.
 TP is used to denote Pulse Timers.

4. Cascaded Timers:
 Cascading means more elements are linked together to form a system.
 The cascading timers are linked together to give longer delay times which is easily achieved than
just one timer.

5. ON – OFF Cycle Timer:

 Timers producing an output for some period and no output for some period and an output for
some period.
 The timer is designed to switch an output for T sec and off for another T second

Page. No: 17
ii. PROGRAMMING WITH COUNTERS:
 A counter is a PLC instruction that either increment or decrements an integer number value when
prompted by the transition of a bit from 0 to 1.
 Counters are used to count a specified number of contact operations.

 Counter instruction come in three basic types:

1. Up Counters
2. Down counters
3. Up/Down counters
 For both UP and Down counters, there is only one trigger is needed to start the counting, But for
up / down counter it is needed two triggers. One for up and other for down counter.

1. Up Counters:
 Up counters count up from the zero to pre – set value
 The events are added until the pre – set value is reached
 When the counter reaches the set value, its contacts change state
 Up counter is an increment counter. which means it counts "up" with each off-to-on transition
input to its "CU" input.
 Whenever there is a true value entry in the CU input, the counter will turn on and CV will display
the count.

Fig. 4.4.2 Up Counter

 This counter output must be activated whenever the current value is equal to or greater than the

Page. No: 18
 preset value (Q is active if CV ≥ PV).

 The counter output instruction will increase by 1 each time the counted event occurs.
Down Counters:
 The down-counter instruction will count down or decrease by 1 each time the counted event
occurs.

Fig. 4.4.3 Down Counter

 Each time the countdown event occurs, the accumulated value decreases.
 Normally, the down counter is used together with the ascending counter to form an up/down
counter.
Up-Down Counters:
 Up-Down counter do both the function of Up and Down counters.
 The counter will increase (count up) when sensor B de-energizes only if sensor A is already in the
deactivated state (ie beam A breaks before B).
 The counter will decrease (countdown) when sensor A is de-energized only if sensor B is already
in the de-energized state (i.e, beam B breaks before A).
 The up / down counter has a "reset" input (R) and a "load" ("LD") input to force the current value.
 Activating the reset pin forces the counter to set zero, activating the load input forces the current
value of the counter to the preset value (PV).

iii. PROGRAMMING WITH INTERNAL RELAY:

 An internal relay behaves like relays with their associated contacts, buy they are not actual relays
whose simulations are controlled by the PLC software.
 Internal relays can be very useful in the implementation of switching sequences.
 They are often used when there are programs with multiple input conditions.
 They are also known as Auxiliary relays or markers.
 In using an internal relays, it has to be activated on one rung of a program and then its output
used to operate switching contacts on another rung of a program.
 Consider the situation where the excitation of an output depends on two various input activities.

Page. No: 19
 Figure 4.4.4 (a) shows how we can draw a ladder diagram using internal relays.

Figure 4.4.4 (a) Internal Relay

 The first rung shows one input arrangement being used to control the coil of internal relay IRI.
 The second rung shows the other input arrangement controlling the coil of internal relay IR2.
 The contacts of the two relays are then put in an OR situation to control the output.
 Another use of internal relays is for the starting of multiple outputs.
 Figure 4.4.4 (b) shows such a ladder program.

Figure 4.4.4 (b) Ladder Program

 When the start contacts are closed, the internal relay is activated and latches the input.
 It also starts output 1 and makes it possible for outputs 2 and 3 to be activated.

LATCHING:
 There are often situations where it is necessary to hold an output energized, even when the input
ceases. e.g. a motor started by pressing a switch.
 Though the switch contacts do not remain closed, the motor is required to continue running until
a stop push button is pressed.
 Latch circuit is used to implement such situation. Fig. 4.4.5 shows latched circuit.

Page. No: 20
 Fig. 4.4.5 latched circuit
 When the input A contacts close, there is an output. However, when there is an output another set
of contacts associated with the output closes.
 The contacts form an OR logic gate system with the input contacts. Thus, even if the input A
opens, the circuit will still maintain the output energized.
 The only way to release the output is by operating the normally closed contact B.
Solved Example:
 As an illustration of application of a latching circuit, consider a motor controlled by stop and start
push button.
 Switches and for which one signal must be illuminated when the power is applied to the motor
and another when it is not applied.
 Fig. 4.4.6 shows ladder diagram with mitsubishi make PLC notations.

Inputs: X400, X401 (Both NO switches)

Outputs: Y430 (motor)
Y431 Lamp indication (power not applied)
Y432 Lamp indication (power applied)

 When X400 is momentarily closed, Y430 is energised and it's contacts close. This results in
latching and also the switching off of Y431 and the switching on off Y432.
 To switch the motor off, X401 is pressed and opens. Y430 contacts open in the top rung and third
rung, but close in the second rung. Thus Y431 comes on and Y432 off.

Page. No: 21
4.5 DATA HANDLING
The steps involved in data handling with a PLC system are :

1. Moving data from one memory location to another

2. Comparison of Magnitudes of data
3. Arithmetic operations
4. Data conversion

1. Data Movement:
Instruction: MOV
Function: To copy a value from one address to another
Program:
LD X400
MOV
D1
D2
 When there is an input to X400,
 The data moves from the designated source address to the designated destination address.
 The data transfer might move a constant into a data register

2. Data Comparison:
 The data comparison instruction gets the PLC to compare two data values.
 It compare a preset value (1) to the input values (2)
 Instruction :
< or LES
= or EQU
> or GRT
< or LEQ
≠ or <> or NEQ
> or GEQ

 For data comparison the typical instruction will contain the data transfer instruction to
compare the data from source address and designation address

Page. No: 22
Example:

 It is required to sound an alarm if a sensor indicates a temperature above 90˚C and remain
sounding until the temperature falls below 75˚C.
 For this, the ladder diagram is shown above.
 The input temperature data is inputted to the source address and the destination address
contains the set value.
 When the temperature rises 90˚C or higher, the data value in the source address becomes >
the destination address value and there is an output to the alarm which latches the input
 When the temperature falls to 75˚C or lower, the data value in the source address becomes <
the destination address value and there is an output to the relay which then opens the
contacts and so switches the alarm off.

3. Data Arithmetic Operations:

 PLCs are offered with the ability to carry out the arithmetic operations such as addition,
subtraction, multiplication and division only.
 They cannot carry out exponential functions.
 Addition and subtraction operations are used to alter the value of data held in data registers.
 Multiplications are used to multiply some input before adding to or subtracting it from
another.
4. Code Conversions:
 All the internal operations in the CPU of a PLC are carried out through binary numbers.
 Most PLCs provide BCD-to-binary and binary-to-BCD conversion for use.
 When a decimal (input) signal is given, BCD conversion is used.
 Similarly, when a decimal output is required, Decimal conversion is used.
 The data at the source address is in BCD and converted to binary and placed at the
destination address.

Page.No. 23
4.6 SELECTION OF PLC.
PLC selection criteria consists of:
1. System (task) requirements
2. Application requirements
3. Electrical requirements
4. Speed of operation
5. Communication requirements
6. Operator interface
7. Physical environments
8. What input/output capacity is required?
9. What type of inputs/outputs are required?
10. What size of memory is required?
11. What speed is required of the CPU?
12. Software

1. System requirements:
 The starting point in determining any solution must be to understand what is to be achieved.
 The program design starts with breaking down the task into a number of simple understandable
elements, each of which can be easily described.

2. Application requirements
 Input and output device requirements. After determining the operation of the system, the next
step is to determine what input and output devices the system requires.
 List the function required and identify a specific type of device.
 The need for special operations in addition to discrete (On/Off) logic APP
 List the advanced functions required beside simple discrete logic.

3. Electrical Requirements
 The electrical requirements for inputs, outputs, and system power; When determining the
electrical requirements of a system, consider three items:
i. Incoming power (power for the control system);
ii. Input device voltage; and
iii. Output voltage and current.

4. Speed of Operation
 How fast the control system must operate (speed of operation)?
 When determining speed of operation, consider these points:

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 How fast does the process occur or machine operate ?
 Are there Time critical operations or events that must be detected?
 In what time frame must the fastest action occur (input device detection to output device
activation.
 Does the control system need to count pulses from an encoder or flow-meter and respond
quickly?

5. Communication requirements
 Communication requires sharing data outside the process, ie. communication.
 Communication involves sharing application data or status with another electronic device, such
as a computer or a monitor in an operator's station.
 Communication can take place locally through a twisted-pair wire, or remotely via telephone or
radio modem.

6. Operator Interface
 If the system needs operator control or interaction. In order to convey information about machine
or process status, or to allow an operator to input data, many applications require operator
interfaces.
 Traditional operator interfaces include pushbuttons, pilot lights and LED numeric display.
 Electronic operator interface devices display messages about machine status in descriptive text,
display part count and track alarms.
 Also, they can be used for data input.

7. Physical Environment
 The physical environment in which the control system will be located. Consider the environment
where the control system will be located.
 In harsh environments, house the control system in an appropriate IP-rated enclosure.
 Remember to consider accessibility for maintenance, troubleshooting reprogramming.

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