PROGRAMMABLE LOGIC CONTROLLER (PLC)

Is an industrial computer designed for multiple inputs and output arrangements.

It is capable of storing the instructions to implement control functions such as sequencing,
timing, counting, arithmetic, data manipulation, and communication.

HISTORY OF PLC
 PLC was introduced in late 1960’s
 First commercial & successful Programmable Logic Controllers was designed and
developed by Modicon as a relay replacer for General Motors.
 Earlier, it was a machine with thousands of electronic parts.
 Later, in late 1970’s, the microprocessor became reality & greatly enhanced the role of
PLC permitting it to evolve form simply relay to the sophisticated system as it is today.

WHAT TASKS DO PLC PERFORM?

The logic control task such as interlocking, sequencing, timing and counting (previously
undertaken with relays or pneumatics).
In addition, PLCs can perform a variety of calculation, communication and monitoring tasks.

LEADING BRANDS OF PLC

American:
 Allen Bradley
 Gould Modicon
 Texas instrument
 General Electric
 Westinghouse
 Cutter Hammer
 Square D
European:
 Siemens
 Klockner & Mouller
 Telemechanique
Japanese:
 Toshiba
 Omron
 Fanuc
 Mitsubishi

PLC Size:
Small:
 It covers units with up to 128 I/O’s and memories up to 2 Kbytes.
 These PLC’s are capable of providing simple to advance levels or machine controls.
Medium:
 Have up to 2048 I/O’s and memories up to 32 Kbytes.
Large:
 The most sophisticated units of the PLC family.
 They have up to 8192 I/O’s and memories up to 750 Kbytes.
 Can control individual production processes or entire plant.

MAJOR COMPONENTS
1. Power Supply
Provides the voltage needed to run the primary PLC components.

2. I/O Modules
Provides signal conversion and isolation between the internal logic – level signal inside the PLC
and the field’s high level signal.

3. Processor
Provides intelligence to command and govern the activities of the entire PLC systems.

4. Programming Device
Used to enter the desired program that will determine the sequence of operation and control of
process equipment or driven machine.

PLC OPERATION SEQUENCE

1. Self-test
Testing of this own hardware and software for faults.
2. Input scan
If there are no problems, PLC will copy all the inputs and copy their values into memory.
3. Logic solve/scan:
Using inputs, ladder logic program is solved once and outputs are updated.

4. Output scan
While solving logic the output values are updated only in memory when ladder scan is done, the
outputs will be updated using temporary values in memory.

I/O Module
- The I/O interface section of a PLC connects it to external field devices.
- The main purpose of the I/O interface is to condition the various signals.

Processor- provides intelligence to command and govern the activities of the entire PLC
systems.
Programming Device - used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.

I/O Module (Direct Current (DC) Input Module)

Current Limiting Resistor – Use to drop the voltage to logic level.
Opto-isolator – Prevent voltage transients from damaging the processor.
Helps reduce the effects of electrical noise.

I/O Module (Alternating Current (AC) Input Module)

Rectifier, Resistor Network – Converts the AC input to DC and drops the voltage to logic level.

DIFFERRENT TYPES OF I/O CIRCUITS

1. Pilot Duty Outputs – Outputs of this type typically are used to drive high-current
electromagnetic loads such a solenoids, relays, valves, and motor starters.

2. General Purpose Outputs – There are usually low-voltage and low-current and are used
to drive indicating lights and other non-inductive loads. Noise suppression may or may
not be included of this type of modules.

3. Discrete Inputs – Circuits of this type are used to sense the status of limit switches, push
buttons, and other discrete sensors. Noise suppression is great importance in preventing
false indication of inputs turning on or off because of noise.

4. Analog I/O – Circuits of this type sense or drive analog signal.

5. Special Purpose I/O – Circuits of this type are used to interface PLC to very specific
types of circuits such as servomotor, stepping motors PID (Proportional plus Integral plus
Derivative) loops, high-speed pulse counting, resolver and decoder inputs, multiplexed
displays and keyboards.

INPUT DEVICES
  Push Button
 Limit Switch
 Thumbwheel Switch
 Level Switch
 Flow Switch
OUTPUT DEVICES
 Motor
 Solenoid
 LED Display
 Heater Coil
 Lamp

Discrete Input
A discrete input also referred as digital input is an input that is either ON or OFF are
connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a logic high
and in the OFF condition maybe referred to as logic o or logic low.

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open Switch

Normally Closed Switch

Normally Open Contact

Normally Closed Contact

Analog Input
An analog input is an input signal that has a continuous signal, Typical inputs may vary
from 0 to 20mA, 4 to 20mA or 0 to l0V.
Digital Output
A discrete output is either in an ON or OFF condition. Solenoids, contactors coils, lamps
are example of devices connected to the Discrete or digital outputs.
Analog Output
An analog output is an output signal that has a continuous signal. Typical outputs may
vary from 0 to 20mA, 4 to 20mA or O to 10V.
PROCESSOR
 The processor module contains the PLC's microprocessor, its supporting circuitry, and its
memory system.
The main function of the microprocessor is to analyze data coming from field sensors through
input modules, make decisions based on the user's defined control program and return signal
back through output modules to the field devices.
Field sensors: switches, flow, level, pressure, temp. transmitters, etc.
Field output devices: motors, valves, solenoids, lamps, or audible devices.

The memory system in the processor module has two parts: a system memory and an
application memory.

MEMORY MAP ORGANIZATION

 System memory includes an area called

the EXECUTIVE, composed of
permanently stored programs that direct
all system activities, such as execution
of the users control program,
communication with peripheral devices,
and other system activities.
 The system memory also contains the
SYSTEM routines that implement the PLC's
instruction set, which is composed of
specific control functions such as logic,
sequencing, timing, counting, and
arithmetic.

 System memory is generally built from

read-only memory devices.

 The application memory is divided into

the data table area and user program
area.

APPLICATION  The data table stores any data associated

with the user's control program, such as
system input and output status data, and any
stored constants, variables, or preset values.
The data table is where data is monitored,
manipulated, and changed for control
purposes.

 The user program area is where the

programmed instructions entered by the
user are stored as an application control
program.

MEMORY
Volatile
- A volatile memory is one that loses its stored information when power is removed.
- Even momentary losses of power will erase any information stored or programmed on a
volatile memory chip.

Common Type of Volatile Memory

RAM. Random Access Memory (Read/Write)
 Read/write indicates that the information stored in the memory can be retrieved or read,
while write indicates that the user can program or write information into the memory.
 The words random access refers to the ability of any location (address) in the memory to
be accessed or used. Ram memory is used for both the user memory (ladder diagrams)
and storage memory in many PLC's,
 RAM memory must have battery backup to retain or protect the stored program.

Several Types of RAM Memory

 MOS
 CMOS

The CMOS-RAM (Complementary Metal Oxide Semiconductor) is probably one of the

most popular. CMOS-RAM is popular because it has a very low current drain when not
being accessed (15microamps.), and the information stored in memory can be retained by
as little as 2Vdc.

NON-VOLATILE
Has the ability to retain stored information when power is removed, accidentally or intentionally.
These memories do not require battery back-up.

Common Type of Non-Volatile Memory

ROM, Read Only Memory
 Read only indicates that the information stored in memory can be read only and
cannot be changed, Information in ROM is placed there by the manufacturer for the
internal use and operation of the PLC.

Other Types of Non – Volatile Memory

PROM, Programmable Read Only Memory
 Allows initial and/or additional information to be written into the chip.
 PROM may be written into only once after being received from the PLC
manufacturer; programming is accomplish by pulses of current.
 The current melts the fusible links in the device, preventing it from being
reprogrammed. This type of memory is used to prevent unauthorized
program changes.

EPROM, Erasable Programmable Read Only Memory

 Ideally suited when program storage is to be semi-permanent or additional
security is needed to prevent unauthorized program changes.
 The EPROM chip has a quartz window over a silicon material that contains
the electronic integrated circuits. This window normally is covered by an
 opaque material, but when the opaque material is removed and the circuitry
exposed to ultraviolet light, the memory content can be erased.
 The EPROM chip is also referred to as UVPROM.

EEPROM, Electrically Erasable Programmable Read Only Memory

 Also referred to as EPROM, is a chip that can be programmed using a standard
programming device and can be erased by the proper signal being applied to the
erase pin.
 EEPROM is used primarily as a non-volatile backup for the normal RAM memory.
If the program in RAM is lost or erased, a copy of the program stored on an
EEPROM chip can be downloaded into the RAM.

PLC OPERATION
Basic Function of a Typical PLC
Read all field input devices via the input interfaces, execute the user program stored in
application memory, then, based on whatever control scheme has been programmed by the user,
turn the field output devices on or off, or perform whatever control is necessary for the process
application.

This process of sequentially reading the inputs, executing the program in memory, and updating
the outputs is known as scanning.

PHASE 1 – Input Status Scan

 A PLC scan cycle begins with the CPU reading the status of its inputs.

PHASE 2 - Logic Solve/Program Execution

 The application program is executed using the status of the inputs.

PHASE 3 - Logic Solve/Program Execution

 Once the program is executed, the CPIJ performs diagnostics and communication
tasks.

PHASE 4 – Output Status Scan

 An output status scan is then performed, whereby the stored output values are sent
to actuators and other field output devices. The cycle ends by updating the outputs.

The time it takes to implement a scan cycle is called SCAN TIME, the scan time
composed of the program scan time, which is the time required for solving the control
program, and the I/O update time, or time required to read inputs and update outputs. The
program scan time generally depends on the amount of memory taken by the control
program and type of instructions used in the program. The time to make a single scan can
vary from I ms to 100 ms.

PLC COMMUNICATION
Serial Communications
PLC communications facilities normally provide serial transmission of information.

Common Standards
RS 232

 Used in short-distance computer communications, with the majority of

computer hardware and peripherals.

 Has a maximum effective distance of approx. 30 m at 9600 baud.

Local Area Network (LAN)

- Local Area Network provides a physical link between all devices plus providing overall
data exchange management or protocol, ensuring that each device can "talk" to other
machines and understand data received from them.
- LANs provide the common, high-speed data communications bus which
interconnects any or all devices within the local area.
- LANs are commonly used in business applications to allow several users to share
costly software packages and peripheral equipment such as printers and hard disk
storage.

RS 422 / RS 485

 Used for longer-distance links, often between several PCs in a distributed

system, RS 485 can have a maximum distance of about 1000 meters.

Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network

Allen Bradley Data Highway

Gould Modicon Modbus
General Electric GE Net Factory LAN

Mitsubishi Melsec-NET

Square D SYNET

Texas Instruments TIWAY

SPECIFICATION
Several factors are used for evaluating the quality and performance of programmable
controllers when selecting a unit for a particular application. These are listed below.

NUMBER OF I/O PORTS

This specifies the number of I/O devices that can be connected to the controller. There should be
sufficient I/O ports to meet present requirements with enough spares to provide for moderate
future expansion.

PLC PROGRAMMING

PLC is software driven equipment like computer

Working of PLC (process) is decided by user through program.
Depending on process requirement program (set of instruction) is prepared.
CPU sequentially read these instruction and operates control elements based on
input signals and program instruction.

Programming can be done On-line or Off-line.

Normally programming / change in program is done in memory of
programming unit and then simply this change is loaded in CPU memory of
PLC.

PROGRAMMING

Power flows through these contacts when they are closed. The normally open (NO) is
true when the input or output status bit controlling the contact is 1. The normally closed
(NC) is true when the input or output status bit controlling the contact is O.

COILS

Coils represent relays that are energized when power flows to them. When a coil is
energized it causes a corresponding output to turn on by changing the state of the status
bit controlling the output to 1 . That same output status bit maybe used to control
normally open or normally closed contact anywhere in the program.

BOXES

Boxes represent various instructions or functions that are Executed when power flows
to the box. Some of these Functions are timers, counters and math operations.

PROGRAMMING LANGUAGES OF PLC

Most common languages encountered in PLC Programming are:
1. Ladder Logic
2. Functional Block Diagram
3. Sequential Function Chart
4. Boolean mnemonics

LADDER LOGIC
Ladder Logic is a programming language used to develop software for PLC used in
industrial control applications.
It is well suited to express Combinational logic.
The main ladder logic symbols represent the elements.

LADDER LOGIC FOR BASIC GATES

AND Gate
A B Logic (Y)
OFF OFF OFF
OFF ON OFF
ON OFF OFF
ON ON ON

OR Gate

A B Logic (Y)
OFF OFF ON
OFF ON OFF
ON OFF OFF
ON ON OFF

NOR Gate
A B Logic (Y)
OFF OFF ON
OFF ON OFF
ON OFF OFF
ON ON OFF

NAND Gate
A B Logic (Y)
OFF OFF OFF
OFF ON ON
ON OFF ON
ON ON ON

ADVANTAGES OF PLCs
  Reliability.
 Flexibility in programming and reprogramming.
 Cost effective for controlling complex systems.
 Small physical size.
 High speed of operation.
 Ease of maintenance/troubleshooting.
 Reduced space.
 Energy saving.

DISADVANTAGES OF PLCs
 PLC devices are proprietary it means that part or software of one manufacturer
can’t be used in combination with parts of another manufacturer.
 Limited design and cost option.
 Fixed Circuit Operations.
 PLCs manufacturers offer only closed architectures.

APPLICTIONS:
Wherever automation is desired the PLCs are best suited to meet the task.
Few examples of industries where PLCs are used:

1. Robots manufacturing and control

2. Car park control
3. Train control station system
4. Food processing
5. Materials handling
6. Machine tools
7. Conveyer system etc.