Programmable Logic Controller

2ICOE51

LPTC

2203

Course Coordinator: Dr. Nital S. Patel

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Programmable Logic Controllers

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 Programmable Logic Controllers

➢ an industrial grade computer that is capable of being programmed to

perform control functions.
➢eliminated much of the hardwiring associated with conventional relay
control circuits
➢ designed for multiple input and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to
vibration and impact
➢a digital computer designed for machine control. Unlike a personal
computer
➢A PLC is an example of a real-time system since the output of the system
controlled by the PLC depends on the input conditions
➢Initially the PLC was used to replace relay logic
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 RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil Output contact

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 Advantages of PLCs

Programmable controllers offer several advantages over a conventional

relay type of control
➢ Increased Reliability :Once a program has been written and tested, it
can be easily downloaded to other PLCs
➢ More Flexibility: is easier to create and change a program in a PLC than
to wire and rewire a circuit.
➢ Lower Cost

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 Advantages of PLCs

Relay based control panel PLC based control panel

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 Advantages of PLCs

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 Advantages of PLCs

➢ Communications Capability: A PLC can communicate with other controllers or computer

equipment to perform such functions as supervisory control, data gathering.
➢ Faster Response Time: PLCs are designed for high speed and real-time application
➢ Easier to Troubleshoot: PLCs have resident diagnostics and override functions easily
trace and correct software and hardware problems

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Areas of Application
 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical

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PLC Size
➢In general, the nano is the smallest size with less than 15 I/O points.
➢ micro types (15 to 128 I/O points),
➢ medium types (128 to 512 I/O points),
➢ large types (over 512 I/O points).

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 There are three major types of PLC application:

➢ Single ended, multitask, and control management.

Single ended PLC Application

➢ A single ended or stand-alone PLC
application involves one PLC controlling one
process .
➢ This would be a stand-alone unit and would
not be used for communicating with other
computers or PLC

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Multitask PLC application
➢ A multitask PLC application involves one PLC controlling several processes.
Adequate I/O capacity is a significant factor in this type of installation.
➢ In addition, if the PLC would be a subsystem of a larger process and would
have to communicate with a central PLC or computer, provisions for a data
communications network are also required.
A control management PLC application

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➢ A control management PLC application involves one PLC controlling
several others
➢ This kind of application requires a large PLC processor designed to
communicate with other PLCs and possibly with a computer.
➢ The control management PLC supervises several PLCs by downloading
programs that tell the other PLCs what has to be done.
➢ It must be capable of connection to all the PLCs so that by proper
addressing it can communicate with any one it wishes to.

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 PLCs versus Computers

➢ unlike PCs, the PLC is designed to operate in the industrial environment with
wide ranges of ambient temperature and humidity
➢ PLC is programmed in relay ladder logic or other easily learned languages.
➢ PLCs come equipped with terminals for input and output fi eld devices as well
as communication ports.
➢ Most PLCs, on the other hand, execute a single program in an orderly and
sequential fashion from fi rst to last instruction

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Software :
➢ associated with a PLC but written and run on a personal computer
falls into the following two broad categories
➢ PLC software that allows the user to program and document gives
the user the tools 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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 Parts Of PLC
➢ central processing unit (CPU)
➢ input/output (I/O) section
➢ power supply
➢ programming device.

Modular type
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 Fixed type

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Central Processing Unit

➢ The processor (CPU) is the “brain” of the PLC.

➢ consists of a microprocessor for implementing the logic and controlling

the communications among the modules.
➢ The processor requires memory for storing the results of the logical
operations performed by the microprocessor.
➢ Memory is also required for the program and data storage.

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➢ The CPU controls all PLC activity
➢ The PLC program is executed as part of a repetitive process referred
to as a scan
➢ A typical PLC scan starts with the CPU reading the status of inputs
then, the application program is executed. Once the program
execution is completed, the CPU performs internal diagnostic and
communication tasks, Next, the status of all outputs is updated.
➢ This process is repeated continuously as long as the PLC is in the run
mode

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Fixed I/O
➢ small PLCs that come in one package with no separate, removable
units
➢ processor and I/O are packaged together, and the I/O terminals will
have a fixed number of connections

Fixed I/O configuration.

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Modular I/O
➢ is divided by compartments into which separate modules can be
plugged
➢ The basic modular controller consists of a rack, power supply,
processor module (CPU), input/output (I/O modules), and an
operator interface for programming and monitoring.
➢ The modules plug into a rack. When a module is slid into the
rack, it makes an electrical connection with a series the
backplane, located at the rear of the rack.
➢ The PLC processor is also connected to the backplane and can
communicate with all the modules in the rack.

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Power supply
➢The power supply supplies DC power to other modules that plug into the
rack
➢With larger systems, 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.

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 Programming device

➢ A programming device is used to enter the desired program into the

memory of the processor.
➢ The program can be entered using relay ladder logic, which is one of
the most popular programming languages.
➢ Instead of words, ladder logic programming language uses graphic
symbols that show their intended outcome.
➢ A program in ladder logic is similar to a schematic for a relay control
circuit.
➢ It is a special language written to make it easy for people familiar
with relay logic control to program the PLC.
➢ Hand-held programming devices are sometimes used to program
small PLCs because they are inexpensive and easy to use.
➢ Both compact hand-held units and laptop ,computers are frequently
used on the factory floor for troubleshooting equipment, modifying
programs, and transferring programs to multiple machines.
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 Example

➢ mixer motor is to be used to automatically stir

the liquid, when the temperature and pressure
reach preset values.
➢ In addition, direct manual operation of the
motor is provided by means of a separate
pushbutton station.
➢ The process is monitored with temperature and
pressure sensor switches that close their
respective contacts when conditions reach their
preset values.

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Example
➢ First, the pressure switch, temperature switch, and pushbutton inputs are
examined and their status is recorded in the controller’s memory.
➢ A closed contact is recorded in memory as logic 1 and an open contact as
logic 0.
➢ Next the ladder diagram is evaluated, with each internal contact given an
OPEN or CLOSED status according to its recorded 1 or 0 state.
➢ When the states of the input contacts provide logic continuity from left to
right across the rung, the output coil memory location is given a logic 1
value and the output module interface contacts will close.
➢ When there is no logic continuity of the program rung, the output coil
memory location is set to logic 0

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➢ The completion of one cycle of this sequence by the controller is called a scan.
➢ The scan time, the time required for one full cycle, provides a measure of the speed
of response of the PLC

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 PLC Memory
➢ element that stores information, programs, and data in a PLC
➢ The complexity of the program determines the amount of memory required
➢ The program is stored in the memory as 1s and 0s, which are typically
assembled in the form of 16-bit words.
➢ The memory size varies from as small as 1 K for small systems to 32 MB
for very large systems
➢ Memory location refers to an address in the CPU’s memory where a binary
word can be stored.

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 Typical PLC memory sizes.

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➢ The memory of a PLC may be broken into sections that have specific
functions.
➢ Sections of memory used to store the status of inputs and outputs are called
input status files or tables and output status fi les or tables
➢ Each bit is either a 1 or 0, depending on whether the input is open or
closed.
➢ 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.
➢ Each time a memory location is examined, the table changes if the contact
or coil has changed state.

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 Input and output tables.

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 input and output sections

➢where the processor receives information from external devices and

communicates information to external devices
➢The inputs might thus be from switches, temperature sensors, flow sensors,
photoelectric cells
➢ The outputs might be to motor starter coils, solenoid valves, or
similar things.

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➢ a rack-based I/O section made up of
individual I/O modules.
➢ Each slot in the rack is capable of
accommodating any type of I/O module.
➢ A logical rack is an addressable unit
consisting of 128 input points and 128
output points. A rack uses 8 words in the
input image table file and 8 words in the
output image table file.
Rack-based I/O section

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➢ One benefit t of a PLC system is the
ability to locate the I/O modules near
the fi eld devices
➢ A rack is referred to as a remote rack
when it is located away from the
processor module.
➢ To communicate with the processor,
the remote rack uses a special
communications network.
➢ Each remote rack requires a unique
station number to distinguish one
from another.
➢ The remote racks are linked to the
local rack through a communications Remote I/O rack.

module.
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➢PLC’s memory system stores information about the status of all the inputs
and outputs.
➢ To keep track of all this information, it uses a system called addressing.
➢ An address is a label or number that indicates where a certain piece of
information is located in a PLC’s memory. Just as your home address tells
where you live in your city, a device’s or a piece of data’s address tells
where information about it resides in the PLC’s memory.

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 Logical Rack

A chassis is a physical hardware assembly that houses

devices such as I/O modules, processor modules, and
power supplies.
A logical rack is an addressable unit consisting of
128 input points and 128 output points.
 Logical Rack
A word in the output
image table file and its
corresponding word in
the input image table
file are called an I/O group.
Input and output addresses
for the PLC-5 family of A rack uses 8 words
controllers are in the octal in the input image tabl
numbering system (numbers file and 8 words in the
8 and 9 are not used). output image table file

A rack can contain a

maximum of 8 I/O
groups.
I/O Module Addressing
The location of a module within a rack
and the terminal number of the module
to which an input or output device
is connected will determine the device’s
address.

Each input and output device must have

a specified address.

This address is used by the processor

to identify where the device is located
in order to monitor or control it.
 I/O Module Addressing

In general, the basic addressing elements include:

Type – the type determines if an input or

output is being addressed.

Slot – the slot number is the physical location

of the I/O module.

Word and Bit – the word and bit are used to

identify the actual terminal connection
in a particular I/O module.
PLC-5 Addressing
SLC 500 Addressing
 Discrete I/O Module Addressing

Input module in slot 0, terminal 0 Output module in slot 0, terminal 0

Input module in slot 0, terminal 5

Output module in slot 0, terminal 6
Analog I/O Module Addressing
➢ Mitsubishi PLC might have inputs with addresses X400, X401, X402, and so on and
outputs with addresses Y430, Y431, Y432, and so on
➢ X indicating an input and the Y an output

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 SLC 500 bit level addressing

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 SLC 500 word level addressing
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 Discrete I/O Modules

➢ This type of interface connects

field input devices of the
ON/OFF nature such as
selector switches,
pushbuttons, and limit
switches.
➢ Likewise, output control is
limited to devices such as
lights, relays, solenoids, and
motor starters that require
simple ON/OFF switching

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➢ Each discrete I/O module is powered by
some field supplied voltage source.
➢ Since these voltages can be of different
magnitude or type, I/O modules are available
at various AC and DC voltage ratings
➢ The modules themselves receive their
voltage and current for proper operation
from the backplane of the rack enclosure
into which they are inserted

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 Discrete AC input module block diagram.

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➢ The input noise filter consisting of the
capacitor and resistors R1 and R2
removes false signals that are due to
electrical interference.
➢ When the pushbutton is closed, 120
VAC is applied to the bridge rectifier
input.
➢ This results in a low-level DC output
voltage that is applied across the LED
of the optical isolator.
➢ The zener diode (Z D ) voltage rating
sets the minimum threshold level of
voltage that can be detected.

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➢ When light from the LED strikes the phototransistor, it switches into
conduction and the status of the pushbutton is communicated in logic to
the processor
➢ The optical isolator not only separates the higher AC input voltage from the
logic circuits but also prevents damage to the processor due to line voltage
transients
➢ An AC/DC type of input module is used for both AC and DC inputs as the
input polarity does not matter.
➢ A PLC input module will have either all inputs isolated from each other with
no common input connections or groups of inputs that share a common
connection

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 AC Discrete Output Module
The output circuit is composed of two basic sections:
the power section and the logic section, coupled by
an isolation circuit.

The output interface can be thought of as a simple

electronic switch to which power is applied to
control the output device.
 AC Discrete Output Module Operation
The processor sets the output status
according to the logic program.

When the processor calls for

an output, a voltage is applied This in turn switches the
across the LED of the isolator, Triac into conduction which,
which switches the in turn, turns on the lamp.
phototransistor into conduction.
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 Programming languages. Five languages are defined:
I. ladder diagram (LAD)
II. sequential function charts (SFC)
III. function block diagram (FBD)
IV. structured text (ST)
V. instruction list (IL)

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 Ladder Diagrams

➢ The diagram shows the circuit for switching on or off an electric

motor.

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 Ladder Diagrams

➢ The vertical lines of the diagram represent the power rails between which
circuits are connected.
➢ The power flow is taken to be from the left-hand vertical across a rung
➢ Each rung on the ladder defines one operation in the control process
➢ A ladder diagram is read from left to right and from top to bottom
➢ The top rung is read from left to right. Then the second rung down is read from
left to right and so on
➢ The end rung might be indicated by a block with the word END or RET, for
return, since the program promptly returns to its beginning.
➢ Each rung must start with an input or inputs and must end with at least one
output

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 Ladder Diagrams
➢ The term input is used for a control action, such as closing the contacts of a
switch.
➢ The term output is used for a device connected to the output of a PLC, such as a
motor.

➢ The inputs and outputs are all identified by their addresses; the notation used
depends
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 Ladder Diagrams

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 Ladder Diagrams
Nested Input and Output Branches

Input and output branches can be nested to avoid

redundant instructions and to speed up the processor
scan time.
A nested branch starts or ends within another branch.
 Ladder Diagrams
PLC Matrix Limitation Diagram
Max series
contacts

Max parallel No. outputs

lines per rung and
location of the
output in the rung

There may be limitations to the number of series

contacts instructions, number of parallel lines, and
the number of outputs and their location on the rung.
 Ladder Diagrams

Programming of Vertical Contacts

Y = (AD) + (BCD) + (BE) + (ACE)

A D Y

B C D

B E

A C E
 Ladder Diagrams
Internal Control Relay
The internal output operates just as any other output
that is controlled by programmed logic; however, the
output is used strictly for internal purposes.

The internal output does not directly control an

output device.

The advantage of using internal outputs is that there

are many situations where an output instruction is
required in a program, but no physical connection to
a field device is needed. Their use in this type of
instance can minimize output card requirements.
 Ladder Diagrams
Extending the Number of Series Contacts Using
an Internal Control Relay
Internal
relay coil
Rung 1

Rung 2

Internal Discrete output (requires

relay one physical connection
contact on the output module)
 Ladder Diagrams

“On a ladder diagram, contacts in a horizontal rung, that is, contacts in

series, represent the logical AND operations

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 Ladder Diagrams
OR

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 Ladder Diagrams
NOT

➢ shows an electrical circuit controlled by a switch that is normally closed

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 Ladder Diagrams
NAND

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 Ladder Diagrams

NOR

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 Sourcing and Sinking

➢ The terms sourcing and sinking are used to describe the way in which DC devices
are connected to a PLC.
➢ With sourcing, using the conventional current flow direction as from positive to
negative, an input device receives current from the input module, that is, the
input module is the source of the current

Inputs sourcing

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➢ With sinking, using the conventional current flow direction, an input device supplies
current to the input module, that is, the input module is the sink for the current

Inputs sinking

➢ If the current flows from the output module

to an output load, the output module is referred to as
sourcing

Output sourcing

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➢ If the current flows to the output module from an output load, the output module
is referred to as sinking

Output sinking

➢ It is important to know the type of input or output concerned so that it can

be correctly connected to the PLC.

➢ sensors with sourcing outputs should be connected to sinking PLC inputs and sensors
with sinking outputs should be connected to sourcing PLC inputs
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