PLC

PLC
(Programmable Logic Controller)
SUBMITTED BY
MOHIT GUPTA
BTECH 4th YEAR ECE.
Industrial Automation
computers are used in factories...
Robotic arm, CNC, injection molding
Ice cream sandwich machines
Today this is usually accomplished with

Programmable Logic Controllers (PLCs)
PLCs are the answer to a variety of needs:

durability, reliability, flexibility, scalability,
reprogrammability, etc...
Programmable Logic Controllers

( Definition according to NEMA standard ICS3-1978)
A digitally operating electronic apparatus which uses a

programming memory for the internal storage of
instructions for implementing specific functions such as
logic, sequencing, timing, counting and arithmetic to
control through digital or analog modules, various types
of machines or process.
History
Machines become autonomous.
Common method: relay logic
Relay Logic
Conditional logic can be represented in

terms of contacts and coils.
current
Contact: A simple input switch.
Coil: An output load, e.g., a relay or motor.
Symbolic representation called ladder

logic.
Relay Logic
To clarify: Ladder Logic is a notation

originally used to describe & document
relay logic configurations.
Later became the basis for PLC
programming languages
Ladder Logic
Power supply rails drawn as parallel

vertical lines on left and right
Connection of rails implies current will flow
An output is on when a connection is

completed and current flows through the
loads coil
Ladder Logic
Simple always on load:
[Always_On = 1] note: sometimes

illegal
Boring... Load controlled by a single contact:

[Switch_Con = Switch]
Programmable Controller Development

1968
1969
1974
1976
1977
Programmable concept developed

Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
Remote input/output systems introduced
Microprocessors - based PLC introduced
11
Programmable Controller Development

Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983
Low - cost small PLCs introduced
1985 on Networking of all levels of PLC, computer
and machine using SCADA software.
1980
12
PLC
The first PLC was invented by Dick Morely

in 1978.
Morely designed a computer with three

components: a processor, memory, and a
logic solver.
[The logic solver] allowed us to get the

speed we needed in this applicationspecific computer to solve the perceptually
simple problem of several cabinets full of
relay wiring. -Morely
The first commercial successful PLC, the 184, was

introduced in 1973 which was designed by Michael
Greenberg.
Step7-1200
S7-1200 PLC
1.Power connector
2.Memory card slot under the top door
3.Removable user wiring connectors
4. Status LEDs for on board I/O
5.Profinet connector
Major Components of a Common PLC

POWER
SUPPLY
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
I M
N O
P D
U U
T L
E
O M
PROCESSOR
U
T
P
U
T
O
D
U
L
E
To
OUTPUT
contactors,
alarms
etc.
PROGRAMMING
DEVICE
17

POWER SUPPLY
Provides the voltage needed to run the primary PLC
components
I/O MODULES
Provides signal conversion and isolation between the
internal logic- level signals inside the PLC and the
fields high level signal.
18

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.
19
While the PLC is running, the scanning process

includes the following four phases, which are repeated
continuously as individual cycles of operation:
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
20
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 CPU performs

diagnostics and communication tasks
21
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.
22
PROGRAMMING
Normally Open
(NO)
Normally Closed
(NC)
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 0.
23
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.
24
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.
25
AND OPERATION
A
Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).
26
OR OPERATION
A
input
B
In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).
27
NOT OPERATION
A
input
In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.
28
Inside a PLC
Communications
Port
I
n
p
u
t
C
i
r
c
u
i
t
s
Central
Processor
Unit
(CPU)
High
Voltage
Isolation
Barrier
O
u
t
p
u
t
Isolation
Barrier
MEMORY
data
program
Low Voltage
AC Power Supply
or
C
i
r
c
u
i
t
s
DC Power Supply
CR
High
Voltage
PLCs
Widely Applied in Every Industry
Were Developed to Simplify the Implementation of

Control Automation Systems in Plants and Assembly
Lines
Designed to Minimize the Number of Control Relays

in a Process and Maximize the Ways Relays can be
Used
First Applied to Automobile Industry in the Late

1960s
Flexible, Reliable and Low Cost
PLC Components
I/O Modules
Input Modules: Input Signals can be AC or

DC, Analog or Digital
Output Modules: Outputs are either AC or

DC Analog Signals (Although it is possible
to Construct Digital Outputs)
Modern PLCs have Expansion Ports to

Increase the Number of Available Inputs
and Outputs
Examples of I/O Signals
Inputs:
Pushbutton
Relay
DC
Contact Output
Voltage Level
Digital
Logic Signal (+5V or 0 V, etc)
Outputs:
24
(Energizing or Grounding an Input)
V ac
120
V ac
120
Vdc
etcetera
Relays
In General, Relays Transform a Control

Signal into a Control Action
Relays Provide:
Isolation
Between Input and Output
Leverage
(Small Signal Can Control

Large Action)
Automation
(Minimize Human
Interaction with a Control Process)
Relay Components
Basic Relay Symbols
Relay Applications
Relays can be Designed to Perform Many

Functions
Detect
Out of Limit Conditions on

Voltages and Currents
Start
Motors
Prevent
Control
Adjust
Motors from Over Heating

Assembly Lines
Lighting
INTRODUCTION TO PLCS
Advantages of PLCs
Less wiring.
Wiring between devices and relay contacts are done
in the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming easier
and reduce downtime.
Reliable components make these likely to operate
for years before failure.
Areas of Application
Manufacturing / Machining
Food / Beverage
Metals
Power
Mining
Petrochemical / Chemical
39
PLC Operating Cycle

Four Steps in the PLC Operations
Input Scan
Scan the state of the Inputs
Program Scan
Processes the program logic
START
Housekeeping
Input
Scan
Output
Scan
Output Scan
Energize/de-energize the outputs
Program
Scan
Housekeeping
This step includes communications, Internal
Diagnostics, etc.
The steps are continually repeated - processed in
a loop

PLC

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PLC

(Programmable Logic Controller)

computers are used in factories...

Robotic arm, CNC, injection molding

Ice cream sandwich machines

Today this is usually accomplished with

PLCs are the answer to a variety of needs:

Programmable Logic Controllers

A digitally operating electronic apparatus which uses a

Machines become autonomous.

Common method: relay logic

Conditional logic can be represented in

Contact: A simple input switch.

Coil: An output load, e.g., a relay or motor.

Symbolic representation called ladder

To clarify: Ladder Logic is a notation

Power supply rails drawn as parallel

Connection of rails implies current will flow

An output is on when a connection is

Simple always on load:

[Always_On = 1] note: sometimes

Boring... Load controlled by a single contact:

Programmable Controller Development

Programmable concept developed

Programmable Controller Development

The first PLC was invented by Dick Morely

Morely designed a computer with three

[The logic solver] allowed us to get the

The first commercial successful PLC, the 184, was

Major Components of a Common PLC

Major Components of a Common PLC

Major Components of a Common PLC

While the PLC is running, the scanning process

PHASE 1 Input Status scan

The application program is executed using the status

Once the program is executed, the CPU performs

PHASE 4 - Output Status Scan

Coils represent relays that are energized when power flows to

Boxes represent various instructions or functions that are

Each rung or network on a ladder program represents

In the rung above, it can be seen that either input A or B

In the rung above, it can be seen that if input A is be true (1),

Widely Applied in Every Industry

Were Developed to Simplify the Implementation of

Designed to Minimize the Number of Control Relays

First Applied to Automobile Industry in the Late

Flexible, Reliable and Low Cost

Input Modules: Input Signals can be AC or

Output Modules: Outputs are either AC or

Modern PLCs have Expansion Ports to

Examples of I/O Signals

Logic Signal (+5V or 0 V, etc)

(Energizing or Grounding an Input)

In General, Relays Transform a Control

Between Input and Output

(Small Signal Can Control

Basic Relay Symbols

Relays can be Designed to Perform Many

Out of Limit Conditions on