©T.C.

Chang

Chapter 7.
PROGRAMMABLE
LOGIC CONTROLLER

Dr. T.C. Chang

School of Industrial Engineering
Purdue University

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FUNCTIONS OF CONTROLLERS

1) on-off control,
2) sequential control,
3) feedback control, and
4) motion control.

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CONTROL DEVICES

1) mechanical control - cam, governor,

etc.,
2) pneumatic control - compressed air,
valves,etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.

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PROGRAMMABLE LOGIC
CONTROLLER
Invented in 1968 as a substitute for hardwired relay panels.

"A digitally operating electronic apparatus which uses a

programmable memory for the internal storage of instructions
by implementing specific functions such as logic sequencing,
timing, counting, and arithmetic to control, through digital or
analog input/output modules, various types of machines or
processes. The digital computer which is used to perform the
functions of a programmable controller is considered to be
within this scope. Excluded are drum and other similar
mechanical sequencing controllers."

National Electrical Manufacturing Association (NEMA)

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VENDOR
S
MODICOM - GOULD
ALLEN-BRADLEY
GE
SQUARE-D
etc.

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PLC
Input
CPU Input
Module
Flag
System
Output
Output Module
User Ladder
Diagram

Working
memory
registers

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An Large Size PLC

• The main module

measures 19” x 20” x 14.5”.

• have upto 10,000 I/O points

• supports all functions
• expansion slots to
accommodate PC and
other communication
devices.

Allen-Bradley PLC-3

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A Small Size PLC

• Measures 4.72”x 3.15” x

1.57”.
• 32 I/O points
• Standard RS 232 serial
communication port

Allen-Bradley MicroLogix 1000

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SWITCHES

Non-locking Locking

Normally Ope n Normally Clos e d

SPDT
P1
DPST
P2

Multiple Throw Multiple Pole

Break-before -make Make -be fore -bre ak

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TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual
circuits).

SPDT A serial switch box (A-B box) has

two 25 pin serial ports to switch from.

A B

Output
DPST Input

Knob
How is this switch classified?
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TYPES OF SWITCHES
• Selector switches RATING:
• Pushbutton switches
•24 Volts AC/DC
• Photoelectric switches •48 Volts AC/DC
• Limit Switches •120 Volts AC/DC
• Proximity switches •230 Volts AC/DC
•TTL level
• Level switches (Transistor-to-transistor
• Thumbwheel switches ±5V)
• •Isolated Input
Slide switches

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RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil
R1
Output contact R1

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COUNTE
R
Digital counters output in the form of a relay contact when a preassigned
count value is reached.

input
Register 5

Accumulator
reset

contact

output

Input

Reset

Output

Count 0 12 3 4 5 0 1

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TIMER
A timer consists of an internal clock, a count value register, and an
accumulator. It is used for or some timing purpose.

Clock

Accumulator
reset

Register

contact
Contact
Clock
output

Reset

Output

Count 0 1 2 3 4 5

Time 5 seconds.
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AN EXAMPLE OF RELAY LOGIC

For a process control, it is desired to have the process start (by turning
on a motor) five seconds after a part touched a limit switch. The
process is terminated automatically when the finished part touches a
second limit switch. An emergency switch will stop the process any
time when it is pushed.
L1
LS1 PB1 LS2 R1

R1

TIMER R2
R1 PB1
LS1 LS2

PR=5

TIMER

5
Motor
R2

R1

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PLC
ARCHITECTURE
Programmable controllers
software programming.
replace most of the relay panel wiring by

PC
Program
Loader
Switches

Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader

Peripherals External Devices

A typical PLC
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PLC COMPONENTS
1. Processor Microprocessor based, may allow arithmetic
operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.

2. Memory Measured in words.

ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electric Erasable Programmable ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.

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3. I/O
PLC COMPONENTS
Modular plug-in periphery
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g., high speed timers,

Stepping motor controllers, etc. PID, Motion

4. Power supply AC power
5. Peripheral hand-held programmer (HHP)
CRT programmer
operator console
printer
simulator
EPROM loader
graphics processor
network communication interface
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Discrete I/O

• AC Voltage I/O
• DC Voltage I/O
• numerical input and output
• special-purpose modules, for example, high-
speed timers, and stepping motor controllers

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Analog I/O
Analog inputs:
• Flow sensors
• Humidity sensors
• Potentiometers
• Pressure sensors
• Temperature sensors

Analog outputs:
• Analog meters
• Analog valves and actuators
• DC and AC motor drives

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Some Special I/O

• Thermocouple input
– Low level analog signal, filtered, amplified, and digitized before
sending to the processor through I/O bus.
• Fast input
– 50 to 100 microsecond pulse signal detection.
• ASCII I/O
– Communicates with ASCII devices.
• Stepper motor output
– Provide directly control of a stepper motor.
• Servo interface
– Control DC servo motor for point-to-point control and axis positioning.

• PID control
– The Proportional Integral Derivative is used for closed loop process
control.
• Network module
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A Hand Held Programmer

An Allen-Bradley hand-held programmer for MicroLogix 1000

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LADDER
DIAGRAM
A ladder diagram (also called contact symbology) is a means of
graphically representing the logic required in a relay logic system.

Rail
start emergency stop
PB1 PB2
R1

Rung R1

R1

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PLC WIRING DIAGRAM

Input PLC Output

A
01 01 02 20 11 C
B 02
12
20
03
20 11

External
switches

Stored program

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Input Connections

AC DC TTL

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Output Connections

AC DC TTL

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SCA
Nall the outputs are updated based
A PLC resolves the logic of a ladder diagram (program) rung by rung,
from the top to the bottom. Usually,
on the status of the internal registers. Then the input states are checked
and the corresponding input registers are updated. Only after the I/Os
have been resolved, is the program then executed. This process is run
in a endless cycle. The time it takes to finish one cycle is called the
scan time. In some controllers the idle state is eliminated. In this case,
the scan time varies depends on the program length.
Output
Input
begin

Idle

Scan cycle

Resolve
logic

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PLC Programming

• Ladder Diagram - most common

• Structure Text Programming (ST)
• Functional Block Programming (FB)
• Instruction List (IL)
• Sequential Function Chart (SFC)

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PLC Ladder Diagram

INSTRUCTIONS

1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.

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LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize, etc.

Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.

(In the notes we use the symbol "~" to represent

negation. AND and OR are logic operators. )

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AND and OR LOGIC

PB1 PB2 R1

R1 = PB1.AND.PB2

AND PB3 PB4

R2
R2 = PB2.AND.~PB4

PB1 R1

R1 = PB1 .OR. PB2

OR PB2

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COMBINED AND &

OR
R1 = PB1 .OR. (PB2 .AND. PB3)

PB1 R1

PB2 pb3

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RELA
Ycoil and the contact(s).
A Relay consists of two parts, the

Contacts:

a. Normally open -| |-
b. Normally closed -|/|-
c. Positive transition sensing -|P|-
d. Negative transition sensing -|N|-

()
Coil:
a. Coil -( )-
b. negative coil -(/)-
c. Set Coil -(S)-
d. Reset Coil -(R)-

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Relay (continue)

Coil:
e. Retentive memory Coil -(M)-
f. Set retentive memory Coil -(SM)-
g. Reset retentive memory Coil -(RM)-
h. Positive Transition-sensing Coil -(P)-
h. Negative Transition-sensing Coil -(N)-

(set coil latches the state, reset coil deenergize the set coil.
retentive coil retain the state after power failure.)

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TIMERS AND
COUNTERS Input
Timers: True False True

RTO counting stop counting

a. Retentive on delay -(RTO)- resume
b. Retentive off delay -(RTF)-
RTF stop counting stop
c. Reset -(RST)-

Counter: RTO reach PR value, output ON

RTF reach PR value, output OFF

a. Counter up -(CTU)- PR value in 0.1 second

b. Counter down -(CTD)-
c. Counter reset -(CTR)-

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SEQUENCE
R
Sequencers are used with machines or processes involving
repeating operating cycles which can be segmented into
steps.

Output
Step A B C Dwell time
1 ON OFF OFF 5 sec.
2 ON ON OFF 10 sec.
3 OFF OFF ON 3 sec.
4 OFF ON OFF 9 sec.

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A-B PLC
I/O points are numbered, they correspond to the I/O slot on the
PLC.

For A-B controller used in our lab

I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982

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PROGRAMMING EXAMPLE 1
Bar code reader
microswitch Stopper

Part Conveyor

Robot
Machine

id description state explanation

MSI microswitch 1 part arrive
R1 output to bar code reader 1 scan the part
C1 input from bar code reader 1 right part
R2 output robot 1 loading cycle
R3 output robot 1 unloading cycle
C2 input from robot 1 robot busy
R4 output to stopper 1 stopper up
C3 input from machine 1 machine busy
C4 input from machine 1 task complete
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SOLUTION
Input
Output
MS1 R1
01 11
C1 02 12 R2
C2 R3
03 13
C3 R4
04 14
Programmable
C4 05 15
Controller
PLC
Rung 1. If part arrives and no
part is stopped, trigger the
bar code reader.
Rung 2. If it is a right part,
11
01 14 activate the stopper.
Rung 3. If the stopper is up,
02 14 the machine is not busy
and the robot is not busy,
12
load the part onto the
14 04 03
machine.
Rung 4. If the task is
05 03 13
completed and the robot is
not busy, unload the
machine.
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Structured Text Programming

• a high level language
• used to express the behavior of functions, function blocks
and programs
• In IEC 1131-3 standard, it has a syntax very similar to
PASCAL
• strongly typed language
• Functions:
– assignments
– expressions
– statements
– operators
– function calls
– flow control

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Data Types
SINT short integer 1 byte BOOL boolean 1 bit
INT integer 2 bytes BYTE byte 1 byte
DINT double integer 4 bytes WORD 16 bit bit string 16 bits
LINT long integer 8 bytes DWORD 32 bit bit string 32 bits
USINT unsigned short integer 1 byte LWORD 64 bit bit string 64 bits
UINT unsigned integer 2 bytes
UDINT unsigned double integer 4 bytes
ULINT unsigned long integer 8 bytes
REAL real 4 bytes
LREAL long real 8 bytes

TIME time duration

DATE calendar date
TOD time of day
DT date and time of day
STRING character strings

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Derived Data
Types
TYPE (* user defined data types, this is a comment*)
pressure : REAL;
temp : REAL;
part_count : INT;
END_TYPE;

Structure:

TYPE data_packet:
STRUCT
input : BOOL;
t : TIME;
out : BOOL;
count : INT;
END_STRUCT;
END_TYPE;

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Variable Declarations

Local variable:

VAR Use VAR, VAR_INPUT,

VAR_OUTPUT, VAR_IN_OUT,
I,j,k : INT; VAR_GLOBAL,
v : REAL; VAR_EXTERNAL for different
END_VAR variable types.

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Operators and Expressions

( ) parenthesized expression
function( ) function
** exponentiation
- negation
NOT Boolean complement
+-*/ math operators
MOD modulus operation
Y := X+1.0;
< > <= >= comparison operators
= equal
<> not equal y := a AND b;
AND, & Boolean AND
v := (v1 + v2 + v3)/3
XOR Boolean XOR
OR Boolean OR output := (light = open) OR
(door = shut);

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Condition Statements

IF a > 100 THEN CASE dial_setting OF

redlight := on; 1: x := 10;
ELSEIF a > 50 THEN 2: x := 15;
3: x := 18;
yellowlight := on;
4,5: x := 20; (* 4 or 5 *)
ELSE ELSE
greenlight := on; x := 30;
END_CASE
END_IF;

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Iteration Statements

FOR I:= 0 to 100 BY 1 DO

light[I] := ON; I := 0;
END_FOR REPEAT
I := I + 1;
light[I] := on;
I := 0; UNTIL I > 100;
WHILE I < 100 DO END_REPEAT
I := I + 1;
light[I] := on;
END_WHILE

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Functions
FUNCTION add_num : REAL
VAR_INPUT
I,J : REAL
END_VAR
add_num := I + J;
END_FUNCTION

Call a function:
x:= add_num(1.2, 5.6);
Built-in Functions:
ABS, SQRT, LN, LOG, EXP, SIN, COS, TAN, ASIn, ACOS,
ATAN, ADD, MUL, SUB, DIV, MOD, EXPT, MOVE), logic
functions (AND, OR, XOR, NOT), bit string functions (SHL,
SHR shift bit string left and right , ROR, ROL rotate bit
string), etc.
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Programs
PROGRAM example7.1
VAR_INPUT R1 := MS1 AND (NOT R4);
MSI : BOOL; R2 := R4 AND (NOT C3) AND (NOT C2);
C1 : BOOL; R3 := C4 AND (NOT C3);
C2 : BOOL;
R4 := C1;
C3 : BOOL;
END_PROGRAM
C4 : BOOL;
END_VAR
VAR_OUTPUT
R1 : BOOL : FALSE;
R2 : BOOL : FALSE;
R3 : BOOL : FALSE;
R4 : BOOL : FALSE;
END_VAR

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Functional Block Programming

Functional block (FB) is a well packaged element of

software that can be re-used in different parts of an
application or even in different projects. Functional
blocks are the basic building blocks of a control system
and can have algorithms written in any of the IEC
languages.

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An Up Counter Function Block

The algorithm in Structured Text:

FUNCTION BLOCK CTU

VAR_INPUT
CU : BOOL;
R : BOOL;
PV : INT;
END_VAR
VAR_OUTPUT
Q : BOOL;
CV : INT;
END_VAR
IF R THEN
CV := 0;

CU : input to be counted ELSEIF CU

AND (CV < PV) THEN
R : reset CV := CV + 1;
PV : preset value END_IF;
Q := (CV >= PV);
Q : contact output END_FUNCTION_BLOCK
CV : counter value.

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A PID Control Function Block

block diagram
SP set point
PV sensor feedback
Vout  K p E  Tr  Edt  Td dE
KP proportional error gain dt

TR integral gain
TD derivative gain control algorithm
AUTO calculate
XOUT output to process
XO manual output adjustment
cycle time between execution
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Instruction List Programming

A low level language which has a structure similar to an
assembly language. Since it is simple, it is easy to learn and
ideally for small hand-held programming devices. Each line
of code can be divided into four fields: label, operator,
operand, and comment.

e.g.

LD MS1
ST R1
loop ANDN C3

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Operator
Operator Modifiers Description s GT
than
( greater
LD N load
operand into register
GE ( greater
STN store register
value into operand than and equal to
S set operand true EQ ( equal
R reset operand false NE ( not
AND N, ( Boolean equal
AND
& N, ( Boolean AND LE ( less than
OR N, ( Boolean and equal to
OR
LT ( less than
XOR N, ( Boolean
XOR JMP C, N jump to
ADD ( addition label
SUB ( CAL C, N call
subtraction
function block
MUL (
multiplication Modifier “N” means RET C,defers
negate. “(“ N the return
DIV ( division from function
operator. “C” is a condition modifier, or
the
operation is executed if the register value is true.
function block
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Instruction List for Example 1

PROGRAM example7.1
LD MS1
VAR_INPUT
ANDN R4
MSI : BOOL;
ST R1
C1 : BOOL;
C2 : BOOL;
LD R4
C3 : BOOL; ANDN C3
C4 : BOOL; ANDN C2
END_VAR ST R2
VAR_OUTPUT LD C4
R1 : BOOL : FALSE; ANDN C3
R2 : BOOL : FALSE; ST R3
R3 : BOOL : FALSE;
LD C1
R4 : BOOL : FALSE;
ST R4
END_VAR

END_PROGRAM

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Sequential Function Chart

(SFC)
A graphics language used for depicting sequential
behavior. The IEC standard grew out of the French
standard Grafcet which in turn is based on Petri-net. A
SFC is depicted as a series of steps shown as rectangular
boxes connected by vertical lines. Each step represent a
state of the system being controlled. The horizontal bar
indicates a condition. It can be a switch state, a timer, etc.
A condition statement is associated with each condition
bar. Each step can also have a set of actions. Action
qualifier causes the action to behave in certain ways. The
indicator variable is optional. It is for annotation
purposes.

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SFC
Action Qualifiers:
N non-stored, executes while the
step is active
R resets a store action
S sets an action active
L time limited action, terminates
after a given period
D time delayed action.
P a pulse action, executes once in
a step
SD stored and time delayed
DS time delayed and stored
SL stored and time limited

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SFC for Example 1

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