1

Programmable Logic Controller(PLC)

Training Description
-This training introduces the hardware and software
components of Programmable Logic Controller(PLC).
-It details the architecture and basic instruction set
common to all PLCs
-Basic Programming techniques and Logic designs are
covered
- Training will describes the operating features of the PLC.
-Practical applications will be Covered
-Basic Maintenance and Trouboshoting of PLC will be
covered.
 Objectives
At the end of the training the participants
should be able to:
-Describe the major components of a
common PLC.

-Interpret PLC specifications.

- Apply troubleshooting techniques.

-Convert conventional relay logic to a
PLC language.

-Operate and program a PLC for a
given application.
 Course Contents
• Introduction to PLC
• Major Components of PLC
• PLCs Operations
• PLCs Specification
• Programming Languages
• Programming softwares
• Programming Concepts
• Practical applications
• Troboshooting and Maintenance
 Introduction to PLCs
• PLC is a processor that has been
programmed to perform Logical
functions
• PLC assist Central Processing Unit
(CPU ) such as Computer to
communicate with other devices
through Automation.
• PLC acts a mediator between a CPU
and device by sending data in both
directions and translating the data into
the necessary signals or values for
each type of device.
Advantages of PLCs
• Less wiring.
• Wiring between devices and relay
contacts are done in the PLC program.
• Easier and faster to make changes.
• Trouboshoting aids make
programming easier and reduce
downtime.
• Reliable components make these
likely to operate for years before failure.
 PLC Size
1. 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.
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. 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.

7
 Areas of
Application

Manufacturing / Machining


Food / Beverage


Metals


Power


Mining


Petrochemical / Chemical 8
Major Components of PLCs
Programming Device/Com.port
Types:


-Hand held unit with LED / LCD display


-Desktop type with a CRT display


-Compatible computer terminal

10
 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 PLC’s have Expansion Ports to
Increase the Number of Available Inputs
and Outputs
 Examples of I/O Signals
• Inputs:
-Pushbutton (Energizing or Grounding an Input)
-Relay Contact Output
-DC Voltage Level
-Digital Logic Signal (+5V or 0 V, etc)
• Outputs:
-Magnetic contractor
-Relay
-Solenoid valve
-Lamp
-Digital Logic Signal(-24Vac, -120Vac or -120Vdc
 PLC Central Processing Unit(CPU)
• The CPU controls and supervises all operations
within the PLC, carrying out programmed instructions
stored in the memory.
• An internal communications highway, or bus system,
carries information to and from the CPU, memory and
I/O units, under control of the CPU.
• Microprocessor. This unit interprets the input
signals and carries out the control actions according
to the program stored in its memory, communicating
the decisions as action signals to the outputs. (5 V)
necessary for the processor and the circuits in the
input and output interface modules. processor.
 PLC Power Supply
• The function of the power supply is to
lower the in coming AC voltage to the
desired level, rectify it to direct current,
and then filter and regulate it. The
internal logic of a PLC generally
operates on 5 to 24 volts DC,
depending on the type of controller. This
voltage must be free of voltage spikes
and other electrical noise and be
regulated to within 5% of the required
voltage value.
 PLCs 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.
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

16
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– Diagnostics/Communication
 Once the program is executed, the CPU performs
diagnostics and communication tasks

17
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.

18
As soon as Phase 4 are completed, the entire cycle
begins again with Phase 1 input scan.

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 1 ms to 200 ms.

19
Specifications
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.

20
Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying

sufficient voltage and current to drive the output
peripheral connected to it.

SCAN TIME

This is the speed at which the controller executes the

relay-ladder logic program. This variable is usually
specified as the scan time per 1000 logic nodes and
typically ranges from 1 to 200 milliseconds.

21
Specifications
MEMORY CAPACITY

The amount of memory required for a particular

application is related to the length of the program and
the complexity of the control system. Simple applications
having just a few relays do not require significant amount
of memory. Program length tend to expand after the
system have been used for a while. It is advantageous to
a acquire a controller that has more memory than is
presently needed.

22
Selecting a PLC

Criteria

• Number of logical inputs and

outputs.
• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
 PLCs Programming Languages

• Ladder diagram
• Functional Block Diagram
• Sequential Function Chart
• Instruction List etc
 PLC Programming software

• GMWIN 4.0-Grofa PLC

• Simatic 7 Professional-Siemens PLC
• Zelio soft 2-Schnider PLC etc
 Programming Concepts

• Basic Ladder symbols

 PLC Special Features
• Special Functions-Logic Gates
• Timer
• Counter
 Special Functions

• simple ladder rung for AND Gate

NAND LOGIC GATE
OR LOGIC GATE
NOR LOGIC GATE
 PLC INDICATORS
• PLCs have three status Indicators
-Power On
-Run Mode
- Fault
 Relay Applications

• Relays can be Designed to Perform Many

Functions
– Detect Out of Limit Conditions on
Voltages and Currents
– Start Motors
– Prevent Motors from Over Heating
– Control Assembly Lines
– Adjust Lighting
 Time Delay Relays

• When TD Relay Pick-Up Coil is

Energized, a Delay is Initiated
• Normally Open Contacts Wait to Close
until Delay is Completed
• Normally Closed Contacts Wait to Open
until Delay is Completed
• Very Useful for Creating a Sequence of
Control Events
 Counters
• Counter Relays must “Count” a pre-determined
number of events before changing contact status
• Can Count Up (UpCounter) or Count Down
(DownCounter)
• e.g. An UpCounter is set to 8 and is programmed
to detect every occurrence of a 5 Volt pulse.
When it has detected 8 such occurrences, the NO
Contacts close and the NC contacts open.
• Great for making Real-Time Clocks, etc
 Motor Protection
• Essential Part of Motor Control
• Protect against:
– Under Voltage
– Under Frequency (AC Machines Only)
– Over Current
– Over Heating
– Over Speed
– Over Load
PLCs Troubleshooting
1. Look at the process
2. PLC status lights
HALT - something has stopped the CPU
RUN - the PLC thinks it is OK (and
probably is)
ERROR - a physical problem has occurred
with the PLC
3. Indicator lights on I/O cards and sensors
4. Consult the manuals, or use software if
available.
5. Use programming terminal / laptop.
List of items required when working with PLCs:

1. Programming Terminal - laptop or desktop PC.

2. PLC Software. PLC manufacturers have
their own specific software and license key.
3. Communication cable for connection from Laptop
to PLC.
4. Backup copy of the ladder program (on diskette,
CDROM,
hard disk, flash memory). If none, upload it from the
PLC.