PLC programming

Part 1: Structure and operation

Topics
 Evolution of logic controller devices
 Leading PLC manufacturers around the world
 PLC architecture
 PLC operation
 Criteria for PLC selection
Evolution of logic controller devices
 Relay controllers
 Semi-conductor logic controllers
 Programmable Logic Controllers (PLC)
Relay controllers
 Large dimensions
 Slow
 Noisy
 Requires a lot of energy to work
 Sensible for dirt
Semi-conductor logic controllers
 Fast
 Small
 Reduced energy
 Silent
 Hard to adapt to another controlling task
Programmable Logic Controllers (PLC)
 Alladvantages of the semi-conductor logic controllers
 Easy to adapt (re-programming)
 Real-time working
 Minimal maintenance
 Low costs
Areas of application
 Water handling
 Agriculture
 Traffic control
 Food industry
 Manufacturing / Machining
 Mining
Leading PLC manufacturers (US)
 AllenBradley
 Gould Modicon
 Texas Instruments
 General Electric
 Westinghouse
 Cutter Hammer
 Square D
Leading PLC manufacturers (EU)
 Siemens
 Klockner & Mouller
 Festo
 Telemechanique
Leading PLC manufacturers (Japan)
 Toshiba
 Omron
 Fanuc
 Mitsubishi
PLC architecture
System
memory

Programming Program Input

unit memory module
Processor

Data Output
memory module

Communication
unit
Processor
 Themain 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.
Memory
 System memory
 ROM (Read Only Memory)
 PROM (Programmable Read Only Memory)
 EPROM (Erasable Programmable Read Only Memory)
 EEPROM (Electric Erasable Programmable ROM)
 Program/Data memory
 RAM (Random Access Memory)
System memory
 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 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.
ROM
 Read Only Memory
 A non-volatile memory. It has the ability to retain stored
information when power is removed, accidentally or
intentionally. A ROM does not require battery back-up.
 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.
PROM
 Programmable ROM
 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 PROM
 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 ultra violet light, the memory
content can be erased.
 The EPROM chip is also referred to as UVPROM.
EEPROM
 Electrically
EPROM
 Also referred to as E2PROM, 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 down loaded into the RAM.
Program/Data memory
 The program and data memories are called together
application memory.
 The data memory 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 memory 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.
RAM
 Random Access Memory (Read/Write)
 A volatile memory, that 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.
 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.
RAM – Random Access
 The words random access refer 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.
Types of RAM Memory
 MOS (Metal Oxide Semiconductor)
 HMOS (High Density, short channel MOS )
 CMOS (Complimentary MOS)
 The CMOS-RAM is probably one of the most 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.
Input/Output modules
 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 received from or sent to the external input and output devices.
 Input modules converts signals from discrete or analog input devices
to logic levels acceptable to PLC’s processor.
 Output modules converts signal from the processor to levels capable
of driving the connected discrete or analog output devices.
DC Input module
Standard Digital Input signals: 24V
Prevents voltage transients from
Used to damagigng the processor.
drop the
voltage to Helps to reduce the effects of
logic level electrical noise.

Current Buffer,
DC input limiting Opto- filter, Processor
resistor isolator hysteresis
circuits
AC input module
Standard Analog Input signals: 4-20mA; 0-10V
Prevents voltage transients from
Converts the AC damagigng the processor.
input to DC and
drops the voltage Helps to redice the effects of
to logic level electrical noise.

Rectifier, Buffer,
AC input Resistor Opto- filter, Processor
Network isolator hysteresis
circuits
DC/AC output module
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V

Processor TTL Opto- Aplifier Output

circuits isolator
Programming unit
 Usuallya hand-held
programmer or a PC
 For simple tasks
Communication unit
Manages the communication between the PLC and
 the controlled process,
 an other PLC,
 a PC,
 different peripheries.
Used ports:
 Serial (RS 232, RS 422, RS 485 )
 Ethernet
Serial ports
 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.
 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.
Ethernet: 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.
Advantages of PLC communication
 The less cable the less cost.
 Higher reliability and performance.
 Smaller installation and service costs.
 The ability of teleprogramming and telemonitoring.
 Changing resident PLC programs - uploading/downloading from a
supervisory controller (Laptop or desktop computer).
 Forcing I/O points and memory elements from a remote terminal.
 Linking a PLC into a control hierarchy containing several sizes of PLC
and computer.
 Monitoring data and alarms, etc. via printers or Operator Interface
Units (OIUs).
PLC operation
 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.
PLC operation scheme
Input signals
Power-on the PLC

… Clear the output table

Input links Input table update

PLC program

Instruction 1
Instruction 2
Output links …
Instruction n

… Output table update

Output signals
Scan cycle and scan time
 Input table update is also called input scan.
 Output table update is output scan.
 The process from input scan to output scan is a scan cycle.
 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 100 ms.
Criteria for PLC selection
 Number of logical inputs and outputs.
 Memory
 Number of special I/O modules
 Scan Time
 Communications
 Software
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.
I/O number
 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.
Scan time
 Thisis 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 100 milliseconds.
Categorization of PLC-s by 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.
References
 http://www.gandhcontrols.com/Downloads/Manuals/PLC
Programming.ppt
 http://rdjoudjou.freehostia.com/livre/Basic PLC.ppt