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Programmable Logic
Controllers

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Courseto Content
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• Introduction to Controllers

• Architecture of PLC

• Details Component Study of PLC

• Programming Methods of PLC

• Selection of PLC

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 Introduction to
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• Due to the rapid advances in technology, all industrial processing

systems, factories, machinery, test facilities, etc. turned from
mechanization to automation.

• As new and efficient control technologies evolved, computerized

automation control is being driven by the need for high accuracy,
quality, precision and performance of industrial processes.

• Industrial automation is the use of control devices such as PC/PLCs

etc. to control industrial processes and machinery by removing as
much labor intervention as possible, and replacing dangerous
assembly operations with automated ones.

• Industrial automation is closely linked to control engineering.

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 Supervisory Control and Data Acquisition
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“
Distributed Control System

Programmable Logic Controller

Relay Logic

Microcontroller

Microprocessor

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Introduction
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• A programmable logic controller (PLC) is an industrial grade computer capable of

being programmed to perform control functions.
• The PLC is designed for multiple I/O arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
• It has been designed to operate in the industrial environment and is equipped with
special I/O interfaces and a control programming language.
• The structure of a PLC is based on the computer architecture.
• It is capable of performing relay switching tasks, timing, counting, calculating,
comparing, and the processing of analog signals.
• Programs for the control and operation of manufacturing process equipment and
machinery are typically stored in battery-backed or nonvolatile memory.
• IN PLC Scan time refers to the entire time to execute.
• The difference b/w Online and Off-line PLC is where the edited program resides.

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Advantages
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• Increased Flexibility
• Fast response
• Easy programming and installation
• High control speed
• Network compatibility
• Troubleshooting and testing convenience
• High reliability
• Low Cost.

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The Comparison title style
Table

Characteristic Relay Systems Digital Logic PLC Systems

Price Comparatively Costly Low Low

Size Bulky Compact Compact

Operating Speed Slow Very Fast Fast

Maintenance Poor Poor (if Soldered) Good

Time Consuming to Design, Test and fine Simple to program and

Installation
design and Install tuning is time consuming Install

Noise Immunity Excellent Good Good

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“
Richard E Dick Morley, An American
Mechanical Engineer considered as
the father of PLC.

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Architecture of PLC
GNB

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Definition
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• A PLC is a Specialized Computer used to control

machines and Process.
• It uses programmable memory to store
instructions and execute specific functions that
include on/off control, timing, counting,
sequencing, arithmetic and data handling.
• It is an assembly of Solid State logic elements
designed to make logical decisions and provide
outputs.
• It is basically a computer designed for use in
machine control.

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 Architecture of
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PLC

• PLC Architecture is Proprietary ( Closed Architecture).

• Central Processing Unit, I/O Section, Power Supply and
Programming Devices.
• PLC programs cannot be interchanged among
different PLC manufacturers.
• PLC I/O – Fixed and Modular Types.
• The power supply supplies DC power to other
modules that plug into the rack. 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.
• The processor consists of a microprocessor for
implementing the logic and controlling the
communications among the modules

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 Architecture of
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PLC

• Input devices such as pushbuttons, limit switches, and

sensors are hardwired to the input terminals.
• Output devices such as small motors, motor starters,
solenoid valves, and indicator lights are hardwired to
the output terminals.
• To electrically isolate the internal components from
the input and output terminals, PLCs commonly
employ an optical isolator, which uses light to couple
the circuits together.
• The external devices are also referred to as “field” or
“real-world” inputs and outputs.
• A programming device is used to enter the desired
program into the memory of the processor. A personal
computer (PC) is the most commonly used
programming device.

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 Architecture of
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PLC

• A program is a user-developed series of instructions that directs the PLC to execute

actions. A retentive function is not to reset after power cycle.
• A programming language provides rules for combining the instructions so that they
produce the desired actions.
• Relay ladder logic (RLL) is the standard programming language used with PLCs.
• PLC software – to write a PLC program using ladder logic or another programming
language and document it. PLC S/w is used 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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 Size
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• Nano is the smallest size with less than 15 I/O points.

• Micro type PLC 15 to 128 I/O points
• Medium type PLC 128 to 512 I/O points
• Large type PLC over 512 I/O points.
• In general it is not advisable to buy a PLC system that is larger than current needs dictate.
• There are three types of PLC application: Single-Ended, Multitask & Control Management.
• A single-ended or stand-alone PLC application involves one PLC controlling one process.
• A multitask PLC application involves one PLC controlling several processes.
• A control management PLC application involves one PLC controlling several other PLC’s.
• The largest integer number that a PLC counter function can reach is 65535

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 Memory
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• Memory is the part of a PLC that stores data, instructions, and the control program. Memory size is usually
expressed in K values: 1 K, 6 K, 12 K, and so on(1 K means 1024).

• Modern computers usually have a word size of 16, 32, or 64 bits.

• PLC that uses 8-bit words has 49,152 bits of storage with 6 K word capacity(8 x 6 x 1024 = 49,152).

• PLC using 32-bit words has 196,608 bits of storage with the 6 K memory(32 x 6 x 1024 = 1,96,608).

• Factors affecting the memory size needed for a particular PLC installation include:
1. Number of I/O points used

2. Size of control program

3. Data-collecting requirements

4. Supervisory functions required

5. Future expansion

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I/O SECTION (PLC)

GNB

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 I/Oto
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• The input/output (I/O) section of a PLC is the

section to which all field devices are connected
and provides the interface between them and
the CPU.
• The input interface allows status information
regarding processes to be communicated to the
CPU.
• The CPU communicates the operating signals
through the output interface to the process
devices under its control.
• Combination I/O modules can have both input
and output connections in the same physical
module.
• Its function is to Accept signals from field
devices and convert them into signals that can
be used by the processor

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 I/Oto
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• A module is made up of a PCB and a

terminal assembly. The PCB contains the
electronic circuitry used to interface the
circuit of the processor with that of the I/O
device.
• Modules are designed to plug into a slot or
connector in the I/O rack or directly into the
processor.
• Modules contain terminals, status lights, and
connections to the power supply for each
and every inputs and outputs. Terminal and
status light arrangements vary with different
manufacturers.

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 I/Oto
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• I/O modules can be 8, 16, 32, or 64

point cards.
• The number refers to the number of
inputs or outputs available.
• The standard I/O module has eight
inputs or outputs. A high-density
module may have up to 64 inputs or
outputs.
• Basically, I/O section of PLC is classified
into two types, Discrete and Analog
Type.
• Points per module defines the no. of
field I/O connected in single module.
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 rete Type I/O
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• This type of interface connects field input devices

of the ON/OFF nature such as selector switches,
pushbuttons, and limit switches.
• Output control is limited to devices such as lights,
relays, solenoids, and motor starters that require
simple ON/OFF switching.
• The classification of discrete I/O covers bit
oriented inputs and outputs.

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 c rete Input
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• The input circuit is composed of two basic sections: the power section and the logic section.
• An optical isolator is used to provide electrical isolation between the field wiring and the PLC
backplane internal circuitry.

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 c rete Input
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 r ete O utput
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 r ete O utput
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 I/O Section
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Discreto
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• If the module is a current-sourcing module,

then the input or output device must be a
current-sinking device.
• Conversely, if the module is specified as
current sinking, then the connected device
must be current sourcing.
• If a device provides current when it is ON, it
is said to be sourcing current.
• Conversely, if a device receives current
when it is ON, it is said to be sinking
current.

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 I/O Section
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Analoto
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• Analog devices represent physical

quantities that can have an infinite number
of values.
• Typical analog inputs and outputs vary
from 0 to 20 mA, 4 to 20 mA, or 0 to 10 V.
• Analog input modules normally have
multiple input channels that allow 4, 8, or
16 devices to be interface to the PLC.
• The two basic types of analog input
modules are Voltage Sensing & Current
Sensing.
• Analog Parameters : temperature, speed,
level, flow, weight, pressure, and position.
• Analog voltage input modules are available
in two types: Unipolar & Bipolar.

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 I/O Modules
Specia
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• High Speed Counter Module
• Thumbwheel Module
• TTL Module
• Encoder Counter Module
• BASIC or ASCII Module
• Stepper Motor Module
• BCD Output Module
• PID Module
• Motion and Position Control Module
• Communication Module

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 e I/O Specs I/O Specs
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• Nominal Input Voltage • Channels per module

• Input Threshold Voltage • Input Current Voltage Range
• Nominal Current Per Input • Output Current Voltage Range
• Ambient Temperature Rating • Input Protection
• Input ON/OFF Delay • Resolution
• Output Voltage • Input Impedance and Capacitance
• Output Current • Common Mode Rejection
• Inrush Current
• Short Circuit Protection
• Leakage Current
• Electrical Isolation
• Points per Module
• Backplane Current Draw
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• A processor module is divided into two

sections: the CPU section and the
memory section.
• The CPU section executes the program
and makes the decisions needed by
the PLC to operate and communicate
with other modules.
• The memory section electronically
stores the PLC program along with
other retrievable digital information.
• PLC power supplies are normally
designed to withstand momentary
losses of power without affecting the
operation of the PLC.
• Hold-up time, which is the length of
time a PLC can tolerate a power loss,
typically ranges from 10 ms to 3 s.
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• The difference is that the program

used with the microprocessor is
designed to facilitate industrial control
rather than provide general-purpose
computing.
• The CPU executes the operating
system, manages memory, monitors
inputs, evaluates the user logic (ladder
program), and turns on the appropriate
outputs.
• The CPU of a PLC system may contain
more than one processor.
• One advantage of using
multiprocessing is that the overall
operating speed is improved.

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 og ram m ing
M emory Pr
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• Memory is the element that stores • A programming terminal device is
information, programs, and data in a needed to enter, modify, and
PLC. troubleshoot the PLC program.
• Data are stored in memory locations • The most popular method of PLC
by a process called writing. programming is to use a personal
computer (PC) in conjunction with the
• Data are retrieved from memory by
manufacturer’s programming software.
what is referred to as reading.
• The functions of programming device is
• The complexity of the program
to change, monitor and enter the user
determines the amount of memory
program.
required.
• A 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.
• Memory Types : Volatile & Non-Volatile

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 tures of PLC
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• At start, PLC scans the status of all inputs are read.

• The control plan stored in the PLC is called Program.
• Optical isolator circuit cannot rectify AC signal
• The main difference between a plc and control system is that it uses hardwired relay
control logic and the other uses programmed instructions.
• The IO system provides interface between CPU and field equipment
• The function of PLC is to make logical decisions and control outputs based on them
• BCD output module is a special type of IO module

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Switches Relays
GNB

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Switches

• Switches are used for operator • The momentary pushbutton switch is

input to send instructions to the activated when the button is
control circuit. pressed, and deactivated when the
• Switches are installed on the button is released.
moving parts of a machine to • The deactivation is done using an
provide automatic feedback to the internal spring
control system. • The maintained pushbutton activates
• The most common switch is the when pressed, but remains activated
pushbutton. when it is released.
• There are two types of pushbutton, • Then to deactivate it, it must be
the momentary and maintained. pressed a second time.

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Switches

• The contacts on switches can be of

two types. These are normally
open (N/O) and normally closed
(N/C).
• Whenever a switch is in
deactivated position, the N/O
contacts will be open (non-
conducting) and the N/C contacts
will be closed (conducting).
• Mushroom Head switches are used
for emergency stop/run.
• Other types include, Rotary switch,
Limit switch.

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Relaysto edit Master title style

• Early electrical control systems were composed of

mainly relays and switches.
• A relay, or contactor, is an electromagnetic device
composed of a frame with an electromagnet coil
and contacts.
• It is possible to construct a relay with a built-in time
delay device that causes the relay to either switch
on after a time delay, or to switch off after a time
delay.
• Few Advantages may be it is available in all
different shapes and sizes; Easy to troubleshoot.
• Few disadvantages may be like, low switching
speed; internal components wear and tear; noise
happens during switching.

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Programming Languages
in PLC
GNB

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Programming title style
Languages in PLC

The term PLC programming

language refers to the method
by which the user
communicates information to
the PLC.
When placed in the program
mode, the processor does not
scan/execute the ladder
program

The standard IEC 61131 was

established to standardize the
multiple languages associated
with PLC programming by
defining the following five
standard languages:

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Ladderto Diagram
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• Ladder diagram is the universal
programming language of PLC. It has a
short abbreviation as LD and also known as
Ladder Logic. And it is one of the oldest
programming languages for PLC.
• Most popular all over the world. This
language is easy to learn by using a logic
gate and some important programming
rules.
• This looks like relay racks, each device in
the relay rack would be represented by a
symbol on the ladder diagram.
• The name ladder diagram is based on the
programming language pattern similar to a
ladder, with two vertical rails that shows
electrical connection among a series of
horizontal rungs between them.
• Ladder Logic consists of virtual
relaycontacts and coils
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Function Master
Block title style
Diagram
• Function block diagram (FBD) is a popular
and easy way to write a program like a
Ladder Diagram.
• FBD is represented like box which consists
of a number of lines of code for putting
different programming functions.
• It is a graphical language for programming
logic controller. So, it makes easy to
describe a system.
• In Function Block Diagram inputs and
outputs are connected in blocks by
connection lines.
• Function blocks are mainly used to do
repetitive tasks like starters, closed-loop
control, PID loops, etc.

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Structured Master title style

• Structured Text PLC language is shortly

denoted by the ‘ST’ and ‘STX‘.
• It uses high-level programming language
syntax.
• The syntax of ST is similar to the syntax of a
high-level programming language with
loops, variables, conditions, and operators.
• It is a very powerful language that can
easily execute complex mathematical logic.
• The ST consists of various statements with
complex statements and instructions like IF,
WHILE, CASE, RETURN, FOR, REPEAT, etc.

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Click to editList
Instruction Master title style
• Instruction List (IL) is another type of PLC
programming language which uses the
mnemonic code.
• So the syntax of this programming language
is easy to remember.
• In general, AB PLC brand works on the
Instruction List (IL) programming language.
• Instruction List(IL) is one of the PLC
programming languages which is like an
assembly programming language.
• The mnemonic codes like LD, AND, OR, A,
etc. are used in this PLC programming
language.
• Sometimes it is easy to remember the code
while using this programming language.

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Click to editFunction
Sequential Master title
Chartstyle

• Sequential function charts (SFC) is also a

graphical programming language.
• It has become a popular method of
accurately specifying sequential control
requirements.
• The benefit of SFC is easy to understand
because you can visualize what is
happening and when it is happening in the
procedure of the code.
• The main function of SFC is only the active
parts of the code are executed. Due to this,
it makes easier to troubleshoot and to
change the code if problems occur.

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TIMERS &
COUNTERS
GNB

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• Timers are used to provide delay for energizing or de-energizing the output.
• A good application of timed interrupt is PID function block
• There are three types of Timers available in PLC.
1. ON Delay Timer
2. OFF Delay Timer
3. Retentive Timer
• There are few properties associated with timer. They are:
1. Time Base
2. Preset Value
3. Accumulated Value
4. Timer Name
5. Enable Bit
6. Done Bit

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On Delay Master title style
Timer

• ON delay Timer is used to provide delay function only after the particular rung becomes true.

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On Delay Master title style
Timer

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Off Delay Master title style
Timer

• The off-delay timer (TOF) operation will keep the output energized for a time period after the rung
containing the timer has gone false.

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Off Delay Master title style
Timer

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Retentive Master title style
Timer

• A retentive timer accumulates time

whenever the device receives power,
and it maintains the current time even
if power is removed from the device.
• When the timer accumulates time
equal to its preset value, the contacts
of the device change state.
• Loss of power to the timer after
reaching its preset value does not
affect the state of the contacts.
• The retentive timer must be
intentionally reset with a separate
signal for the accumulated time to be
reset and for the contacts of the device
to return to its non-energized state.

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Counters

• Electronic counters can count up, count down, or be combined to count up and down.
• Although the majority of counters used in industry are up-counters, numerous applications
require the implementation of down-counters or of combination up/down-counters.
• The attributes used for Counters are:
1. Counter Type
2. Counter Address
3. Counter Preset Value
4. Counter Accumulated Value
5. Counter Enable Bit
6. Done Bit
• Counters are classified into 3 types:
1. Up Counter
2. Down Counter
3. Up/Down Counter
4. High Speed Counter

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Up Counter

• The up-counter is an output

instruction whose function is
to increment its accumulated
value on false-to-true
transitions of its instruction.

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Counter

• The down-counter instruction will count down or decrement by 1 each time the counted event occurs.
• Each time the down-count event occurs, the accumulated value is decremented.

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Thank You

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