Basic PLC

Unit 3
PLC (Programmable Logic Controller )
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Objectives

 Evolution of PLC.
 Introduction to PLC.
 Comparison with RLC.
 Describe the major components of a common PLC.
 I/O addressing.
 Specifications of PLCs.

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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.

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PLC Origin

 Developed to replace relays in the late 1960s

 Costs dropped and became popular by 1980s
 Now used in many industrial designs

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Historical Background
The Hydramatic Division of the General Motors Corporation
specified the design criteria for the first programmable controller in 1968.

Their primary goal was to eliminate the high costs associated with
inflexible, relay-controlled systems.

The controller had to be designed in modular form, so that sub-

assemblies could be removed easily for replacement or repair.

 The control system needed the capability to pass data collection to a

central system.

 The system had to be reusable.

 The method used to program the controller had to be simple, so that it

could be easily understood by plant personnel.
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Evolution of PLC

1968 Programmable concept developed

1969 Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974 Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976 Remote input/output systems introduced
1977 Microprocessors - based PLC introduced

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Evolution of PLC

1980 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 PLC’s introduced
1985 onwards Networking of all levels of PLC, computer
and machine using SCADA software.

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Advantages of PLCs

1. Less wiring.
2. Wiring between devices and relay contacts are done
in the PLC program.
3. Easier and faster to make changes.
4. Trouble shooting aids make programming easier and
reduce downtime.
5. Reliable components make these likely to operate for
years before failure.

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Comparison between PC and PLC

 The main difference from other computers is that PLCs are
armored for severe conditions (dust, moisture, heat, cold, etc) and
have the facility for extensive input/output (I/O) arrangements.
Advantages over PC :
1. Cost effective for controlling complex systems.
2. Flexible and can be reapplied to control other systems quickly
and easily.
3. Computational abilities allow more sophisticated control.
4. Trouble shooting aids make programming easier and reduce
downtime.
5. Reliable components make these likely to operate for years
before failure.
Disadvantages over PC :
6. Too much work required in connecting wires.
7. Difficulty with changes or replacements. 23
8. Difficulty in finding errors; requiring skillful work force.
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PLC: functions

PLC = PMC: Protection, Measurement and

Control
• Measure

• Control (Command and Regulation)

• Protection
• Event Logging

• Communication

• Human interface

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PLC: Location in the control architecture

Enterprise Network
Engineer Operator Supervisor gateway
station station Station
Control Bus
(e.g. Ethernet)

Control PLC
large

COM1

COM 2
Station

COM1
PLC

COM 2
COM1

CPU
gateway
CPU
CPU

I/O
PLCs with Field Bus

I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O

Field Bus Field Bus

COM

COM

COM

COM
COM
CPU

CPU

CPU
direct I/O
I/O
I/O
I/O
I/O

I/O
I/O
I/O
Field Stations FB
small PLC gateway Field Devices
data concentrators,
not programmable,
but configurable Sensor Bus (e.g. ASI)

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Why 24V / 48 V supply ?

… After the plant

lost electric
power, operators
could read
instruments only
by plugging in
temporary
batteries…

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Leading Brands Of PLC

AMERICAN 1. Allen Bradley

2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Bosch
3. Festo
4. Telemechanique

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Leading Brands Of PLC

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

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Areas of Application

 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical

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Types of PLC: Based on Structure
(1) Compact (Micro PLC)
Monolithic construction
Monoprocessor
Fieldbus connection
Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities (no MMC)
Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7
(2) Modular PLC
Modular construction (backplane)
One- or multiprocessor system
Fieldbus and LAN connection
3U or 6U rack, sometimes DIN-rail
Large variety of input/output boards
Connection to serial bus
Small MMC function possible
Typical products: SIMATIC S5-115, Hitachi H-Series, ABB AC110, Bosch L20 DP

(3) Soft-PLC
Windows NT or CE-based automation products
Direct use of CPU or co-processors

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Modular PLC Classification based on 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 of machine controls.

2. MEDIUM - have up to 2048 I/O’s and memories up

to 32 Kbytes.
- can control part of process or complete process.

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.
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Compact (Micro) PLC

binary inputs
network

analog inputs / outputs

binary outputs
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Small modular PLC

mounted on DIN-rail, 24V supply

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Medium/ Large Modular PLC
CPU1
PLC in a cabinet CPU2

serial connections
redundant
field bus inputs/outputs
connection

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Soft-PLC (PC as PLC)

• PC as engineering workstation
• PC as human interface (Visual Basic, Intellution, Wonderware)
23 12 • PC as real-time processor (Soft-PLC)
4 2 2 • PC assisted by a Co-Processor (ISA- or PC104 board)
3
3 • PC as field bus gateway to a distributed I/O system

I/O modules

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PLC evolution
Binary World Analog World
relay controls, Pneumatic and electromechanical
Relay control controllers
pneumatic sequencer
I1

A
B

C
P1
P2

combinatorial sequential Regulation, controllers

discrete processes continuous processes

Programmable Logic Controllers

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Continuous Plant
Example: traction motors, ovens, pressure vessel,...
The state of continuous plants is described by continuous (analog) state
variables like temperature, voltage, speed, etc.
There exist a fixed relationship between input and output , described by a continuous
model in form of a transfer function F.
This transfer function can be expressed by a set of differential equations.
If equations are linear, the transfer function may expressed as Laplace or Z-transform.
y

(1+Ts)
x F(s) = y
(1+T1s + T2 s )2 time

Continuous plants are normally reversible and monotone.

This is the condition to allow their regulation.
The time constant of the control system must be at least one order of
magnitude smaller than the smallest time constant of the plant.

the principal task of the control system for a continuous plant is its regulation.
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Discrete Plant
b
init c+d
2 3 4
a e
Examples: Elevators, c + ¬d
traffic signaling, e
1
warehouses, etc.
7 6 5

The plant is described by variables which take well-defined, non-overlapping values.

The transition from one state to another is abrupt, it is caused by an external event.

Discrete plants are normally reversible, but not monotone, i.e. negating the event
which caused a transition will not revert the plant to the previous state.

Example: an elevator doesn't return to the previous floor when the button is released.

Discrete plants are described e.g. by finite state machines or Petri nets.

the main task of a control system with discrete plants is its sequential control.
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Example of Discrete state system:

Tank Used to Mix Two Liquids
MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

SOLENOID
C
TIMER

1 -MINUTE

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Tank Used to Mix Two Liquids

A tank is used to mix two liquids. The control circuit operates
as follows:

1. When the start button is pressed, solenoids A and B

energize. This permits the two liquids to begin filling the tank.

2. When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used to
mix the liquids together.

3. The motor is permitted to run for one minute. After one

minute has elapsed, the motor turns off and solenoid C
energizes to drain the tank.

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Tank Used to Mix Two Liquids

4. When the tank is empty, the float switch de-energizes
solenoid C.

5. A stop button can be used to stop the process at any

point.

6. If the motor becomes overloaded, the action of the entire

circuit will stop.

7. Once the circuit has been energized it will continue to

operate until it is manually stopped.

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Major Components of PLC

POWER
SUPPLY

I M PROCESSOR O M
N O  CPU
P D  ALU U O
From U U  Memory T D
SENSORS T L P U To
E U L OUTPUT
Pushbuttons, T E Solenoids,
contacts, contactors,
limit switches, alarms
PROGRAMMING
etc. etc.
DEVICE

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Major Components of a Common PLC

POWER SUPPLY

Provides the voltage needed to run the primary PLC components

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Major Components of a Common PLC

I/O MODULES

Provides signal conversion and isolation between the internal logic

level signals inside the PLC and the field’s high level signal.
Performs the following functions:
1. Termination: Provides terminals for connection to field devices
2. Isolation: Provides isolation between the high power field
devices and low power controller generally by making use of
optical couplers.
3. Signal Conditioning: Performs signal conversion like A to D or
D to A.
4. Indication: Makes use of low power LEDs to indicate the
absence (low state) or presence (high state) of the field devices.
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Classification of I/O Module

1) Serial I/O

2) Parallel I/O

3) Discrete I/O : AC , DC Discrete I/O

4) Analog I/O : Analog Input (0-10 V, -10 to+10 V,4-20 mA)

Analog Output (4-20 mA, 0-10 V, -10 to+10 V)

5) Special purpose I/O : ASCII communication module, Stepper

motor module, Thermocouple module, Bar code module, Vision
system module, PID Controller module.
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Major Components of a Common PLC

PROCESSOR
Provides intelligence to command and govern the activities of the
entire PLC systems. Consists of :
1. CPU
2. ALU
3. Memory: RAM, ROM and Files ( Program and Data)

PROGRAMMING DEVICE
External device used to enter the desired program that will determine
the sequence of operation and control of process equipment or
driven machine. Different types of programming devices used with
PLC are:
4. Hand held terminals
5. Dedicated terminals
6. Microcomputer (PC) 46
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Programming Device
Also known as:

 Industrial Terminal ( Allen Bradley )

 Program Development Terminal ( General Electric )

 Programming Panel ( Gould Modicon )

 Programmer ( Square D )

 Program Loader ( Idec-Izumi )

 Programming Console ( Keyence / Omron )

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Programming Device
1. Hand held unit with LED / LCD display : It is a small self contained
unit in which the ladder diagram is displayed one rung at a time in a
special liquid crystal display. The user can enter a program, perform
diagnostic tests, run the program through the programmable
controller and perform editing of the installed program. The installed
program is stored in a temporary memory that will be lost without ac
power or battery back up. The program can be permanently burned
into a ROM for final installation.

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2. Dedicated terminals: These are used with only one type and make
of PLC and is used when programming has to be done in mass for
the same type of the controller.

3. Microcomputer (PC) : It is able to display many rungs of the ladder

Diagram. The advantage of PC is that it can be used for programming
Different makes of PLC by running their respective loaded software and
when not on the network can be used for other applications such as
design or accounting.

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Discrete Input Module
Most common input interface used with PLCs.

DISCRETE DC INPUT MODULE

IS NEEDED TO:
USE TO · Prevent voltage
DROP THE transients
VOLTAGE from damaging
TO LOGIC the processor.
LEVEL · Helps reduce
the effects of
electrical noise

Current Signal
FROM Limiting Conditioning
OPTO- TO
INPUT Resistor ISOLATOR Buffer, Filter,
PROCESSOR
DEVICE hysteresis
Circuits

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DISCRETE AC INPUT MODULE

IS NEEDED TO:
CONVERTS THE AC · Prevent voltage
INPUT TO DC AND transients
DROPS THE VOLTAGE from damaging
TO LOGIC LEVEL the processor.
· Helps reduce
the effects of
electrical noise

Rectifier, Signal
FROM Resistor Conditioning
OPTO- TO
INPUT Network ISOLATOR Buffer, Filter,
hysteresis PROCESSOR
DEVICE
Circuits

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DISCRETE OUTPUT MODULE

They are most widely used and simply act as switches to control
output field devices.

DISCRETE DC OUTPUT MODULE

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DISCRETE AC OUTPUT MODULE

IS NEEDED TO:
· Prevent voltage
transients
from damaging
the processor.
· Helps reduce
the effects of
electrical noise

Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

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Analog Input Module

 It is used to interface a PLC to analog input signals.

 The module converts analog input signals to 16-bit binary values

for storage in processor’s input image table.

 It accepts signals 0 to 10 V DC,-10 V to +10 V DC, 1 to 5 V DC,

4 to 20 mA, 0 to 20 mA, -20 to +20 mA.

ADC
Analog
Filtering Optical (Analog to
Input CPU
and Scaling Isolation Digital
Signal
Conversion)

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Analog Output Module
 It accepts a 16 bit output status word which they convert into an analog
value through digital to analog converter.

 Typical analog signals 0 to 10 V DC,-10 V to +10 V DC, 1 to 5 V DC, 4 to

20 mA, 0 to 20 mA, -20 to +20 mA.

 Analog output modules are selected to send out either a varying current
or voltage signal.

 For Ex: If the speed of the DC motor is to be varied over a range of say
1000-3000 rpm, the voltage of an output module of range 0 – 1 V DC will
represent a specific speed over the range.
DAC
(Digital to Optical Field
CPU Amplifier
Analog Isolation Devices
Conversion)

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General PLC architecture
RS 232 Ethernet

Real-Time flash serial port ethernet

CPU ROM
Clock EPROM controller controller
extension
bus
parallel bus buffers

field bus analog- digital- external

Digital
controller digital analog Digital Output I/Os
Input
converters converters

signal power signal

conditioning amplifiers
relays conditioning

direct Inputs and Outputs

field bus
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The signal chain within a PLC
y y(i) y(i)

time time time

analog filtering analog- digital- analog

011011001111
variable & sampling digital analog amplifier variable
(e.g. 4..20mA)scaling converter converter e.g. -10V..1

1
processing
binary transistor
binary
variable filtering sampling or
variable
(e.g. 0..24V) 0001111 relay

non-volatile
counter memory
y

time
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Signal chain in a protection device
Anti
Input aliasing Sample and hold Digital Protection Output
transformer filter A/D conversion filter algorithm driver

U/I 
 A/D 
 Trip
  CPU

reaction < 10 ms

f = 200 kHz f = 300 -1200 Hz

f = 1 MHz f = 100 kHz

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Selecting a PLC

Criteria

• Number of logical inputs and outputs.

• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
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OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS

PLC
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I/O Addressing

L1 L2 I= Input
Module slot no. in
rack /Byte no. in
%IX0.0 Input Table

Module
P. B SWITCH Terminal no./ Bit
no. in Input Table
Address %IX0.0

LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM
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CONTACTOR
L2 L1 N.O

MOTOR
L2
C • SOLENOI
L1 D
FIELD WIRING • VALVES
• LAMP
• BUZZER
Module slot no. in
OUTPUT MODULE rack / Byte no. in
WIRING Output Table

L1 %QX0.0 L2

Module
Terminal no./ Bit
Q= Output no. in Output Table
LADDER PROGRAM

I/O Addressing