General PLC architecture

RS 232

CPU

Real-Time
Clock

ROM

flash
EPROM

Ethernet

serial port ethernet

controller controller
extension
bus

parallel bus

fieldbus
controller

field bus

buffers

analogdigital
converters

digitalanalog
converters

Digital Output

Digital
Input

signal
conditionin
g

power
amplifiers

relays

signal
conditioning

external
I/Os

direct Inputs and Outputs

1

Plc programmable logical

circuit
A digitally operated electronic equipment
which uses a programmable memory for internal
storage of instruction by implementing specific
function through analog or digital modules.
specific instruction such as

Logical sequence

Timing

Counting

Arithmetic

 A PLC (i.e. Programmable Logic Controller) is a device

that was invented to replace the necessary sequential
relay circuits for machine control.

Major Component of PLC

The three basic element of PLC are
Central Processing unit
Input Modules
Output Modules

Central Processing unit(CPU)

The CPU receives i\p signals from
the various i\p modules and based on
the programs stored in the memory,
decided on the appropirate signals,
which it transmits to the respective
output module.

Memory
VOLATILE.
A volatile memory 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.
Common Type of Volatile Memory
RAM. Random Access Memory(Read/Write)
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.

 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 PLCs.
RAM memory must have battery backup to retain or
protect the stored program.

 NON-VOLATILE
Has the ability to retain stored information when power
is removed, accidentally or intentionally. These
memories do not require battery back-up.
Common Type of Non-Volatile Memory
ROM, Read Only Memory
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 Read Only Memory

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 Programmable Read Only Memory

Ideally suited when program storage is to be semipermanent 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 Erasable Programmable Read

Only Memory
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.

INPUT/OUTPUT MODULE
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 PLCs processor.
Output modules converts signal from the processor to levels capable of driving
the connected discrete or analog output devices.

12

I/O Module
DC INPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

USE TO
DROP THE
VOLTAGE
TO LOGIC
LEVEL

FROM
INPUT
DEVICE

Current
Limiting
Resistor

OPTOISOLATOR

Buffer,
Filter,
hysteresis
Circuits

TO
PROCESSOR

13

I/O Module
AC INPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

CONVERTS THE AC
INPUT TO DC AND
DROPS THE VOLTAGE
TO LOGIC LEVEL

FROM
INPUT
DEVICE

Rectifier,
Resistor
Network

OPTOISOLATOR

Buffer,
Filter,
Hysteresis
Circuits

TO
PROCESSOR

14

Programming the PLC

PLC is programmed by means of a programming
device.
Programming language of PLC are:
Ladder diagram
Low level language based on boolean
expression
Functional Block
High level languages
Most of the programming method used today for
plcs are based on ladder logic diagram

Ladder Diagram
Ladder logic uses graphic symbols similar to
relay schematic circuit diagrams.
Ladder diagram consists of two vertical lines
representing the power rails.
Circuits are connected as horizontal lines
between these two verticals.

Ladder builder diagram

features
1.Power flows from left to right.
2.Otput on right side can not be connected directly with left side.
3. Contact can not be placed on the right of output.
4.Each rung contains one output at least.
5. Each ouutput can be used only once in the program.
6.A particular input a/o output can appear in more than one rung of a
ladder.
7.The inputs a/o outputs are all identified by their addresses, the
notation used depending on the PLC manufacturer.

LADDER DIAGRAM FORMAT

A ladder rung is TRUE when it has logic continuity.

Logic continuity exists when power flows through
the rung from left to right.
The execution of logic events that enable the
output provide this continuity.
18

19

There are five program elements/operations commonly

used in PLC ladder diagram they are

1.
2.
3.
4.
5.

PLC Bit logic operations

Timer Operations
Counter operations
Comparison operations
Arithmetic operations.

Example
1.Double acting cylinder is used to
perform
machinng
operation.
Pneumatic cylinder is advanced by
pressing
two
push
buttons
simultaneously. If any one of the
push button is released, cylinder
comes back to start position. Draw
the pneumatic circuit, PLC wiring
diagram and ladder diagram to
implement this task.

As shown in the PLC wiring diaram , The pushbuttons

PB1 and PB2 are connected at memory address I1 and
I2. I1 and I2 are connected in series in ladder diagram
to relase this AND logic funtion. When the push
buttons PB1 and PB2 are pressed simultaneously, the
addresses I1 and I 2 turn to state 1 from state 0 , as a
result power flows thorugh the coil and there will be
output at coil 01. Output at the coil 01 operated the
solenoid coil and cylinder moves foraward to do the
required operation. If any one of PB1 and PB2 is
pressed, then corresponding bit addresses turns to 0,

Functional block
The term function block diagram (FBD) is used for PLC
programs described in terms of graphical blocks. It is
described as being a graphical language for depicting
signal and data flows through blocks, these being
reusable software elements. A function block is a
program instruction unit which, when executed, yields
one or more output values.

Enhanced functional block format

Functional block instructions

(a) one enable line and one output
(b) one enable line, a start timing command, and
two outputs.

27

PLC 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.

PLC operation
PHASE 1

Read Inputs
Scan
PHASE 2

Program
Execution
PHASE 3

Diagnostics/
Comm
PHASE 4

Output
Scan
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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 Logic Solve/Program Execution

Once the program is executed, the CPU performs diagnostics and

communication tasks

30

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.

31

PLC widely used in industries area

due to following reasons
Cost of PLC automation is less and PLC is very
versatile
PLC can be commissioned and installed easily
Programming of PLC is quite simple. Ladder
programming is flexible
They are not hard wired control. They can be
programmed and reprogrammed to
accommodate frequent changes in program
Monitoring of on line work process is easy,
therefore trouble shooting and maintenance of
PLC is not a difficult task.