Programmable Logic

Controllers
PLCs

 Overview
Course Contents

What is a PLC ?

History

Overview of Technology

PLC Configuration and Selection

Programming PLCs
 Course Contents
Introductions to PLC
Programming
PLC Hardware
Internal Relays
Input / Output
Processing Timers

Input Devices Counters

Output Devices

Projects
What is a PLC ?
 What is a PLC ?
A PLC works by looking at its inputs and depending on
their state, and the user entered program, turns on/off
outputs.

A PLC can be thought of as:

Industrial Computers with specially designed architecture

in both their central units (the PLC itself) and their
interfacing circuitry to field devices (input / output
connections to the real world).
Commercial And Industrial
Computers

Commercial
Computer

Industrial
Computer
 History 1/5
Early control systems consisted PB1 LS1 SOL2

of huge control boards consisting

of hundreds to thousands of
LS1 PB2 CR3
electromechanical relays.

An Engineer would design the LS3

system logic.

Electricians would receive a CR3 LS4 M1

schematic outline of logic then |/|

implement the logic with relays.

 History 2/5
The schematic was commonly called Ladder
Schematic

The Ladder displayed all switches, sensors, motors,

valves, relays etc in the system.

Problems: Long implementation time, Mechanical

dependence, Any system logic design change required
the power to the control board to be isolated stopping
production
 History 3/5
General Motors was among the first to recognize a need to
replace the systems wired control board

Hydromantic Division of GM specified the design criteria for

the programmable controller in 1968.

Goal Eliminate the high cost associated with inflexible,

Relay controlled systems.
 History 4/5
New Controller Specifications:

Solid State System

Computer Flexibility

Operate in Industrial Environment (vibrations, heat,

dust etc.)

Capability of being reprogrammed

Easily programmed and maintained by electricians

and technicians.
 History 5/5
In 1969 Gould Modicon developed the first PLC.

Strength Programmed with Ladder Logic

Initially called Programmable Controllers PCs

Now PLCs, Programmable Logic Controllers

PLCs have evolved from simple on/off control to being

able to communicate with other control systems, provide
production reports, schedule production, diagnose
machine and process faults.
Relay Logic vs. PLC & Ladder
Logic
PB1 LS1 SOL2 Inputs Outputs

Programmable
Logic
Controller
LS1 PB2 CR3
C
R

LS3 X0 X1 Y0
|| || ()
X2 X3 M0
|| || ()
CR3 LS4 M1 X4
||
|/|
M0 X5 Y1
|/| || ()
 PLC Configuration

RACK

SHOE BOX (UNITARY) MICRO

 The Configuration of PLC
The configuration of PLC refers to the packaging of the components.

Typical configurations are listed below from largest to smallest.

Rack Type : A rack is often large (up to 18 by 30 by 10) and

these use a range of modules that use together to build up a
system.

Shoebox: A compact, all-in-one unit that has limited expansion

capabilities. Lower cost and compactness make these ideal for
small applications.

Micro: These units can be as small as a deck of cards. They tend

to have fixed quantities of I/O and limited abilities, but costs will
be lowest.
 Most Basic of PLC Systems
In the most basic of PLC systems, a self contained (shoe box)
PLC has 2 terminal blocks, one for Inputs and one for Outputs

Today, most PLCs in this category are know as Micrologix.

Typically they provide front panel LED status indication of I/O
and Processor states

Inputs Outputs

Programmable
Controller
C
R
 Modular Chassis Based PLCs
The vast majority of PLCs installed today are modular chassis
based systems consisting of:

1. Processor Module (CPU)

2. Input & Output Modules

3. Chassis

4. Power Supply
Modular Chassis Based PLCs
 Sizing of PLC
Micro PLCs: I/O up to 32 points

Small PLC: I/O up to 128 points

Medium PLC: I/O up to 1024 points

Large PLC: I/O up to 4096 points

Very Large: I/O up to 8192 points

Overview of Technology
 Basic PLC Schema
CPU

Power Supply

Memory

Input Module

Output Module

Programming devices

Communications

Expansion Connections
CPU Module
 CPU Module Contd
The Central Processing Unit (CPU) Module is the brain of the
PLC.

CPU architecture may differ from one manufacturer to another,

but in general, most CPUs follow this typical three-component
organization (Processor, Memory, Power Supply)

The term CPU is often used interchangeably with the word

Processor; however, the CPU encompasses all of the necessary
elements that form the intelligence of the systemthe processor
plus the memory system and power supply
 PLC Operating Cycle
The basic function of a
Self Scan
programmable controller is to Check Inputs
read all of the field input devices
PLC Program
and then execute the control SCAN
program, which according to the
logic programmed, will turn the Update Execute
Outputs Code
field output devices ON or OFF.

A PLC works by continually

scanning a program
 PLC Operating Cycle Contd.
START
Housekeeping
Internal checks on
memory, speed and
operation. Service any
communication
requests, etc.
Output Scan
The Output Image
data is transferred to
the external output
circuits, turning the
output devices ON or
OFF.
Input Scan
The status of external inputs
(terminal block voltage) is
written to the Input image
(Input file).
Program Scan
Each ladder rung is
scanned using the data in
the Input file. The resulting
status (Logic being solved)
is written to the Output file
(Output Image).
 Scan Time

The scan time is the total time the PLC takes to complete
the program and I/O update scans
 Scan Time Contd
The program scan time generally depends on two
factors:

the amount of memory taken by the control program

the type of instructions used in the program (which

affects the time needed to execute the instructions)

The time required to make a single scan can vary from a

few tenths of a millisecond to 50 milliseconds.
 Power Supply
The system power supply plays a major role in the total
system operation.

Its responsibility is not only to provide internal DC voltages to

the system components (i.e., processor, memory, and
input/output interfaces), but also to monitor and regulate the
supplied voltages and warn the CPU if something is wrong.

PLC power supplies require input from an AC power source;

however, some PLCs will accept a DC power source. Most
PLCs, however, require a 120 VAC or 220 VAC power source,
while a few controllers will accept 24 VDC.
 Memory
The memory includes pre-programmed ROM memory
containing the PLCs operating system, driver
programs and application programs and the RAM
memory.

PLC manufacturer offer various types of retentive

memory to save user-programs and data while power
is removed, so that the PLC can resume execution of
the user-written control program as soon as power is
restored.
 Memory contd
Many PLCs also offer removable memory modules,
which are plugged into the CPU module.

Memory can be classified into two basic categories:

volatile and non-volatile.

- Volatile memory is that which loses state (the

stored information) when power is removed.

- Non-volatile memory, on the other hand, maintains

the information in memory even if the power is
interrupted.
 Memory contd

Some types of memory used in a PLC

include:

ROM (Read-Only Memory)

This memory is permanent and cannot be erased. It is

often used for storing the operating system for the PLC.
 Memory contd
RAM (Random Access Memory)

This memory is fast, but it will lose its contents when

power is lost, this is known as volatile memory. Every PLC
uses this memory for the central CPU when running the
PLC.

For the most part, todays programmable controllers use

RAM with battery support for application memory.

Random-access memory provides an excellent means for

easily creating and altering a program, as well as allowing
data entry
 Memory contd
EEPROM (Electrically Erasable Programmable Read-Only Memory)

This memory can store programs like ROM. It can be

programmed and erased using a voltage, so it is becoming more
popular than EPROMs.

Several of todays small and medium-sized controllers use

EEPROM as the only memory within the system. It provides
permanent storage for the program and can be easily changed
with the use of a programming device (e.g., a PC) or a manual
programming unit.
 Application Memory
The application memory stores
programmed instructions and any
data the processor will use to
perform its control functions.

The controller stores all data in

the data table section of the
application memory, while it
stores programmed instructions in
the user program section.
 Application Memory Contd
The input table is an array
of bits that stores the status
of digital inputs connected to
the PLCs input interface.
The maximum number of
input table bits is equal to the
maximum number of field
inputs that can be connected
to the PLC
 Application Memory Contd
The output table is an array of
bits that controls the status of
digital output devices that are
connected to the PLCs output
interface. The maximum
number of bits available in the
output table equals the
maximum number of output
field devices that can interface
with the PLC.
 I/O Modules
Input and output (I/O) modules connect the PLC to
sensors and actuators.

Provide isolation for the low-voltage, low-current signals

that the PLC uses internally from the higher-power
electrical circuits required by most sensors and actuators.

Wide range of I/O modules available including: digital

(logical) I/O modules and analog (continuous) I/O
modules.
 Inputs Modules
Inputs come from sensors that translate physical or
chemical phenomena into electrical signals.

The simplest form of inputs are digital/discrete in AC/DC.

In smaller PLCs the inputs are normally built in and are

specified when purchasing the PLC.

For larger PLCs the inputs are purchased as modules, or

cards, with 8,16, 32, 64, 96 inputs of the same type on
each card.
 Inputs Modules Contd
The list below shows typical ranges for input
voltages.
5 Volts DC TTL level

24 Volts AC/DC

48 Volts AC/DC

110 Volts AC/DC

220 Volts AC/DC

An AC/DC Input
Block diagram

Circuit
 SOURCING vs. SINKING

Sensor With PNP Sensor With NPN

Output Output
(Sourcing) (Sinking)
 Sinking DC Inputs

When a PLC input card does not have a common but it has
a V+ instead, it can be used for NPN sensors. In this case
the current will flow out of the card (sourcing) and we must
switch it to ground.
 Sourcing DC Inputs

When we have a PLC input card that has a common then we

can use PNP sensors. In this case the current will flow into
the card and then out the common to the power supply.
 Rules
Sourcing field devices must be connected
to sinking I/O cards

Sinking field devices must be connected to

sourcing I/O cards
 Device connections
for an AC input module for DC input module
 Input Devices
Pushbuttons
Selector Switches
Limit Switches
Level Switches
Photoelectric Sensors
Proximity Sensors
Motor Starter Contacts
Relay Contacts
Thumbwheel Switches
 Outputs Modules
Output modules rarely supply any power, but instead act as
switches.

External power supplies are connected to the output card and

the card will switch the power on or off for each output.

A common choice when purchasing output cards is relays,

transistors or triacs.

Relay are the most flexible output devices. They are capable
of switching both AC and DC outputs. But, they are slower,
cost more, and they will wear out after millions of cycles.
An AC Output

Circuit
 DC Output
As in DC inputs, DC output modules may have either sinking or
sourcing configurations. If a module has a sinking
configuration, current flows from the load into the modules
terminal, switching the negative (return or common) voltage to
the load. The positive current flows from the load to the
common via the modules power transistor.

In a sourcing module configuration, current flows from the

module into the load, switching the positive voltage to the load
An Example of a 24Vdc Output Card With a
Voltage Input (Sourcing)
An Example of a 24Vdc Output Card (Sinking)
 Relays

When using relay outputs it is possible to have each output

isolated from the next. A relay output card could have AC and DC
outputs beside each other.

Relay outputs are usually used to control up to 2 amps or when a

very low resistance is required. Transistor outputs are open
collector common emitter or emitter follower
An Example of a Relay Output Card
 Outputs
Typical output voltages are listed below,
5 Volts DC TTL level

24 Volts AC/DC

48 Volts AC/DC

110 Volts AC/DC

220 Volts AC/DC

WARNING: Always check rated voltages and currents for PLCs and
never exceed.
 Output Devices
Valves
Motor Starters
Solenoids
Control Relays
Alarms
Lights
Fans
Horns
Programmable controller I/O
connection diagram
 Analogue Cards
Typical Analogue Input Analogue Output signals
signals are: control:
Flow sensors Analogue Valves
Humidity sensors Variable Speed Drives
Pressure sensors Typical Analogue Signal
Temperature sensors Levels

Vibration 4 - 20mA
1 - 5 Vdc
0 - 10 Vdc
-10 10Vdc
 Analogue Inputs/Outputs
Analogue input cards convert continuous signals via a
A/D converter into discrete values for the PLC

Analogue output cards convert digital values in then PLC

to continuous signals via a D/A converter.

Resolution can be important in choosing an applicable

card
 Programming Devices
PLC manufacturers have always maintained an easy human
interface for program entry. This means that users do not have to
spend much time learning how to enter a program, but rather they
can spend their time programming and solving the control problem.

Most PLCs are programmed using very similar instructions. The

only difference may be the mechanics associated with entering the
program into the PLC, which may vary from manufacturer to
manufacturer

The two basic types of programming devices are:

Mini-programmers

personal computers
Mini-Programmers
 Mini-Programmers Contd
Mini-programmers, also known as handheld or manual
programmers, are an inexpensive and portable way to program
small PLCs (up to 128 I/O).

Mini-programmers can also be useful tools for starting up, changing,

and monitoring the control logic

Some mini-programmers offer removable memory cards or modules,

which store a complete program that can be reloaded at any time
into any member of the PLC family

Most mini-programmers are designed so that they are compatible

with two or more controllers in a product family
 Personal Computer
Common usage of the personal computer
(PC) in our daily lives has led to the
practical elimination of dedicated PLC
programming devices.

Due to the personal computers general-

purpose architecture and standard
operating system, most PLC manufacturers
provide the necessary PC software to
implement ladder program entry, editing,
documentation, and real-time monitoring of
the PLCs control program.
 Selecting a PLC
Number of logical inputs and outputs

Memory

Number of special I/O modules

Expansion Capabilities

Scan Time

Communication

Software

Support

Dollars
Example of PLC Specifications
 Manufactures
Major Brands
OMRON

Allen Bradley

Schneider (Modicon, Telemecanique, Square D)

GE Fanuc

Siemens

Automation Direct (Koyo)

Toshiba

Mitsubishi

Hitachi
 Programming PLCs
The purpose of a PLC Program is to control the state of PLC
outputs based on the current condition of PLC Inputs

A program is a connected series of instructions written in a

language that the PLC can understand.

There are three forms of program format:

instruction: a word/mnemonic entry system

Ladder: a graphical program construction method using a

relay logic symbols

SFC (Sequential Function Chart) :a flow chart style of STL

(STep Ladder) program entry
 Programming PLCs Contd

Not all programming tools can work in all programming forms.

Generally hand held programming panels only work with
instruction format while most graphic programming tools will
work with both instruction and ladder format. Specialist
programming software will also allow SFC style programming.
Programming PLCs Contd
 Ladder Logic Concepts

Read / Conditional Write / Control

Instructions Instructions
Start (Rung #1) || ()

|| |/| ()

|| || |/| ()

|| |/| ()
||

End (Rung #5) || |/| ()

 Ladder Logic Concepts
The vertical line of the diagram represent the power
rails
Each rung on the ladder defines one operation in
the control process
Ladder diagram is read from left to right and from
top to bottom
Each rung must start with an input or inputs and
must end with at least one output
One device can appear in more than one rung of
ladder
Inputs and outputs are all identified by their address
the notation used depending on the plc manufacture
Ladder Logic Concepts
 Advantages Of PLC
The advantages they offer are:

Cost effective for controlling complex systems

Flexible and can be reapplied to control other systems

quickly and easily

Trouble shooting aids make programming easier and

reduce downtime

Reliable components, ensure operation for years

Variety of I/O interfaces

 Advantages Of PLC Contd
Small size

Growing with technology, faster scan times, capability etc

Quick I/O disconnects that aids in field servicing

Software Timers/Counter, Relays

Clean failure mode

On-line programming

Availability of replacement parts

 Input Devices
The most common class of input interfaces is digital (or
discrete).
Discrete input interfaces connect digital field input
devices (those that send noncontinuous, fixed-variable
signals) to input modules of programmable controller.
The discrete, noncontinuous characteristic of digital input
interfaces limits them to sensing signals that have only
two states (ON/OFF, OPEN/CLOSED, TRUE/FALSE). To
an input interface circuit, discrete input devices are
essentially switches that are either open or closed,
signifying either 1 (ON) or 0 (OFF).
 Input Devices Contd
Analog signals have an infinite number of states.
Temperature, for example, is an analog signal because it
continuously changes by infinitesimal amounts.
Consequently, a change from 70F to 71F is not just
one change of 1F, but rather an infinite number of
smaller changes of a fraction of a degree.
Analog input modules digitize analog input signals,
thereby bringing analog information into the PLC
 Mechanical Switch
The mechanical switch generates an on/off signal or
signals as a result of some mechanical input causing the
switch to open or close
Switches are available with normally open (NO) or
normally close (NC)
NO contact has its contact open in the absence of a
mechanical input and the mechanical input is used to
close the switch
NC contact has its contact closed in the absence of a
mechanical input and the mechanical input is used to
open the switch
 Mechanical Switch contd
1. On/Off switch (Toggle switch)

2. Limit switch
 Mechanical Switch contd
3. Limit switch
 Proximity switches
Proximity sensors are discrete sensors
that sense when an object has come near
to the sensor face. There are four
fundamental types of proximity sensors
the inductive proximity sensor, the
capacitive proximity sensor, the ultrasonic
proximity sensor, and the optical proximity
sensor.
 Inductive Proximity Sensor
Inductive proximity sensors operate on the principle that
the inductance of a coil vary as a metallic (or
conductive) object is passed near to it. Because of this
operating principle, inductive proximity sensors are only
used for sensing metal objects. They will not work with
non-metallic materials.
Small diameter sensors (approximately in diameter)
have typical sensing ranges in the area of 1mm, while
large diameter sensors (approximately 3" in diameter)
have sensing ranges in the order of 50mm or more
Inductive Proximity Sensor contd
 Capacitive Proximity Sensor
Capacitive proximity sensors are available in shapes and
sizes similar to the inductive proximity sensor
capacitive proximity sensors will sense both metallic and
non-metallic objects.
The principle of operation of the sensor is that an internal
oscillator will not oscillate until a target is moved close to
the sensor face. The target varies the capacitance of a
capacitor in the face of the sensor that is part of the
oscillator circuit.
The Ultrasonic Proximity Sensor
An ultrasonic ping is sent from the face of the sensor. If
a target is located in front of the sensor and is within
range, the ping will be reflected by the target and
returned to the sensor.
When an echo is returned, the sensor detects that a
target is present, and by measuring the time delay
between the transmitted ping and the returned echo, the
sensor can calculate the distance between the sensor
and the target.
The Ultrasonic Proximity Sensor
 Optical Proximity Sensor
Optical sensors are an extremely popular
method of providing discrete-output sensing of
objects. Since the sensing method uses light, it
is capable of sensing any objects that are
opaque.
They operate over long distances (as opposed
to inductive or capacitive proximity sensors), will
sense in a vacuum (as opposed to ultrasonic
sensors), and can sense any type of material no
matter whether it is metallic or nonmetalic
Transmissive Type
Reflective Type
 Benefits

The benefits achieved with programmable

controllers will grow with the individual using
them:

The more you learn about PLCs, the more you

will be able to solve other control problems.
Thank you.

Questions ?