PLC and Industrial Drives LAB Lab 01

Introduction to Programmable Logic Controller and its peripherals

Objectives

This exercise aims to study the basic microcontroller architecture and get introduced to a
Programmable Logic Controller (PLC).
Introduction to Microcontroller

In a broader sense, the components which constitute a microcontroller are the memory, peripherals,
and most crucially a processor. Microcontrollers are present in devices where the user has to exert a
degree of control. They are designed and implemented to execute a specific function such as
displaying integers or characters on an LCD module of a home appliance. The application of
microcontrollers is myriad. In simpler terms, any gadget or equipment that has to deal with
functions such as measuring, controlling, displaying, and calculating the values consists of a
microcontroller chip. They are present in almost all the present-day home appliances, toys, traffic
lights, office instruments, and various day-to-day appliances.

Figure 1: Microcontroller Architecture

The most important part of a microcontroller is a central processing unit with a word length ranging
from 4-bit to 64-bit and in some modern microcontrollers the word length goes even beyond the
limit of 64-bit. A timer is one other constituent of a microcontroller. There is a watchdog timer.
Memory spaces such as RAM, ROM, EEPROM, and EPROM are there to store data and programs.
For data storage, volatile memory RAM is used while for the program and operating parameter
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storage ROM and other memory spaces are used.

CPU: Being regarded as the brain of the microcontroller, the central processing unit fetches,
decodes, and executes the instructions. It coordinates various activities taking place in the
microcontroller.

I/O ports: A microcontroller has several parallel input/output ports. They are used to interface
various peripherals such as printers, external memories, LEDs, and LCDs to the microcontroller.
Apart from parallel ports, there are serial ports to interface serially connected peripherals with the
microcontroller.

Memory: As in the case of a microprocessor, a microcontroller has spaces for memories such as
RAM, and ROM including EEROM and EPROM. It also allocates a certain amount of flash
memory to store program source code.

Timers and counters: These are the fascinating constituent parts of a microcontroller. Timers and
counters are used in operations which include modulation, clock functions, frequency generation,
and measuring and pulse generation.

Analog to digital converters (ADCs): Such converters are useful while converting the output of a
sensor which would be in analog form.

Digital to analog converter (DAC): The working of a DAC is just the reverse of an analog to
digital converter. As it is obvious, the output will be an analog signal which can be used to control
the analog peripherals such as a motor.

Features of a Microcontroller:
 The main advantage of a CISC (complex instruction set computer) architecture, with which the
modern microcontrollers are built, is the macro-type instructions. A macro instruction can be used
in a program to replace several instructions.
 The latest microcontrollers are operated at lesser power consumption. Usually, they can
support a working voltage of 1.8-5.5 V.
 Advanced memory is another feature of a microcontroller. The use of ROM memories like
EEPROM and EPROM (flash memory) makes them more reliable and user-friendly. While
EEPROM is a relatively slow memory, EPROM is faster. The fact that it allows more erase/write
cycles also makes it more usable.

Advantages:
The main advantage of a microcontroller is the low cost with all the integral parts mounted together
on a single chip. The design makes it more compact and easier to use. The easiness of using a
microcontroller and the relatively easy maintenance process also make it more reliable. Almost all
the pins in a microcontroller are programmable and it makes the microcontroller a lot more user-
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friendly. The simplicity of the microcontroller, while interfacing ROM, RAM, and I/O ports.
Easiness of troubleshooting and a minimal time requirement for various operations are other crucial
advantages.

Disadvantages:
Since it contains all the components on a single chip, microcontrollers are having relatively
complex architecture. Microcontrollers are not suitable to interface high power devices directly and
they can only perform a limited number of operations simultaneously.

Comparing Microcontroller with a Microprocessor

Microprocessor:
 It has only the CPU inside; i.e., the processing powers such as Intel’s Pentium 1,2,3,4 core
2 duos, i3, i5, etc.
 Don’t have RAM, ROM, and other peripherals on the chip. The system designer has to add
them externally to make them functional.
 The application includes desktop PCs, laptops, notepads, etc.
 Applications are where tasks are unspecific like developing software, games, websites,
photo editing, creating documents, etc.
 Since microprocessors cannot be used stand-alone as it needs RAM, ROM, and other
peripherals the system that uses microprocessors is costlier than a microcontroller.
 The clock speed of the microprocessor is quite high as compared to the microcontroller.
This can operate above 1 GHz as they perform complex tasks.

Microcontroller:
 In a microcontroller CPU, RAM, ROM, and other peripherals are embedded on a single
chip.
 At times it is termed a mini-computer or a computer on a single chip.
 Some giants in the manufacturing business of microcontrollers are ATMEL, microchip, TI,
Freescale, Philips, Motorola, etc.
 Designed to perform specific tasks. i.e., the relationship between the input and output is
defined.
 Since the applications are very specific, they need small resources like RAM, ROM, and
I/O ports and hence can be embedded on a single chip.
 The clock speed of a microcontroller varies from a few MHz to 30-50 MHz

Introduction to Programmable Logic Controller (PLC)

Programmable logic controllers (PLCs) were introduced to the industry between 1968 and 1970 as a
 PLC and Industrial Drives LAB Lab 01
way to replace large expensive panels of relays, timers, and counters. Automotive manufacturers
were looking for ways to simplify the start-up of new car lines after model changeovers each year
and save money on the cost of manufacturing installations.

Historically, relays have been used since the late 1800s to control simple processes. They were
used in the early days to control railroad crossings. Before simple relay logic was introduced to
control railroad crossing arms and alarm lights, accidents at these crossings were contributing to
a high toll on human life.

The term “relay” was coined as the name of the device invented by Samuel F. B. Morse who
invented the telegraph. The relay was invented as a device to extend the signal or “relay” the
signal of the telegraph more than the 20-mile limit of electrical signals at the time of the
the invention of the telegraph (1836).

Relays, timers, and counters had been the favored choice for electrical and systems engineers to
manufacturing facilities, especially in facilities with a large number of machines making discrete
parts. Automotive manufacturers top the list of this type of manufacturing. At the same time that
costs continued to rise for the engineering and construction of automotive assembly lines,
computers were becoming more numerous and less costly. There was, however, a general
discomfort among engineers to replace relays with computers. Most were reluctant to place the
computer on the plant floor. A compromise was necessary for the engineer so that he would be
willing to accept. A computer that appeared to be relay-ladder logic to the electrician but was able
to use the computing capabilities of a computer was the device envisioned. The result of this vision
is what is known today as the PLC (Programmable Logic Controller).

Relays as well as timers and counters were the first devices replaced by the PLC. Relays are
electromechanical devices that use magnetism caused by power flow through the circuit's coil to
energize a core and move a plunger with contacts attached. Contacts change state when the coil
is magnetized. Normally open contacts close while normally closed contacts open. Changing
contacts combine to complete other circuits. Combinations of relay contacts energizing coils
form the basis of Boolean logic. Boolean logic deals with the combination of discrete on-off
states to turn on or off other outputs.

The principle of using PLCs as substitutes for relays to reduce the wiring, panel fabrication, and
engineering cost looked very appealing to the early PLC user. Like most electronic devices
appearing in the early ‘70s, the cost of the early PLC was high and functionality was not well
developed. Early PLCs were developed around a mini-computer or special purpose control
board.

How Do PLCs Work?

The block diagram of PLC consists of different components. Each component has associated
specific functions and operations in the PLC. The list of basic components is-

 Input and Output Modules

 Power Supply
 Control Processing Unit (CPU)
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 Memory System
 Programming

See the flowchart below for a visual representation of the steps above.

Figure 2: Block Diagram of PLC

Functions of various blocks of PLC

1) Input and Output (I/O) Modules:

The input/output modules in PLC are of two types. It can be either digital or analog.
Just like any other device or machine, we have to provide input to the PLC controller.
It yields output. For example, when the user presses a button, the motor starts. Here
the switch button is input. The motor is an output device. In PLC, to take the input
and to return the output, there are I/O modules. The input modules are used for
providing an interface for input devices like different types of switches (push button
switch, selector switch, limited switch), sensors, etc. The output modules are used
for providing an interface for output devices like motor, fan, relay, light, lamp,
electric heater, solenoid valve, buzzer, etc.

2) Power Supply:
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For PLC, we need an electrical power supply. The power supply provides power to all other
components to operate. It provides power to the input/output modules,
memory system, and processor. The function of the power supply is to provide the
DC or AC power to operate the PLC. Most of the PLCs work at 220VAC or 24VDC.

3) Central Processing Unit (CPU):

The Central Processing Unit is the heart of the PLC system. The function of the CPU is to
store and run the PLC software programs. It helps to perform the basic arithmetic,
logic, controlling, and input/output operations specified by the instructions. It
consists of the three subparts as memory, processor, and power supply.

4) Memory System:
A memory system is responsible for storing and retrieving data and information.

5) Programming Device:
It is the platform where the program or the control logic is written. It can be a
handheld devise or a laptop or a computer itself.

Types of PLC :

1) Compact PLC
2) Modular PLC

 What is a Compact PLC?

It is also called Integrated PLC or Fixed PLC. The compact PLC has a fixed number of
input/output modules along with a power supply and CPU.

Figure 3: Block Diagram of Compact PLC

Types of Compact CPU

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 DC/DC/RLY
 DC/DC/DC
 AC/DC/RLY
1st/2nd/3rd
1) In the first position: the power supply voltage; is 24 V DC or 120/230 V AC.
2) In second place: is the input type voltage: only 24 V DC is available.
3) In the third position: the output type and power.

 DC: 24 V DC MOSFET transistor, 0.5 Amp max per channel;

 RLY: 5-30 V DC or 5-250 V AC relay, 2 Amps max. per channel.

 What is a Modular PLC?

It consists of a variable number of inputs and outputs. Inputs and outputs can be
added to the modular PLC systems by the user. If you look at the below PLC design structure, it
looks more like a rack. So, it is also called rack-mounted PLC.

Figure 4: Block Diagram of Modular PLC

PLC Peripherals

 Input Devices
 Output Devices
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Figure 5: Peripherals of PLC

Advantages of PLCs over Electromagnetic Relays

The PLC replaces electromechanical relays due to the following advantages

1) PLCs are more reliable and faster in operation.

2) They are compact and can be expanded easily.

3) They require less electrical power.

4) They are less expensive when compared to Hardwired systems of the same number of control
functions.

5) Hard-wired electromechanical relays lack flexibility.

6) For example, when system operation requirement changes, then the relays have to be rewired.

7) PLCs have very few hardware failures when compared to electro-mechanical relays.

8) Special functions such as time-delay actions and counters, can be easily performed using PLCs.
 PLC and Industrial Drives LAB Lab 01
Different Types of PLC Programming Languages
Based on the “International Electrotechnical Commission (IEC)” standard, PLC programming
languages are classified into five main standards.

1. Ladder diagram (LD)

2. Instruction List (IL)

3. Structured Text (ST)

4. Function Block Diagram (FBD)

5. Sequential Function Charts (SFC)

These languages are accepted internationally. Among all of them, mostly Ladder diagram (LD)
programming language is used in the industry.

Figure 6: PLC Programming Language

A simple chart of the PLC programming language classification

1. Ladder diagram (LD)

A ladder diagram (LD) is also known as “Ladder Logic “. It is used with programmable logic
controllers. Generally, the Ladder diagram is most popular all over the world (including India). This
language is easy to learn. If you look at the ladder diagram, it looks similar to the electrical circuit
diagram.

Advantages of LD:
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1) LD is simple logic construction and more reliable than an electronic circuit controller.
2) Easy to learn and read the program.
3) Every programming symbol performs specific actions.
4) It has a good representation of discrete logic
5) Easy to troubleshoot
6) Shut down the power without the switch (i.e., hardware devices)

2. Instruction List (IL)

Instruction List (IL) is another type of PLC programming language. It 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.

Advantages of IL:

1) It has a high execution speed.

2) It takes less memory as compared to other programming languages.

3. Structured Text (ST)

The “ST” and “STX” are also other abbreviations used for Structured Text PLC language. 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.

Advantages of ST:

1) ST is very easier to understand for both novice and experienced programmers.

2) Because of its standard coding format, it is easy to edit and modify programs written in ST
language.

4. Function Block Diagram (FBD)

Function block diagram (FBD) is a popular and easy way to write a program like a Ladder Diagram.
FBD is represented like a box which consists of several lines of code for putting different
programming functions. It is a graphical language for programming logic controller. So, it makes
your job easy to describe a system.

5. Sequential Function Charts (SFC)

Sequential function charts (SFC) is also a graphical programming language. It is not a text base. 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 makes it easier to troubleshoot and change the code if problems
occur.
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List of PLC manufacturers:
 ABB
 Allen Bradley
 Siemens
 Mitsubishi
 Honeywell
 Motorola
 Hitachi
 General Electric
 Modicon
 Schneider Electric
 Panasonic
 Alstom
 Bosch
 Delta
 Devolo
 Echelon
 Omron
 ON Semiconductor
 Qualcomm Atheros
 SiConnect

Siemens PLC Models

 S7 200: -
 Compact Type PLC.
 Use for small-scale industry.
 CPU Available – CPU 212 to CPU 226.

 S7 300: -
 Compact and Modular type PLC
 Use for Small and Medium Scale industry.
 CPU Available – CPU 312 to CPU 318.

 S7 400: -

 Modular Type PLC.

 Use for Large Scale industry.
 DP Port Available.
 CPU Available – CPU 412 to CPU 418.

 S7 1200: -
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 Compact and Modular type PLC
 Use for Small and Medium Scale industry.
 CPU Available – CPU 1211C to CPU 1217C.

 S7 1500: -
 Modular type PLC
 Use for Medium and Large-Scale industry.
 CPU Available – CPU 1511 to CPU 1518.

Siemens PLC Hardware

Over view of S7 1500 1512c-1 PN

Figure 7: PLC Hardware

View of the CPU

The figure below shows the CPU part of the CPU 1512C-1 PN
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Figure 8: View of CPU

Analog onboard I/O View

The following figure shows the analog onboard I/O (X10) of the CPU 1512C-1 PN

Figure 9: View of Analog I/O's Module

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Properties
The analog onboard I/O has the following technical properties:

 Analog inputs
1) 5 analog inputs
2) Resolution 16 bits including sign
3) Voltage measurement type can be set individually for channels 0 to 3
4) Current measurement type can be set individually for channels 0 to 3
5) Resistor measurement type can be set for channel 4
6) Thermal resistor measurement type can be set for channel 4
7) Configurable diagnostics (per channel)
8) Hardware interrupt on limit violation can be set per channel (two low and two high
limits in each case)
9) Support of the value status (Quality Information, QI)

 Analog outputs
1) 2 analog outputs
2) Resolution: 16 bits incl. sign
3) Voltage output selectable by channel
4) Current output selectable by channel
5) Configurable diagnostics (per channel)
6) Support of the value status (Quality Information, QI)

How Much Analog Inputs are in this module?

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How Much Analog Outputs are available in this Module?

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Maximum Input voltage?

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Maximum Output voltage?

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 PLC and Industrial Drives LAB Lab 01

Digital on-board I/O View

The following figure shows the digital onboard I/O (X11 and X12) of the CPU 1512C-1 PN

Figure 10: View of Digital I/O's Modules

Properties
The digital on-board I/O has the following technical properties:

 Digital inputs
1) 32 high-speed digital inputs for signals up to max. 100 kHz
The inputs can be used as standard inputs and as inputs for technology functions.
2) Rated input voltage 24 V DC
3) Suitable for switches and 2-/3-/4-wire proximity switches
4) Configurable diagnostics
5) Hardware interrupt can be set (for each channel)
6) Support of the value status (Quality Information, QI)

 Digital outputs
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1) 32 digital outputs, 8 of which can be used as high-speed outputs for technology functions
The outputs can be used as standard outputs and as outputs for technology functions.
2) Rated output voltage 24 V DC
3) Rated output current
4) as output for standard mode 0.5 A per channel
5) as output for technology functions, you can select between an output current of up to 0.5 A for an
output frequency up to 10 kHz (load dependent) and a reduced output the current of max. 0.1 A at
an increased output frequency of up to 100 kHz
6) Suitable for, e.g., solenoid valves, DC contactors, and indicator lights or also for signal transmission
or for proportional valves
7) Configurable diagnostics
8) Support of the value status (Quality Information, QI)

How Much Digital Inputs are in this module?

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How Much Digital Outputs are available in this Module?

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Maximum Input voltage?

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Maximum Output voltage?

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What is meant by DI16/DQ16 x 24VDC?

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What is meant by DI32 x 24VDC?

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