PLC

Programmable Logical
Controller
 Index
1. What is PLC? 13.What we required to Program PLC?
2. Architecture of PLC. 14.Wiring Of PLC.
3. Types of PLC. 15.Various Manufacturers of PLC &
Programming Software.
4. Types of Input & Output Modules.
5. How PLC Works? 16.Application Areas of PLC
17.Advantages of PLC.
6. What is Scan Time in PLC?
7. PLC Selection Criteria
8. Protocol
9. Programming Languages of PLC
10.Addressing of Input & Output in PLC
11.Various Modes of PLC Operation.
12.Various Instruction used in PLC.
 What is PLC?
■ A programmable logic controller (PLC) is an industrial solid-state computer
that monitors inputs and outputs, and makes logic-based decisions for
automated processes or machines.
■ A programmable logic controller (PLC) is an Electronic device used for
automation of electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or lighting fixtures.
■ PLC is Industrial Control Hardware which connect between Field Input devices
and Field output Devices.
■ PLCs are used in many industries and machines, PLC is designed for multiple
inputs and output arrangements.
■ To meet the demands of harsh industrial environments, PLCs are designed to
be extremely robust, often capable of withstanding extreme temperatures,
humidity, vibration, and electrical noise.
Architecture of PLC
1. Input Module
2. Output Module
3. CPU (Central
Processing Unit)
4. Bus System
5. Power Supply Module
6. Memory
 Architecture of PLC
■ CPU – Keeps checking the PLC controller to avoid errors. They perform
functions including logic operations, arithmetic operations, computer
interface and many more.
■ Memory – Fixed data is used by the CPU. System (ROM) stores the data
permanently for the operating system. RAM stores the information of the
status of input and output devices, and the values of timers, counters and
other internal devices.
■ I/O section – Input keeps a track on field devices which includes sensors,
switches.
■ O/P Section - Output has a control over the other devices which includes
motors, pumps, lights and solenoids. The I/O ports are based on Reduced
Instruction Set Computer (RISC).
■ Power supply – Certain PLCs have an isolated power supply. But, most of
the PLCs work at 220VAC or 24VDC.
 Architecture of PLC
■ Programming device – This device is used to feed the program into the
memory of the processor. The program is first fed to the programming
device and later it is transmitted to the PLC’s memory.
■ System Buses – Buses are the paths through which the digital signal flows
internally of the PLC. The four system buses are:
■ Data bus is used by the CPU to transfer data among different elements.
■ Control bus transfers signals related to the action that are controlled
internally.
■ Address bus sends the location’s addresses to access the data.
■ System bus helps the I/O port and I/O unit to communicate with each other.
 Types of PLC
 Integrated or Compact PLC:
Built by several modules within a single case. Therefore, the I/O
capabilities are decided by the manufacturer, but not by the user.
 No I/O Expandable
 Modular PLC:
Built with several components that are plugged into a common rack
or bus with extendable I/O capabilities. It contains power supply
module, CPU and other I/O modules that are plugged together in
the same rack, which are from same manufacturers or from other
manufacturers.
 I/O Expandable
Types of Input & Output Modules
■ Input Modules:
 Discrete or digital input signals are two-state signals:
– Input ON or OFF, 1 or 0
 Analog input signals are values:
– 0 to 10 volts DC
– -10 to +10 volts DC
– 4 to 20 milliamps
■ Input Modules:
 Triac Type – For A.C. Supply only
 Tansistor Type – For D.C. Supply only
 Relay Type – For A.C./D.C. both Supply
 How PLC Works?
■ The PLC receives information from connected sensors or
input devices, processes the data, and triggers outputs
based on pre-programmed parameters.
■ It depending on the inputs and outputs, a PLC can
monitor and record run-time data such as machine
productivity or operating temperature, automatically start
and stop processes, generate alarms if a machine
malfunctions, and more.
■ Programmable Logic Controllers are a flexible and robust
control solution, adaptable to almost any application.
 What is Scan Time PLC?
■ PLC Scan Time
 PLC scan time is a time needed for PLC
to completely Scan one cycle of PLC. It
may consist of reading PLC input status,
clearing PLC memory, Executing the PLC
program and updating the Output. It is
sometimes needed PLC with less scan
time but it finds costly.
 There is Delay in Scan Time.
 I/O Delay:
It is Time to take signal and reach it
from Input Devices to CPU and CPU to
Output Devices.
 Selection Criteria of PLC
 Application requirements.
 What number input/output capacity is required?
 What type of inputs/outputs are required?
 What size of memory is required?
 What speed is required of the CPU?
 Electrical requirements.
 Speed of operation.
 Communication requirements.
 Physical environments.
 Protocol of PLC
■ A protocol is a set of rules for communication among
networked devices.
■ Types of Protocol.
 DH+
 RS – 232 / 485 / 422
 MODBUS
 DEVICENET
 PPI / MPI
 UNITELWAY
 PROFIBUS
 CANOPEN
 ETHERNET
 TCP/IP
Programming Languages of PLC
■ Total Five Types of Languages are used to Program PLC.
1. Ladder Logic
2. SFC – Sequential Flow Chart
3. FBD – Functional Block Diagram
4. Instruction List
5. Structure Text
 Addressing Input & Output in PLC
 Addressing types:
1. Byte  0 to 7 bit in use
2. Word  0 to 15 bit in use
INPUT / OUTPUT

I : 0/0 O : 0/0

Module Number
/ Rack Number Slot Number
Addressing Input & Output in PLC
Addressing Input side in PLC
• As we can see here
we have give
address I:1/3 which
means input will go
to slot number 3 of
rack or module
number 1.
• Also the wiring
diagram showing
the sinking wiring
as per input
address of PLC’s
slot.
Addressing Output side in PLC
• As we can see here we
have give address
O:3.1/11 which means
output will go to slot
number 11 but here in
3.1 number 3 is
module or rack number
and .1 is word element
in which output slot 11
will active on
execution.
• Also the wiring diagram
showing wiring as per
output address of
PLC’s slot.
 Various Modes of PLC Operation
■ Program Mode: The mode in which new programs are entered. The program mode also
used to edit or update existing program and used to upload, download files. When the PLC
is switched into the program mode, all outputs from the PLC are forced off regardless of
their rung logic status.
■ Downloading: Process of transferring Data (Program) from PC to PLC for Test &
Development.
■ Uploading: Process of transferring Data (Program) from PLC to PC for troubleshooting and
updating.
■ Run Mode: The run mode is used to execute the user program. Input devices are
monitored and output devices are energized accordingly, After entering all instruction to a
PLC program, the processor is put into run mode.
■ Test Mode: This feature is often used after developing or editing a program to test the
program execution before allowing the PLC to operate real-world outputs. Without
energizing any output a new or modified program is tested with the inputs or it can be
Simulator to test the program without any Physical Hardare.
Various Instructions Used in PLC
■ NO /NC (Normally Open / Normally Close)
■ Logic Gates (AND/OR/NOT/Universal/Exclusive)
■ Timer (On/Off)
■ Counter (Up/Down)
■ Mathematical
■ Compare
■ Move
■ Increment / Decrement
■ Bit Shift
■ Program Control
■ Scaling
What we required to program PLC
PLC • First need PLC it self for configuration and
programming.
• Then need Programming Software and
Programming Software drivers of appropriate PLC.
• We need any Computer or Laptop or any
Device that provides functionality of
PC / Laptop / HHD programming PLC with given software.
• After installation of software to start
programming of PLC we need total number of
Details & Numbers of Input Input and Output devices and details of
/ Output Devices application.
• After completing Programming we have to
download it in PLC from programming device
Interfacing we need interfacing medium that can
communicate both device, it can be either
Medium For PLC wired or wireless.
• To configure PLC into programming device we
need drivers of given PLC to communicate
OPC Driver with programming device.
 Wiring of PLC
■ There are two methods of Wiring input and output Modules of PLC.
1. Sinking Wiring 2. Sourcing Wiring

• When sinking wiring is done at

Input side the output wiring will
be compulsory Sourcing.

Opposite of that

• When Sourcing wiring is done at

Input side the output wiring will
be compulsory Sinking.

• When –Ve Supply connected to • When +Ve Supply connected to

the Common port of PLC and the Common port of PLC and -Ve
+Ve supply connects to the I/O supply connects to the I/O ports
ports it can be notified as it can be notified as Sinking
Sinking Wiring. Wiring.
 Wiring of PLC

Sinking Wiring at Input Side Sourcing Wiring at output Side

• As we can see in sinking wiring Common bus return means –Ve supply is directly given to
the PLC input and +ve supply is given by switch / pushbutton/ limit switch / Sensor etc.
• In sourcing wiring at output side we can see Common return means –Ve Supply is given to
the all output devices and required +ve supply will provided by PLC after executing
Program inside PLC.
Wiring of Sensor with PLC

• When Sourcing wiring is done at

input side of PLC we can only
connect NPN type Sensor at Input
side.

• When Sinking wiring is done at

input side of PLC we can only
connect PNP type Sensor at Input
side.
 Various Manufacturers of of PLC
■ Schneider  Unity Pro / Twido Suite
■ Rockwell (Allen Bradley)  RS Logix-500 / RS Logix 5000
■ Siemens  Step 7 Microwin / Simetic Manager / TIA Portal
■ Delta  WPL Soft / IP Soft
■ Mitsubishi  GX- Daveloper
■ ABB  AC 31 Graf / Automation Builder
■ Omron  CX- Programmer
■ Beckhoff  TwinCAT
■ Fuji  D300win
■ Bosch Rexroth  IndraWorks
■ Hitachi  Control Editor / Pro-H
 Application Areas of PLC?
■ Glass Industry ■ Automobile Industry
■ Cement Industry ■ Chemical Industry
■ Paper Industry ■ Pharma Industry
■ F & B (Food and Beverages) Industry ■ Packaging Industry
■ Oil & Gas Refineries
■ Power Plants
■ Textile Industry
 Advantages of PLC
1. Less Manpower
2. Low Wiring Cost
3. Accuracy
4. Long life then other Equipment
5. Low Maintenance
6. Easy Troubleshooting
7. Increase Productivity
8. Fast Response
9. Less Space Consuming
10.Flexibility