Introduction to PLC

Programmable Logic Controllers (PLCs) are versatile

industrial computers that automate and monitor complex
processes in manufacturing, transportation, and
infrastructure. They offer precise control, real-time data
processing, and reliable performance that are essential for
modern smart systems.
History of PLC
1 1960s: Invention of PLC
The Programmable Logic Controller (PLC) was invented in the 1960s as a replacement for
complex relay-based control systems used in industrial automation.

2 1970s: Widespread Adoption

PLCs gained popularity in the 1970s as they provided greater flexibility, reduced
maintenance, and easier programming compared to traditional relay-based systems.

3 1980s-1990s: Advancements
PLC technology continued to evolve, with improvements in processing power, memory,
and user-friendly programming interfaces, making them more powerful and versatile.
PLC (Programmable Logic Controller) CPU and I/O (Input/Output) modules are essential
components of industrial automation systems used for controlling and monitoring various
processes in manufacturing, assembly, and other industrial environments. Let's discuss each of
these components:

1.PLC CPU (Central Processing Unit):

1. The PLC CPU is the core component of the programmable logic controller. It consists of a
microprocessor, memory (RAM and ROM), and interfaces for communication with other
devices and modules.
2. The CPU executes the control program stored in its memory, which consists of instructions
written in a programming language such as ladder logic, function block diagrams (FBD),
structured text, or other PLC programming languages.
3. The CPU scans the program cyclically, reading input signals from connected I/O modules,
executing control logic based on the program instructions, and updating output signals to
control actuators and devices.
4. Modern PLC CPUs may also include features such as built-in communication ports (e.g.,
Ethernet, serial), real-time clock, data logging capabilities, and support for advanced
networking protocols.
1.I/O Modules:
1. I/O modules are peripheral devices connected to the PLC CPU that interface with external
sensors, actuators, switches, and other devices in the industrial process.
2. Input modules receive signals from sensors or switches and convert them into digital or
analog signals that the PLC CPU can process. These signals may represent states such as
on/off, high/low, or analog values such as voltage or current levels.
3. Output modules receive control signals from the PLC CPU and convert them into signals
suitable for driving actuators, motors, valves, or other devices in the industrial process.
These signals may activate or deactivate devices, control motor speed, or regulate process
variables.
4. I/O modules come in various types and configurations, including digital input (DI), digital
output (DO), analog input (AI), analog output (AO), specialty modules (e.g., high-speed
counters, temperature sensors), and communication modules for interfacing with external
devices or networks.
5. Some PLC systems support modular I/O architecture, allowing users to add or remove I/O
modules as needed to accommodate changes in the industrial process or expand system
capabilities.
Power Supply and Communication
1.Power Supply:
1. A stable and reliable power supply is essential for the proper operation of PLCs and other
automation equipment in industrial environments.
2. PLCs typically require low-voltage DC power, commonly 24 volts DC, although some
systems may operate at different voltage levels.
3. The power supply unit (PSU) converts incoming AC voltage from the mains power grid
(typically 110VAC or 220VAC) to the required DC voltage for powering the PLC and its
peripherals.
4. Power supplies for PLC systems often include features such as short-circuit protection,
overvoltage protection, and noise filtering to ensure the stability and integrity of the power
output.
5. Redundant power supply configurations may be employed in critical applications to
minimize downtime in the event of a power supply failure.
1.Communication:
1. Communication is vital for PLCs to exchange data with other devices, such as human-
machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems,
sensors, actuators, and other PLCs.
2. PLCs support various communication protocols, including serial (RS-232, RS-485),
Ethernet, and fieldbus protocols such as Modbus, Profibus, DeviceNet, EtherNet/IP, and
Profinet, among others.
3. Communication protocols facilitate data exchange for tasks such as remote monitoring,
control, programming, diagnostics, and integration with higher-level systems.
4. PLCs may include built-in communication ports or slots for adding communication
modules to support different protocols and network architectures.
5. Industrial networking standards such as OPC (OLE for Process Control) and OPC UA
(Unified Architecture) provide standardized interfaces for interoperability between PLCs
and other industrial automation systems.
6. Communication reliability, speed, and security are crucial considerations in industrial
environments, where real-time control and data integrity are essential for safe and efficient
operation.
Input and Output Devices
Input Devices:

Sensors: Sensors detect physical phenomena such as temperature, pressure, proximity,

position, flow, level, and presence of objects. Common types of sensors include:
Proximity Sensors: Inductive, capacitive, and photoelectric sensors detect the presence or
absence of objects without physical contact.
Temperature Sensors: Thermocouples, resistance temperature detectors (RTDs), and
thermistors measure temperature variations.
Pressure Sensors: Pressure transducers and pressure switches measure fluid pressure.
Position Sensors: Encoders, limit switches, and proximity sensors determine the position or
movement of machine components.
Switches: Limit switches, push buttons, toggle switches, and selector switches provide
manual inputs for initiating or stopping processes, changing operating modes, or signaling
events.
Analog Input Modules: Analog input modules convert continuous analog signals (e.g.,
voltage, current) from sensors into digital signals that the PLC can process.
1.Output Devices:
1. Actuators: Actuators are devices that convert electrical signals from the PLC into
physical action, such as movement, rotation, or control of process variables. Common
types of actuators include:
1.Solenoid Valves: Control the flow of liquids or gases in pneumatic or hydraulic
systems.
2.Motor Drives: Control the speed, direction, and torque of electric motors in various
applications.
3.Relays: Electromechanical switches that control higher-power devices such as motors,
lights, or heaters.
4.Pneumatic and Hydraulic Cylinders: Linear actuators that produce mechanical
motion using compressed air or hydraulic fluid.
2. Digital Output Modules: Digital output modules convert digital signals from the PLC
into on/off control signals for actuators, relays, solenoid valves, and other devices.
3. Analog Output Modules: Analog output modules generate continuous analog signals
(e.g., voltage, current) to control variables such as motor speed, valve position, or
temperature.
Need of PLC for Industrial Automation
• Flexibility: PLCs offer high flexibility in programming and reprogramming to
accommodate changes in production processes or system requirements. Their modular
design allows for easy expansion and modification, making them suitable for a wide
range of industrial applications.
• Reliability: PLCs are designed for continuous operation in harsh industrial
environments. They have robust hardware components that can withstand temperature
variations, humidity, vibration, and electrical noise commonly found in industrial
settings. Additionally, PLCs often incorporate redundant features to enhance reliability
and minimize downtime.
• Real-Time Control: PLCs provide real-time control capabilities, allowing for precise
timing and coordination of industrial processes. They can execute control logic with
deterministic timing, ensuring consistent and predictable operation of machines and
equipment.
• Integration: PLCs can interface with a variety of input and output devices, including
sensors, actuators, motors, switches, and other control devices. They support multiple
communication protocols for integration with other automation systems, such as HMIs
(Human-Machine Interfaces), SCADA (Supervisory Control and Data Acquisition)
systems, MES (Manufacturing Execution Systems), and enterprise-level networks.
• Scalability: PLCs are scalable to meet the needs of both small-scale and large-scale
industrial applications. They can control a single machine or manage complex
manufacturing processes across multiple production lines or entire facilities. PLCs can
be configured in modular architectures to accommodate changes in system size or
complexity.
• Ease of Programming: PLC programming languages, such as ladder logic, function
block diagrams (FBD), structured text, and sequential function charts (SFC), are
intuitive and easy to understand for engineers and technicians familiar with industrial
control systems. PLC programming software provides graphical interfaces and
debugging tools to streamline the development and maintenance of control logic.
• Safety: PLCs support safety features and standards required for
industrial automation applications, such as emergency stop circuits,
safety interlocks, and redundant control systems. They help ensure
compliance with safety regulations and standards to protect workers
and equipment from hazardous conditions.
 Types of PLC Modules
1.CPU (Central Processing Unit) Module:
1. The CPU module is the brain of the PLC, responsible for executing control programs,
managing communication with other modules, and coordinating input and output
operations.
2. It typically includes a microprocessor, memory (RAM and ROM), and interfaces for
communication with programming devices, operator interfaces, and I/O modules.
3. The CPU module may also incorporate additional features such as real-time clock, data
logging, and networking capabilities.
2.Digital Input (DI) Module:
1. Digital input modules receive binary signals from sensors, switches, or other devices that
represent on/off or high/low states.
2. Each input channel of the DI module can monitor the status of a discrete input signal and
report it to the PLC's CPU for processing.
1.Digital Output (DO) Module:
1. Digital output modules generate binary control signals to actuate devices such as
relays, solenoid valves, motors, or lights.
2. Each output channel of the DO module can drive a discrete output device based on
commands received from the PLC's CPU.
2.Analog Input (AI) Module:
1. Analog input modules convert continuous analog signals, such as voltage or
current, from sensors or transmitters into digital values that the PLC can process.
2. They are used to monitor variables such as temperature, pressure, flow rate, or
position with higher precision than digital inputs.
3.Analog Output (AO) Module:
1. Analog output modules generate continuous analog control signals, such as voltage
or current, to regulate variables such as motor speed, valve position, or
temperature.
2. They convert digital control signals from the PLC's CPU into analog signals
suitable for driving actuators or control devices.
1.Specialty Modules:
1. Specialty modules provide additional functionality or specialized capabilities to
address specific application requirements.
2. Examples include high-speed counter modules for counting pulses or encoder inputs,
pulse width modulation (PWM) modules for controlling motor speed, and
communication modules for interfacing with external devices or networks.
2.Communication Module:
1. Communication modules enable the PLC to communicate with external devices,
networks, or other PLCs.
2. They support various communication protocols such as Ethernet, serial
communication (RS-232/RS-485), Profibus, Modbus, DeviceNet, and EtherNet/IP,
among others.
Introduction About PLC programming

PLC programming is the process of creating and customizing software for Programmable
Logic Controllers (PLCs). PLCs are industrial computers used to automate and control
various industrial processes.

PLC programming involves using specialized software to create ladder logic diagrams,
function block diagrams, or other programming languages to define the control logic for
the PLC.
Types Of PLC programming Software
Ladder Logic Function Block Diagram
Ladder logic is the most common and widely used Function Block Diagram (FBD) is a graphical
PLC programming language. It uses a graphical programming language where the program is
ladder-like interface to represent program logic. defined as a collection of interconnected function
blocks.

Structured Text Sequential Function Chart

Structured Text (ST) is a high-level, text-based Sequential Function Chart (SFC) is a graphical
programming language that resembles programming language used to represent the
programming languages like C or Pascal. sequential operation of a process or machine.
Ladder Logic Diagram
Contacts:
Rungs:
1. Contacts represent inputs to the PLC, such as switches,
sensors, or internal bits.
Ladder logic diagrams consist of multiple
2. Contacts can be normally open (NO), normally closed
horizontal lines called rungs, representing
(NC), or other types depending on their behavior.
different control sequences or operations.
3. Normally open contacts are represented by an open
Each rung typically represents one logical
horizontal line, while normally closed contacts are
operation or step in the control process.
represented by a diagonal line.

Coils: Branches and Connections:

1. Coils represent outputs from the PLC, such 1. Branches allow multiple contacts to be connected in
as relays, solenoids, motors, or internal bits. series or parallel to form logical expressions.
2. Coils are typically represented by a 2. Horizontal lines represent electrical continuity, while
rectangle, often with a label indicating the vertical lines represent branching connections between
output device or function. rungs.
3. When a coil is energized (i.e., the 3. Intersections between vertical and horizontal lines
corresponding output is activated), it causes indicate where contacts are connected.
the associated device to perform its
intended action.
Timers and Counters: Function Blocks:

1. Ladder logic diagrams may include 1. Some PLC programming environments

special symbols to represent timers, support function blocks or special function
counters, and other timing or counting modules that can be used to represent
functions. complex logic or operations in ladder logic
2. Timers are typically represented by a diagrams.
symbol consisting of a T followed by a 2. Function blocks provide pre-defined logic
number, indicating the timer's address. functions, such as arithmetic operations,
3. Counters are represented by a symbol comparisons, mathematical functions, or
consisting of a C followed by a number, communication protocols.
indicating the counter's address.
Structure of a PLC Program
1.Initialization:
1. The program begins with an initialization section where system variables, timers, counters,
and other necessary resources are initialized.
2. Initialization may include setting initial values for variables, configuring communication
settings, and performing system checks.
2.Main Program Routine:
1. The main program routine contains the primary control logic for the PLC program.
2. It consists of a series of sequential or parallel instructions that determine the behavior of the
system based on input conditions, internal states, and control requirements.
3. The main routine typically includes sections for input handling, processing, output control,
and error handling.
3.Input Handling:
1. Input handling routines read signals from sensors, switches, or other input devices
connected to the PLC's input modules.
2. Inputs are processed and evaluated to determine the current state of the system and trigger
appropriate control actions.
1.Processing Logic:
1. The processing logic section contains the core decision-making and processing algorithms
of the PLC program.
2. It implements control algorithms, logic sequences, mathematical calculations, and other
operations necessary to achieve the desired control objectives.
2.Output Control:
1. Output control routines generate control signals to actuate output devices such as motors,
valves, relays, or indicators.
2. Based on the processed input data and control logic decisions, output control routines
activate or deactivate output devices to achieve the desired system behavior.
3.Error Handling and Diagnostics:
1. Error handling and diagnostic routines detect and respond to errors, faults, or abnormal
conditions that may occur during program execution.
2. They provide error messages, alarms, diagnostic information, and error recovery procedures
to ensure the safe and reliable operation of the system.
1.Shutdown or Cleanup:
1. The program may include routines for shutting down the system safely or performing
cleanup tasks at the end of program execution or in response to specific events.
2. Shutdown routines release resources, deactivate output devices, and prepare the system for
maintenance or shutdown.
2.Subroutines or Function Blocks:
1. Subroutines or function blocks are modular segments of code that perform specific tasks or
functions within the PLC program.
2. They promote code reusability, readability, and maintainability by encapsulating common
operations or procedures into reusable units.
Ladder Logic Programming
1.Symbols:
1. Ladder logic programs consist of various symbols that represent
different elements of the control system.
2. Contacts: Contacts represent input devices such as switches or
sensors. They can be normally open (NO), normally closed
(NC), or other types based on their behavior.
3. Coils: Coils represent output devices such as relays, solenoids,
or motors. When energized, coils activate the associated output
device.
4. Timers and Counters: Special symbols are used to represent
timers, counters, and other timing or counting functions within
the program.
5. Function Blocks: Some PLC programming environments support
function blocks or special function modules that provide
predefined logic functions or operations.
Logic Operations:
1. Ladder logic programs consist of a series of rungs, with each
rung representing one logical operation or step in the control
process.
2. Logic operations are performed by arranging contacts and
coils in series or parallel configurations to implement various
control functions.
3. Contacts are connected in series to represent AND logic,
meaning all contacts in the series must be closed for the
associated coil to be energized.
4. Contacts can also be connected in parallel to represent OR
logic, meaning any of the contacts in the parallel branch can
energize the associated coil.
Programming:
1. Programmers create ladder logic programs by arranging symbols on the rungs of
the ladder diagram using specialized programming software provided by the
PLC manufacturer.
2. They define the control logic by connecting input contacts to output coils using
appropriate logic operations.
3. Programmers can add additional functionality such as timers, counters, math
functions, or communication instructions to the ladder logic program as needed.
Simulation and Testing:
4. Before deploying the ladder logic program to the PLC, programmers typically
simulate and test the program using software-based PLC simulators.
5. Simulation allows programmers to verify the correctness and functionality of the
program, identify any errors or issues, and fine-tune the logic as necessary.
Deployment and Execution:
1. Once the ladder logic program has been tested and
validated, it is deployed to the PLC for execution.
2. The PLC scans the program cyclically, evaluating the logic
on each rung and updating the status of input contacts and
output coils based on the current state of the system.
3. The ladder logic program continues to execute repeatedly,
controlling the behavior of the industrial process in real-
time.
Introduction to SCADA Systems
SCADA (Supervisory Control and Data Acquisition) systems are software
applications used in industrial automation to monitor, control, and supervise
processes and equipment in real-time. They provide a centralized interface for
operators to visualize, analyze, and manage complex industrial systems across
multiple sites or locations. Here's an introduction to SCADA systems:
1.Overview:
1. SCADA systems are designed to collect data from various sensors,
instruments, and control devices distributed throughout a facility or process
plant.
2. They provide real-time monitoring of process variables, equipment status,
alarms, and events, allowing operators to identify issues, make informed
decisions, and take corrective actions as needed.
3. SCADA systems play a crucial role in industries such as manufacturing,
energy, utilities, oil and gas, water and wastewater management,
transportation, and building automation.
Introduction to SCADA Systems
1 Centralized Monitoring 2 Data Acquisition
SCADA systems provide a centralized SCADA systems collect real-time data
interface for monitoring and controlling from field devices and sensors to
industrial processes. provide a comprehensive view of the
system.

3 Remote Control
SCADA systems allow operators to remotely manage and adjust industrial processes from a
central location.
SCADA System Architecture
Field Devices Layer:
•The lowest layer of the SCADA system architecture comprises field devices such as sensors, actuators, meters,
switches, and other instruments deployed throughout the industrial process.
Remote Terminal Units (RTUs) or PLCs Layer:
• The next layer in the SCADA architecture includes Remote Terminal Units (RTUs) or Programmable Logic
Controllers (PLCs) installed at remote sites or distributed throughout the facility.
Communication Layer:
• The communication layer facilitates data exchange between field devices, RTUs/PLCs, and the SCADA system.
SCADA Server Layer:
• The SCADA server layer comprises one or more servers that host the SCADA software applications responsible
for data acquisition, processing, monitoring, control, and visualization.
Human-Machine Interface (HMI) Layer:
• The top layer of the SCADA system architecture is the Human-Machine Interface (HMI), which provides
operators with a graphical user interface for interacting with the SCADA system.
SCADA Software and Hardware

Software Servers Field Devices Communication

SCADA software SCADA systems use Field devices, such as SCADA systems rely on
provides the core dedicated servers to host sensors and actuators, various communication
functionality, including the software and provide the physical protocols to connect the
HMI, data management, manage the overall interface to the different components.
and reporting. system. industrial process.