UNIT-4

Programmable
Logic Controller

Introduction – Architecture – Input / Output

Processing – Programming with Timers,
Counters and Internal relays – Data Handling –
Selection of PLC.
 Programmable Logic Controller
(PLC)
Programmable Logic Controller (PLC) or
Programmable Controller is a digital computer
used for automation of typically industrial
electromechanical processes, such as control
of Machinery on factory assembly lines,
amusement rides, or light fixtures.
The PLCs find vast applications in the control
and operation of Automated Manufacturing
Process Equipment and Machinery, Packaging
and Filling equipment, Chemical Mixing,
Conveyor systems and Distillation etc.
 Programmable Logic Controller
(PLC)
Initially, PLCs have been used to replace
relay logic systems. These PLCs were
programmed in “LADDER LOGIC”, which
strongly resembles a schematic diagramof
relay logic.
Ladder logic notation was chosen to reduce
training demands for the existing
technicians; other earLy PLCs used a form
of instruction list programming, based on a
stack based logic solver.
 Programmable Logic Controller
(PLC)
 The PLCs has following features and specific which
distinguish from computers.
 These are,
 They are rugged and designed to withstand vibrations,
temperature, humidity and noise.
 The interfacing for inputs and outputs Is inside the
controller.
 They are easily programmed and have an easily
understood programming language.
 Programming is primarily concerned with logic and
switching
 operations.
 They can be designed with communication capabilities that
allow them to interface with a computer system or human.
 Programmable Logic Controller
(PLC)
Consider a hardwired circuit used for a
simple application shows a Hardwired
Motor Circuit in order to control and
process.
It consisting of two independent switches
and Motor.
 Here, the input devices such as sensors
are connected to PLC and form switching
Operation.
 Programmable Logic Controller
(PLC)
They are wired parallel to generate a
simple logic
Logic-1, when the switch is ON; Motor 1 is
ON otherwise OFF.
Logic-2, introduce more complex logic i.e.,
Motor 2 should be OFF when the Motor 1 is
switched ON.
 Programmable Logic Controller
(PLC)
This will require the redesigning of circuit and
hence we need to rewiring.
Plant machine control involves such a
complex process and hence controller system
inherently requires of relays and circuits.
To implement such a complex logic we need
use a controller circuit to control the switches.
Hence the switcher are not connected directly
to the Motors, instead of that the switches are
connected to the input modules and logic
module are connected to the output modules.
 Programmable Logic Controller
(PLC)
Here, the input devices such as sensors are
connected to PLC and form switching
devices.
The output devices such as Motors and
valves are connected to the PLC only when
the program conditions have been met, the
output devices are switched- ON or OFF
based on logics of inputs.
 Programmable Logic Controller
(PLC)
BASIC STRUCTURE
The PLC is designed as a replacement for
the hardwired relay and timer logic, where
PLC provides ease and flexibility of control
based on programming and executing
logical instructions.
The internal functions such as timers,
counters and shift registers making
sophisticated control possible using even
the smallest PLC.
 Programmable Logic Controller
(PLC)
BASIC STRUCTURE
A typical PLC can be divided into four parts.
They are,
1. I/O MODULE
2. CPU
3. MEMORY
4. PROGRAMMING UNIT
 Programmable Logic Controller
(PLC)
BASIC STRUCTURE
 BASIC STRUCTURE
Input/ Output Module.
 Input/ Output Module are used to transfer data between external
devices and CPU.
 The input and output modules are normally incorporated into PLC in
two ways.
 i) Fixed I/O — It is a small unit that comes in one piece with processor
i.e., the 1/O terminals cannot be changed in fixed I/O.
 ii) Modular I/O - It is packed together i.e., there are several
compartments of I/O Modules are plugged together.
 Input Module ensures a usable signal is available for the CPU circuit
protection capabilities will also be necessary in the module to protect.
the CPU circuitry from faults, surges or spikes in the incoming signal.
 BASIC STRUCTURE
 The output module reads digital signals transmitted from the
CPU, and operates motor starters.
 Solenoids and status monitors.
 The module essentially functions as a switching device and
provides on-off signals to the associated devices.
 If the output module is incapable of handling the power
needed by the device, it sends a signal to an external relay,
which connects with the actual power circuit.
 Input and Output devices are placed outside the PLC, with
connecting wires attached to the terminal strips on the PLC.
 There are no connections in the inputs and output. Each input
and output terminal has a unique address.
 BASIC STRUCTURE
Central Processing Unit (CPU)
 Brain of the PLC, consisting of a microprocessor which interprets
the input signals and carries out the control actions according to
the program stored in the memory, communicating the decision as
an action signal to the outputs.
 It forms the core portion of the PLC.
 The microprocessor based unit contains the logic and control
algorithm for the controller.
 It scans the total information package stored in the memory and
the input and output devices continuously.
 During the scan the CPU also executes instruction based on input
data, sends appropriate output responses to the output devices,
updates data acquisition systems, and indicates condition changes.
 BASIC STRUCTURE
Central Processing Unit (CPU)
 Scan time for larger unit depends on the size of the memory
and on the configuration of the system.
 Smaller PLC has longer scan times than larger units and
has less memory and reduced capacity for special
instructions and peripheral equipment.
 The power supply unit is needed to convert the AC voltage
to the low DC voltage necessary for the processor and to
supply power to other circuits in the input and output
interface module.
 BASIC STRUCTURE
Memory Unit
 The memory unit is where the program is stored that is to be
used for the control actions to be exercised by the
Microprocessor and data stored from input for processing and
for the output.
 The memory in PLC stores the digital control logic, the process
program and the necessary instruction to operate the system.
 It stored in units called “bytes”.
 The memory used in PLC is
 i) Non-volatile Memory - The memory may retain the
information even the power is turned off.
 ii) Volatile Memory - The memory may lose the information
when the electrical power is turned off.
 BASIC STRUCTURE
Memory Unit
 User interface with the PLC mostly works through the volatile
memory.
 According to the purpose of usage, there are two main memory
types.
 i) RAM (Random Access Memory) — It is used for program and
data storage.
 For this we need to provide a battery backup in order to prevent
loss of any data when power is removed. It is a volatile memory.
 ii) ROM (Read Only Memory) — ROM memory cells store
information permanently, and it is used to store the operating
program of the computer-to permit easy startup.
 It is permanent storage hence called as non-volatile memory.
 BASIC STRUCTURE
Programming Unit
 Used to enter the required program into the memory of the
processor.
 The program is developed in the device and then transferred to
the memory unit of the PLC.
 Programming device also enters the required program using
ladder logic into the memory of the processor.
 The sequence of operation and ultimate control of equipment
machinery is specified and determined by the ladder program.
 While entering the ladder program, the program device is
normally connected to the controller.
 Actual programming is usually achieved by pushing keys or a
keyboard and can be programmed by people without much
computer programming experience.
 PLC Architecture
A PLC consists of the following elements.
i. CPU (Central Processing Unit)
ii. Memory
iii. I/O processing devices
 PLC Architecture
CPU (Central Processing Unit)
 In general the CPU consists of,
 An Arithmetic and Logical Unit (ALU) which is
responsible for data manipulation and carrying out
arithmetic operations like addition and subtraction and
logical operation like AND, OR, NOT and EX-OR etc.
 Memory termed registers, located within the processor
and used to store information involves in program
execution.
 A control unit which is used to control the timing of
operations and control the units within the processor to
ensure that operations are carried out in the correct
order.
 PLC Architecture
CPU (Central Processing Unit)
 Functions of CPU:
 To control and process all the operations of memory
and I/O data in the system in accordance with the
program.
 Holds the communication circuits and power supply.
Executes the operating system, manages memory,
monitors inputs, evaluates the user logic and turns
gives appropriate outputs.
In order to do this, the PLC is provided with a clock
signal to sequence its internal operations.
 PLC Architecture
CPU (Central Processing Unit)
 Buses:
 Internal paths used for communication
within PLC.
 Essentially carry the information in the
digital forms.
 There are four types of buses required in a
PLC.
 i) Data Buses – It is used for
communicating data between elements.
 ii) Address Buses - It is used to read the
address of locations for accessing stored
data.
 PLC Architecture
CPU (Central Processing Unit)
 Buses:
iii) Control Buses - It is used for internal control
actions carried by the CPU.
Example: To inform Memory devices whether they
are to receive data from an input or output data.
iv) System Buses – It is used for communication
between the input/output ports and the input/output
unit.
 PLC Architecture
Memory
Memory devices are where the program are
started in the controller or some groups of binary
digits or 1s and 0s stored in the form of bytes at
individual locations identified by their addressed.
The memory of a PLC is divided into many
sections based on specific functions.
i) Sectors to store the status of inputs and
outputs.
ii) Sectors to store system information such
as scan time, fault status, fault codes and
watchdog timers.
There several memory elements in PLC system.
 PLC Architecture
Memory
1. RAM (Random Access Memory)
RAM is used for user’s program and data
storage.
RAM is designed to storage the information
on the status of input and output devices
and the values of timers and
counters and other internal devices.
The data RAM is sometimes referred to as
a data table or register table.
RAM is volatile memory.
It will lose its stored information when
power is turned off.
 PLC Architecture
Memory
2. ROM (Read Only Memory)
ROM is a permanent storage used to store the
operating system and fixed data used by the CPU.
ROM is not volatile memory normally, is designed
so that the
information stored in the memory can only be
read and cannot be changed.
ROM can be classified into three they are,
a) PROM (Programmable Read Only Memory)
PROM is a special type of ROM and allows initial
and/or additional information to be written
into the chip and can be written only once
after being received from the manufacturer.
 PLC Architecture
Memory
b) EPROM (Erasable and Programmable ROM)
It is programmable using a dedicated programmer.
Information stored in the EPROM can be erased
with the use for ultraviolet light source and can
be reprogrammed and stored permanently.
 ¢) EEPROM (Electrically EPROM)
 Here the information stored can be erased with the
electrical pulses rather than ultraviolet light.
 The EEPROM can be electrically over writer with new
data.
 The storage capacity of a memory unit is determined by
the number of binary words then it can store. Thus, if a
memory size, is 256 words then it can store 256 x 8 =
2048 bits if 8-bit words are used and 256 x 16 = 4096
bits if 16-bit words are used.
 PLC Architecture
Input and Output Processing Devices
The input/output unit provides the interface
between the system and the outside
world and allowing connections to be made
through input/output channels to input
devices such as sensors and output devices such
as motors and solenoids. Every
input/output point has a unique address which
can be used by the CPU.
The input/output channels also provide isolation
and signal conditioning functions
so that sensors and actuators can often by
directly connect to them without the need
for other circuitry.
 PLC Architecture
Input and Output Processing Devices
Optoisolator (Opto Coupler)
Electrical isolation from the exteral world is usually by
means of optoisolators.
Principle
When a digital pulse passes through the light emitting
diode, a pulse of infrared radiation is produced.
This pulse is detected by the phototransistor and
givesrise to a voltage in that circuit.
The gap between the light emitting diode and the
photo
transistor gives electrical isolation but the
arrangement still allows for a digital pulse in one
circuit to give rise to a digital pulse in another circuit.
 PLC Architecture
Input and Output Processing Devices
 PLC Architecture
Input and Output Processing Devices
Outputs are often specified as being of,
i) Relay type
i) Transistor type
iii) Triac type
 PLC Architecture
Input and Output Processing Devices
i) Relay Type
In Relay type the signal from the PLC
output is used to operate a relay and so
it able to switch currents of the order of
a few amperes in an external circuit.
The relay isolates the PLC from the
external circuit and can be used for both
d.c and a.c switching.
Relays are slow to operate.
 PLC Architecture
Input and Output Processing Devices
Transistor Type
The transistor type of output uses a
transistor to switch current through the
external circuit.
This gives a faster switching action.
Optoisolators are used with transistor
switches to provide isolation between
the external circuit and the PLC.
The transistor output is only for d.c.
switching.
 PLC Architecture
Input and Output Processing Devices
Transistor Type
Thé switching action of a transistor
would require base current which is
enough for the collector current to reach
the maximum value, and the voltage
drop will be very small at this point.
 PLC Architecture
Input and Output Processing Devices
Triac Type
The Triac type output is used for
switching AC voltages.
 A Triac device is used which acts as a
two-way SCR with one gate connected
at the output unit.
INPUT/OUTPUT PROCESSING
Processing of Input/ Output is through the
programming the PLC.
 The basic form of programming commonly
used with PLCs in “Ladder Programming”.
Ladder Programming involves each
program task being specified as though a
Rung of a Ladder.
Thus such a Rung could specify that the
state of switches A and B, the inputs, be
examined and if A and B are both closed
then a solenoid, the output is energized.
The programming sequences followed by a
PLC are,
Step 1: Scan the inputs associated with one
Rung of the ladder program
Step2: Solve the logic operation involving
those inputs.
Step3: Set/reset the outputs for the Rung.
Step4: Move on to the next Rung and
repeat operations in Step 1,2 and 3.
Step5: Move on to the next Rung and
repeat operations in Step 1, 2 and 3.
And 50 on until the end of the program.
Each rung of the ladder program is then
scanned in turn.
There are two methods that can be used for
input/output processing.
i) Continuous updating
ii) Mass input/output copying
 i) Continuous Updating
 Continuous updating involves the CPU scanning the input
channels as they occur in the program instructions.
 Here each input point is scanned individually and its effect on the
program is determined.
 Due to scanning built in delay may be occurred about 3 ms, when
each input is examined in order to ensure that only valid input
signals are road by the microprocessor.
i) Continuous Updating

This delay enables the microprocessor to avoid

counting as input signal twice, or more frequently,
if there is contact bounce at a switch.
Here the number of inputs may have to be
scanned. Each with a 3ms delay, before the
program has the instruction for a logic operation to
be executed and an output to occur.
The outputs are latched so that they retain their
status until the next updating.
 ii) Mass Input/ Output Copying
 In continuous updating, there has to be a 3ms delay on each
input, the time taken to examine several hundred input/ output
points can become comparatively long time.
 To avoid such a delay, the input/ output is processing in a Mass
Input/Output copying method for a more rapid execution of a
program.
 In Mass Input/ Output copying method, a specific area of RAM
is used as a buffer store between the control logic and the
input/output unit.
 Each input/output has an address in this memory.
 At the start of each program cycle the CPU scan all the inputs
and copies their status into the input/output addresses in RAM.
ii) Mass Input/ Output
Copying
As the program is executed the stored
input data is Read, as required from RAM
and the logic operations are carried out.
The resulting output signals are stored in
the reserved input/output section of RAM.
At the end of each program cycle all the
outputs are transferred from RAM to the
output channels.
The outputs are latched so that they retain
their status until the next updating.
PROGRAMMING
The programming of PLC is based on the
“Ladder Diagram”. Ladder diagram involves
writing a program in a similar manner to
drawing a switching circuit.
The symbols used in ladder diagram are
known as ladder symbols.
PROGRAMMING

And the circuit i.e., inputs and outputs are

connected horizontal.
 Hence the ladder diagram describes the
output A occurs when the input 1 occurs.
PROGRAMMING

Here the ladder diagram describes the

output A occurs when both the inputs 1 and
2 occurs.
PROGRAMMING

Here the ladder diagram describes the

output A when input 1 or input 2 occurs.
PROGRAMMING
PROGRAMMING
LOGIC FUNCTIONS
Logic is the ability of PLC to make decisions
when more than one factor must be taken
into account before a device is operated.
The logic functions can be obtained by
combinations of switches.
AND FUNCTION
An AND function operates like a series
circuit and works with two inputs to
produce a single output.
Consider a situation where a coil is not
energized unless two, normally open,
switches are both closed. Switches A and B
have both to be closed, which thus gives an
AND logic situation.
OR FUNCTION
NOT FUNCTION
NOR FUNCTION
NAND FUNCTION
XOR FUNCTION