1

Course Contents

History of Programmable Controllers

Relay Ladder Logic

Central Processing Unit

Input/Output System

Programming and Peripheral Devices

Programming Concepts

Applications

Troubleshooting and Maintenance

2
INTRODUCTION TO PLCS
Advantages of PLCs

• Less wiring.
• Wiring between devices and relay contacts are done in
the PLC program.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and
reduce downtime.
• Reliable components make these likely to operate for
years before failure.
PLC Origin

•- Developed to replace relays in the late 1960s

•- Costs dropped and became popular by 1980s
•- Now used in many industrial designs
 Programmable Controller Development
1968  Programmable concept developed
1969  Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974  Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976  Remote input/output systems introduced
1977  Microprocessors - based PLC introduced

5
 Programmable Controller Development
1980  Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983  Low - cost small PLC’s introduced
1985 on  Networking of all levels of PLC, computer
and machine using SCADA software.

6
 Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a

programming memory for the internal storage of instructions
for implementing specific functions such as logic,
sequencing, timing, counting and arithmetic to control
through digital or analog modules, various types of machines
or process.

7
 Leading Brands Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

8
 Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

9
 Areas of Application

Manufacturing / Machining


Food / Beverage


Metals


Power


Mining


Petrochemical / Chemical

10
PLC Size
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- these PLC’s are capable of providing
simple to advance levels or machine
controls.
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s and
memories up to 750 Kbytes.
- can control individual production
processes or entire plant.

11
Major sections of a PLC

1. Sensing input or Controlling hardware

2. PLC input hardware

3. The controller or CPU

4. Handheld programming device or personal computer

5. Output PLC hardware

6. Hardware output devices

Major Components of a Common PLC
POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
To
SENSORS T E
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

13
 Major Components of a Common PLC
POWER SUPPLY

Provides the voltage needed to run the primary PLC

components

I/O MODULES

Provides signal conversion and isolation between the

internal logic- level signals inside the PLC and the field’s
high level signal.

14
 Major Components of a Common PLC
PROCESSOR

Provides intelligence to command and govern the activities

of the entire PLC systems.

PROGRAMMING DEVICE

used to enter the desired program that will determine the

sequence of operation and control of process equipment or
driven machine.

15
 Programming Device
Also known as:


Industrial Terminal ( Allen Bradley )


Program Development Terminal ( General Electric )


Programming Panel ( Gould Modicon )


Programmer ( Square D )


Program Loader ( Idec-Izumi )


Programming Console ( Keyence / Omron )
16
Programming Device
Types:


Hand held unit with LED / LCD display


Desktop type with a CRT display


Compatible computer terminal

17
I/O Module
• The I/O interface section of a PLC connects it to
external field devices.

• The main purpose of the I/O interface is to condition the

various signals received from or sent to the external input
and output devices.

• Input modules converts signals from discrete or analog

input devices to logic levels acceptable to PLC’s processor.

• Output modules converts signal from the processor to

levels capable of driving the connected discrete or analog
output devices.

18
 I/O Modules
The Input module performs four tasks electronically
• First it senses the presence or absence of an
input signal at each of its input terminals. The
input terminal tells what switch , sensor, or
other signal is on or off in the process being
controlled.
• Second it converts the input signal for high, or
on, to a DC level usable by the modules
electronic circuit. For low, or off , input signal ,
no signal is converted, indicating off.
19
• Third the input module carries out electronic
isolation by electronically isolating the input
module output from its input.

• Finally its electronic circuit must produce an

output, via output logic, to be sensed by the PLC
CPU.

20
I/O Module
DC INPUT MODULE
IS NEEDED TO:
 Prevent voltage
USE TO
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
Helps reduce the
LEVEL
effects of electrical
noise

Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits

21
I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC  Prevent voltage
INPUT TO DC AND transients from
DROPS THE damaging the
VOLTAGE TO LOGIC processor.
LEVEL Helps reduce the
effects of electrical
noise

Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits

22
23
24
25
I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
 Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

26
27
I/O Circuits
DIFFERENT TYPES OF I/O CIRCUITS

1. Pilot Duty Outputs

Outputs of this type typically are used to drive high-current
electromagnetic loads such as solenoids, relays, valves, and
motor starters.

These loads are highly inductive and exhibit a large inrush

current.

Pilot duty outputs should be capable of withstanding an

inrush current of 10 times the rated load for a short period of
time without failure.

28
I/O Circuits
2. General - Purpose Outputs
These are usually low- voltage and low-current and are used
to drive indicating lights and other non-inductive loads. Noise
suppression may or may not be included on this types of
modules.

3. Discrete Inputs
Circuits of this type are used to sense the status of limit
switches, push buttons, and other discrete sensors. Noise
suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.

29
I/O Circuits
4. Analog I/O

Circuits of this type sense or drive analog signals.

Analog inputs come from devices, such as thermocouples,
strain gages, or pressure sensors, that provide a signal
voltage or current that is derived from the process variable.
Standard Analog Input signals: 4-20mA; 0-10V

Analog outputs can be used to drive devices such as

voltmeters, X-Y recorders, servomotor drives, and valves
through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V

30
I/O Circuits
5. Special - Purpose I/O

Circuits of this type are used to interface PLCs to very specific

types of circuits such as servomotors, stepping motors PID
(proportional plus integral plus derivative) loops, high-speed
pulse counting, resolver and decoder inputs, multiplexed
displays, and keyboards.

This module allows for limited access to timer and counter

presets and other PLC variables without requiring a program
loader.

31
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

32
 Allen-Bradley 1746-1A16

L1 L2 I= Input
Module
I:2 slot # in rack

P. B SWITCH 0 Module
Terminal #
Address I:2.0/0

LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM

33
 CONTACTOR
L2 L1 N.O

MOTOR
L2
C •SOLENOID
L1 •VALVES
FIELD WIRING •LAMP
•BUZZER

OUTPUT MODULE
WIRING
L1 O:4 L2

CONTACTOR 0
LADDER PROGRAM
34
Discrete Input
A discrete input also referred as digital input is an input that is
either ON or OFF are connected to the PLC digital input. In the
ON condition it is referred to as logic 1 or a logic high and in the
OFF condition maybe referred to as logic o or logic low.

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

35
 IN

OFF PLC
Logic 0
Input
Module
24 V dc

IN

OFF PLC
Logic 1
Input
Module
24 V dc

36
Analog Input
An analog input is an input signal that has a continuous
signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA
(Mostly used) or 0 to10V. Below, a level transmitter monitors
the level of
liquid in the tank. Depending on the level Tx, the signal to the
PLC can either increase or decrease as the level increases
or decreases.
Level Transmitter IN

PLC
Analog
Tank Input
Module

37
Why 4 to 20mA is standard?
4-20mA has an inherent ‘live zero’. Zero engineering
units is 4.0mA, not 0.0mA. 0.0mA indicates an open
circuit, a failure or a fault mode like cut wires or a dead
transmitter. 0.0mA is not a valid reading of zero
engineering units and a wake-up call that there’s
something seriously wrong in the loop.
(electrical current level below about 3.6mA is
absolutely necessary because it is used to drive the
electronics of loop powered devices).
38
If 4-20mA current output is fed to the input card of any
controller, we use 250 Ohm resistor in path to convert
this current signal into voltage signal of range 1-5V.
•As a standard, the ADC of the controller only
process voltage signals that are in the range of 1-5V.
It is another reason to use current signal in the range
of 4-20mA.
•Hence, it is best practice to use 4-20mA current signal
instead of 0-20mA. Not only, this range help us in
detecting open circuit faults, but also, it becomes easy
to covert this signal into 1-5VDC voltage signal which
will be processed by the input card of mostly
controllers. 39
4-20 mA can be designed for Intrinsically Safe
approval for use in hazardous areas, which allows
troubleshooting the circuit while it’s ‘live’ and
powered.

4-20 mA can carry HART® (Highway

Addressable Remote Transducer Protocol
) digital data superimposed on its primary DC
signal, without sacrificing any of the properties
above and without interfering with non-HART
enabled analog inputs.
40
Digital Output

A discrete output is either in an ON or OFF condition. Solenoids,

contactors coils, lamps are example of devices connected to the
Discrete or digital outputs. Below, the lamp can be turned ON or
OFF by the PLC output it is connected to.
OUT

PLC
Lamp
Digital
Output
Module

41
Analog Output

An analog output is an output signal that has a continuous

signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V.
Electric to pneumatic transducer

OUT
E Supply air
PLC 0 to 10V P

Analog
Output
Module
Pneumatic control valve

42
Processor
The processor module contains the PLC’s microprocessor,
its supporting circuitry, and its memory system.

The main function of the microprocessor is to analyze data

coming from field sensors through input modules, make
decisions based on the user’s defined control program and
return signal back through output modules to the field
devices. Field sensors: switches, flow, level, pressure, temp.
transmitters, etc. Field output devices: motors, valves,
solenoids, lamps, or audible devices.

The memory system in the processor module has two parts:

a system memory and an application memory.
43
 Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all system
activities, such as execution of the users control program,
communication with peripheral devices, and other system
SYSTEM activities.
•The system memory also contains the routines that implement
the PLC’s instruction set, which is composed of specific control
functions such as logic, sequencing, timing, counting, and
arithmetic.
•System memory is generally built from read-only memory
devices.

APPLICATION
•The application memory is divided into the data table area and
•Data Table user program area.
•The data table stores any data associated with the user’s control
•User Program program, such as system input and output status data, and any
stored constants, variables, or preset values. The data table is
where data is monitored, manipulated, and changed for control
purposes.
•The user program area is where the programmed instructions
entered by the user are stored as an application control program.

44
Memory Designs
VOLATILE.
A volatile memory is one that loses its stored information
when power is removed.

Even momentary losses of power will erase any information

stored or programmed on a volatile memory chip.

Common Type of Volatile Memory

RAM. Random Access Memory(Read/Write)

Read/write indicates that the information stored in the
memory can be retrieved or read, while write indicates that
the user can program or write information into the memory.

45
Memory Designs

The words random access refer to the ability of any

location (address) in the memory to be accessed or used.
Ram memory is used for both the user memory (ladder
diagrams) and storage memory in many PLC’s.

RAM memory must have battery backup to retain or protect

the stored program.

46
 Memory Designs
Several Types of RAM Memory:

1.MOS
2.HMOS
3.CMOS

The CMOS-RAM (Complimentary Metal Oxide

Semiconductor) is probably one of the most popular. CMOS-
RAM is popular because it has a very low current drain when
not being accessed (15microamps.), and the information
stored in memory can be retained by as little as 2Vdc.

47
 Memory Designs
NON-VOLATILE
Has the ability to retain stored information when power is
removed, accidentally or intentionally. These memories do not
require battery back-up.

Common Type of Non-Volatile Memory

ROM, Read Only Memory

Read only indicates that the information stored in memory
can be read only and cannot be changed. Information in ROM
is placed there by the manufacturer for the internal use and
operation of the PLC.

48
 Memory Designs
Other Types of Non-Volatile Memory

PROM, Programmable Read Only Memory

Allows initial and/or additional information to be written into
the chip.

PROM may be written into only once after being received

from the PLC manufacturer; programming is accomplish by
pulses of current.

The current melts the fusible links in the device, preventing it

from being reprogrammed. This type of memory is used to
prevent unauthorized program changes.

49
 Memory Designs
EPROM, Erasable Programmable Read Only Memory

Ideally suited when program storage is to be semi-

permanent or additional security is needed to prevent
unauthorized program changes.

The EPROM chip has a quartz window over a silicon

material that contains the electronic integrated circuits. This
window normally is covered by an opaque material, but when
the opaque material is removed and the circuitry exposed to
ultra violet light, the memory content can be erased.

The EPROM chip is also referred to as UVPROM.

50
 Memory Designs
EEPROM, Electrically Erasable Programmable Read
Only Memory

Also referred to as E2PROM, is a chip that can be

programmed using a standard programming device and can
be erased by the proper signal being applied to the erase pin.

EEPROM is used primarily as a non-volatile backup for the

normal RAM memory. If the program in RAM is lost or erased,
a copy of the program stored on an EEPROM chip can be
down loaded into the RAM.

51
PLC Operation
Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute
the user program stored in application memory, then, based
on whatever control scheme has been programmed by the
user, turn the field output devices on or off, or perform
whatever control is necessary for the process application.

This process of sequentially reading the inputs, executing

the program in memory, and updating the outputs is known
as scanning.

52
While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as
individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan

53
PHASE 1 – Input Status scan

 A PLC scan cycle begins with the CPU reading the status
of its inputs.
PHASE 2– Logic Solve/Program Execution

 The application program is executed using the status of

the inputs

PHASE 3– Logic Solve/Program Execution

 Once the program is executed, the CPU performs
diagnostics and communication tasks

54
PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the
stored output values are sent to actuators and other field
output devices. The cycle ends by updating the outputs.

55
As soon as Phase 4 are completed, the entire cycle begins
again with Phase 1 input scan.

The time it takes to implement a scan cycle is called SCAN

TIME. The scan time composed of the program scan time,
which is the time required for solving the control program, and
the I/O update time, or time required to read inputs and
update outputs. The program scan time generally depends on
the amount of memory taken by the control program and type
of instructions used in the program. The time to make a single
scan can vary from 1 ms to 100 ms.

56
PLC Communications
Common Uses of PLC Communications Ports


Changing resident PLC programs - uploading/downloading
from a supervisory controller (Laptop or desktop computer).


Forcing I/O points and memory elements from a remote
terminal.


Linking a PLC into a control hierarchy containing several
sizes of PLC and computer.


Monitoring data and alarms, etc. via printers or Operator
Interface Units (OIUs).
57
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards

RS 232


Used in short-distance computer communications, with the
majority of computer hardware and peripherals.

Has a maximum effective distance of approx. 30 m at 9600
baud.
58
PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all

devices plus providing overall data exchange management or
protocol, ensuring that each device can “talk” to other
machines and understand data received from them.

LANs provide the common, high-speed data communications

bus which interconnects any or all devices within the local
area.

LANs are commonly used in business applications to allow

several users to share costly software packages and
peripheral equipment such as printers and hard disk storage.
59
PLC Communications
RS 422 / RS 485


Used for longer-distance links, often between several PCs
in a distributed system. RS 485 can have a maximum
distance of about 1000 meters.

60
Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be

connected to the controller. There should be sufficient I/O
ports to meet present requirements with enough spares to
provide for moderate future expansion.

61
The digital signal that is generally compatible
with the microprocessor in the PLC is 5 V d.c.

However, signal conditioning in the input

channel, with isolation, enables a wide range
of input signals to be supplied to it.

A range of inputs might be available with a

larger PLC, e.g. 5 V, 24 V, 110 V and 240 V
digital/discrete, i.e. on− off, signals. A small
PLC is likely to have just one form of input,
e.g. 24 V.
62
63
• The output from the input/output unit will be digital
with a level of 5 V.

• However, after signal conditioning with relays,

transistors or triacs, the output from the output channel
might be a 24 V, 100 mA switching signal, a d.c.
voltage of 110 V, 1 A or perhaps 240 V, 1 A a.c., or 240
V, 2 A a.c., from a triac output channel.

• With a small PLC, all the outputs might be of one type,

e.g. 240 V a.c., 1 A. With modular PLCs, however, a
range of outputs can be accommodated by selection of
the modules to be used.
64
65
Outputs are specified as being of relay type,
transistor type or triac type

1 With the relay type, the signal from the PLC

output is used to operate a relay and is able to
switch currents of the order of a few amperes in
an external circuit. The relay not only allows small
currents to switch much larger currents but also
isolates the PLC from the external circuit.
Relays are, however, relatively slow to operate.
Relay outputs are suitable for a.c. and d.c.
switching. They can withstand high surge currents
and voltage transients.
66
2 The transistor type of output uses a transistor to switch
current through the external circuit. This gives a
considerably faster switching action. It is, however,
strictly for d.c. switching and is destroyed by overcurrent
and high reverse voltage. As a protection, either a fuse or
built-in electronic protection are used. Opto-isolators are
used to provide isolation.

3 Triac outputs, with opto-isolators for isolation, can be

used to control external loads which are connected to the
a.c. power supply. It is strictly for a.c. operation and is
very easily destroyed by overcurrent. Fuses are virtually
always included to protect such outputs.
67
Sourcing and sinking
The terms sourcing and sinking are used to describe
the way in which d.c. devices are connected to a PLC.
With sourcing, using the conventional current flow
direction as from positive to negative, an input
device receives current from the input module, i.e.
the input module is the source of the current . If the
current flows from the output module to an output
load then the output module is referred to
as sourcing .

With sinking, using the conventional current flow

direction as from positive to negative, an input
device supplies current to the input module, i.e. the
input module is the sink for the current. If the current
68
Sourcing

Sinking 69
Selecting a PLC

Criteria

• Number of logical inputs and

outputs.
• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying sufficient

voltage and current to drive the output peripheral connected
to it.

SCAN TIME

This is the speed at which the controller executes the relay-

ladder logic program. This variable is usually specified as the
scan time per 1000 logic nodes and typically ranges from 1 to
200 milliseconds.

71
Specifications
MEMORY CAPACITY

The amount of memory required for a particular application is

related to the length of the program and the complexity of the
control system. Simple applications having just a few relays
do not require significant amount of memory. Program length
tend to expand after the system have been used for a while. It
is advantageous to a acquire a controller that has more
memory than is presently needed.

72
A Detailed Design Process

1. Understand the process

2. Hardware/software selection
3. Develop ladder logic
4. Determine scan times and memory requirements
PLC Status Indicators
•Power On
•Run Mode
•Programming Mode
•Fault
Troubleshooting

1. Look at the process

2. PLC status lights
HALT - something has stopped the CPU
RUN - the PLC thinks it is OK (and probably is)
ERROR - a physical problem has occurred with the PLC
3. Indicator lights on I/O cards and sensors
4. Consult the manuals, or use software if available.
5. Use programming terminal / laptop.
List of items required when working with PLCs:

1. Programming Terminal - laptop or desktop PC.

2. PLC Software. PLC manufacturers have
their own specific software and license key.
3. Communication cable for connection from Laptop
to PLC.
4. Backup copy of the ladder program (on diskette, CDROM,
hard disk, flash memory). If none, upload it from the PLC.
5. Documentation- (PLC manual, Software manual, drawings,
ladder program printout, and Seq. of Operations manual.)
Examples of PLC Programming Software:

1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
 PROGRAMMING

Normally Open Normally Closed

(NO) (NC)

Power flows through these contacts when they are

closed. The normally open (NO) is true when the input
or output status bit controlling the contact is 1.

The normally closed (NC) is true when the input or

output status bit controlling the contact is 0.

78
 Coils

Coils represent relays that are energized when power flows

to them. When a coil is energized it causes a
corresponding output to turn on by changing the state of
the status bit controlling the output to 1. That same output
status bit maybe used to control normally open or normally
closed contact anywhere in the program.

79
Boxes

Boxes represent various instructions or functions that are

Executed when power flows to the box. Some of these
Functions are timers, counters and math operations.

80
 AND OPERATION

A B C
Rung

Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).

81
 OR OPERATION

A C
Rung

In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).

82
 NOT OPERATION

A C
Rung

In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.

83