Introduction

Operation
Of a PLC

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 PLC Applications : Operation of a PLC

Introduction

PLC operates by monitoring input signals from

external devices like push-buttons, limit switches
and proximity sensors. The PLC then, reacts to the
input by outputting signals to external loads.

This lesson discusses the addressing with regard to

the input/output as well as the internal relay. It
describes the operation of the input/output module
and its interfacing with sensors and loads with PLC.

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 PLC Applications : Operation of a PLC

Objectives

At the end of this lesson you should be

able to describe the operation of a
Programmable Logic Controller (PLC).

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 PLC Applications : Operation of a PLC

Main Menu

Input/Output Addressing

Operation of I/O
Module

Interfacing ON-OFF
Sensors

Interfacing ON-OFF
Loads

Exit

Instruction 4
 PLC Applications : Operation of a PLC

Input / Output Addressing

We have seen that the PLC

operates by monitoring
input signals from external
devices like push-buttons,
sensors, limit switches, etc. Input
Module

Instruction 5
 PLC Applications : Operation of a PLC

Input / Output Addressing

We have seen that the PLC

operates by monitoring
input signals from external
devices like push-buttons,
sensors, limit switches, etc. Output
Module
Then, according to the
program in its memory, the
PLC reacts to the input by
outputting signals to
external loads such as
relays, indicator lights, etc.

Instruction 6
 PLC Applications : Operation of a PLC

Input / Output Addressing

In the program, programmable “internal relays” replace

the relays of hard-wired circuits.

Instruction 7
 PLC Applications : Operation of a PLC

Input / Output Addressing

Input devices are connected

to turn on or off “input
relays”.

Input relays

Instruction 8
 PLC Applications : Operation of a PLC

Input / Output Addressing

Output devices are turned

on or off by the setting of
“output relays”.

Output relays

Instruction 9
 PLC Applications : Operation of a PLC

Input / Output Addressing

These input and output

relays are usually available
in groups of 8 or 16 relays
or sometimes 32 relays
called input or output
modules.

Instruction 10
 PLC Applications : Operation of a PLC

Input / Output Addressing

The CPU of a PLC does

not differentiate what
device is connected to
which input or output
terminal.

It will communicate with

the outside world only by
sensing input relays and
setting output relays.

Instruction 11
 PLC Applications : Operation of a PLC

Input / Output Addressing

As far as the CPU is

concerned, it will
communicate with or
address the I/O by
specifying certain numbers
or addresses, e.g., input
relay 0.00 or output relay
0.05.

Instruction 12
 PLC Applications : Operation of a PLC

Input / Output Addressing

In the same way, the

“internal relays” (which
perform the function of the
control relays in relay logic
circuits), timers and
counters which are
programmable all have
their own addresses.

Instruction 13
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

When the pushbutton (PB)

connected to terminal 0.0
of the input module is
pressed, the circuit to
which the PB is connected
to, become a closed circuit
and the internal power
source will cause the LED
to lights up.

Instruction 14
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

When the pushbutton (PB) connected

to terminal 0.0 of the input module is
pressed, the circuit to which the PB is
connected to, become a closed circuit
and the internal power source will
cause the LED to lights up.

When the LED lights up, the

phototransistor, that can be
considered to be a switch,
is closed and the relay is
energized.

Instruction 15
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

When the pushbutton (PB) connected

to terminal 0.0 of the input module is
pressed, the circuit to which the PB is
connected to, become a closed circuit
and the internal power source will
cause the LED to lights up.

When the LED lights up, the

phototransistor, that can be considered
to be a switch, is closed and the relay
is energized.

This will cause switching in

the contacts of the relay.

Instruction 16
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

When the CPU causes

output relay 0.5 to be
energized in the output
module, the contact 0.5 will
close .

Instruction 17
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

When the CPU causes

output relay 0.5 to be
energized in the output
module, the contact 0.5 will
close .

The circuit connected to

terminal 0.5 will be closed
and any device connected
to this circuit will be
energized by the external
power supply.

Instruction 18
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

A programmable logic
controller performs cyclical Read Input
operations in the following
sequence:
1. read the input status;
2. interpret the user program
Interpret Program
containing the instructions
to be executed;
3. set the outputs according
to the inputs and user Set Output
program.

Instruction 19
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

The time for a cycle of

operation is known as a
scan time.

Scan Time

Instruction 20
 PLC Applications : Operation of a PLC

Operation of Input / Output Module

Scan time depends on the

number and types of I/Os Read Program Set
installed, the length of user Inputs Execution Outputs

program, types of Shorter Scan time

instructions, etc.
Read Program Set
Inputs Execution Outputs
A typical scan time for 500
instruction words is 10 ms. Longer Scan time

Instruction 21
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

In the earlier description of

PLC operations, the input
devices were represented
simply by normally open
contacts which when
closed, will complete a
circuit which energises the
Input relays
input relay with power via
the built-in power supply.

Instruction 22
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

On-off sensors for

interfacing with
programmable controllers
can be proximity sensors or
mechanical switches such
as push-buttons and limit
switches.

Instruction 23
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

Proximity sensors, including

capacitive, inductive or
optical type have a variety
of outputs, which can be
classified as :
• AC or DC type operating
at different voltages,
• Relay output, or solid
state output which could
be a 2-wire, 3-wire or 4-
wire type.

Instruction 24
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

The 3-wire solid state

outputs are the most
popular, especially for
connection to PLCs.

The 4-wire type is similar to

the 3-wire except that it has
both NO and NC outputs.

Instruction 25
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

The 3-wire or 4-
wire solid state
outputs can be
either the NPN type
(current sinking) or
the PNP type
(current sourcing).

The 2-wire solid state outputs can be connected to AC or DC power

supply.

Instruction 26
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

Sensors for interface to PLC

AC/DC 2 wire
Mechanical switches DC proximity sensors
proximity sensors

“Dry” contact output

Relay output Solid state output

NPN PNP

Instruction 27
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

When using solid state

sensors, it is important
that an NPN (current
sinking) sensor be
matched with a source
type input module, i.e.
current is sourced from
the input module to be
sunk by the sensor.

Instruction 28
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Sensors with PLC

Likewise, a PNP
sensor (current
sourcing) must be
used with a sink type
input module.

Instruction 29
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Loads with PLC

Output modules of PLC are

always “dry” type of
contacts i.e., the power
supply to drive the load e.g.,
solenoid, pilot light, alarm,
etc., being supplied by a
power source not within the
PC.

Instruction 30
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Loads with PLC

The output module merely

provides a “switch” to
complete the circuit to
which the load and the
power supply is connected
to.

Instruction 31
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Loads with PLC

The criteria for selecting the

correct type of “switch”
depends on:

• load current;
• load type AC or DC; and
• switching speed.

Instruction 32
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Loads with PLC

There are basically three ways of providing this “switch” as

shown in the following table:

Type of Output Load type Load current Response time

Electromechanical
AC / DC 2A typ 10 ms typ
Relay Output
Solid State Relay
AC 1A typ 1 ms typ
Output (Triac)
Transistorised Output
DC 1A typ 0.3 ms typ
(NPN/PNP)

Instruction 33
 PLC Applications : Operation of a PLC

Interfacing ON-OFF Loads with PLC

Output Modules
OUT
OUT L

Internal Circuits
Internal Circuits

X
COM
COM

85 to 250 VAC
Relay Output Triac Output

OUT OUT
Internal Circuits

Internal Circuits
L L

COM COM

5 to 12 VDC 5 to 12 VDC
Transistor Output Transistor Output
(sink type) (source type)

Instruction 34