PLC Programming

Fundamental & Troubleshooting

 Before the
Programmable
Controller
  Control System :
1- apply artificial means to change the behavior of a system.
2- The type of control problem often determines the type of control
system that can be used.
3- Each controller will be designed to meet a specific objective.
The major types of control are

Continuous Discrete
Control System
Conditional Sequential
Linear Non - Linear

MRAC , Fuzzy Boolean Expert Event Temporal

PID System Based
Control
  these Systems either Event Based Or Temporal depends
On basic Function which Is :

 Switching ON , Off
Discrete Control
System
Manual Switches Magnetic Switches
Manual Control
 Manual
Switches
 As shown, this is the power circuit of
Manual manual control system consisting of
Switches main switch and the protective device.
  Starting, stopping and speed control of motor had to be
performed by hand every time.
 The operator had to move a manual switching device from one
position to another.
 Switching of large motors required great physical effort.
 Operator had to remain continuously alert to watch indicators
Dis – Advantages so as to adjust motor performance according to drive
Of Manual requirements
Control  Sequence operations of number of motors could not be
accomplished in common line shaft arrangement.
 The varied needs of individual machines like frequent starts
and stops, periodic reversal of direction of rotation, high-
starting torque requirement, constant speed, variable speed,
etc., could not be accomplished in common line shaft
arrangement
 • To replace man work on switching and this is requiring large amount
of power to operate large motors and it is impossible and inefficient.

• So , we have to find idea that save operation of Large Motors By

Using Small amount of power .

Magnetic
Control Acting On Operate Large
Small Amount
Of Power
????? Machines
 • A contactor can be best described as a magnetically closed switch. It
is the basic unit upon which the motor starter is built. Contactors are
also used for switching ON and OFF of heavy loads like furnaces,
heaters, capacitors, etc. A contactor consists of an electromagnet a
movable core, sets of stationary and moving contacts and an arc
quenching structure. Contactors can be broadly classified in to two

Magnetic general types:

Contactor (a) Solenoid type

(b) Clapper type
Magnetic
Contactor
Magnetic
Contactor
Magnetic Relay
Magnetic Relay
 Types Of
Contacts In Relay
Or Contactor
 Types Of
Contacts In Relay
Or Contactor
  The solid state relay being a purely electronic device has no moving
parts within its design as the mechanical contacts have been replaced
by power transistors, thyristors or triac’s. The electrical separation
between the input control signal and the output load voltage is
accomplished with the aid of an opto-coupler type Light Sensor .
Solid State
Relay
Timer
  It Can Be Classified into three Concept Of Operation :

 Pneumatic Timers

 Motor Driven Timers

Timer
 Electronic Timers
Pneumatic
Timers
Motor Driven
Electronic Timer
  The PLC, like all digital equipment, operates on the
binary principle. The term binary principle refers to the
idea that many things can be thought of as existing in
only one of two states. These states are 1 and 0. The 1
and 0 can represent ON or OFF, open or closed, true or
Fundamentals false, high or low, or any other two conditions. The key to
Of Logics the speed and accuracy with which binary information
can be processed is that there are only two states, each
of which is distinctly different. There is no in-between
state so when information is processed the outcome is
either yes or no.
  An AND gate is a device with two or more inputs and one
output. The AND gate output is 1 only if all inputs are 1. The
AND truth table shows the resulting output from each of the
possible input combinations. Logic gate truth tables show each
The AND possible input to the gate or circuit and the resultant output
Function depending upon the combination of the input(s). Since logic
gates are digital ICs (Integrated Circuits) their input and output
signals can be in only one of two possible digital states, i.e.,
logic 0 or logic 1. Thus, the logic state of the output of a logic
gate depends on the logic states of each of its individual inputs.
The AND
Function
The AND
Function
  An OR gate can have any number of inputs but only one output. The OR
gate output is 1 if one or more inputs are 1. The truth table shows the
resulting output Y from each possible input combination.

The OR
Function
 The OR
Function
The NOT
Function
 Examples
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 PLC
Technology
 PLC
Technology
 PLC
Technology
 PLC
Technology
  Power Supply This can be built into the PLC or
be an external unit. Common
voltage levels required by the
PLC (with and without the power
supply) are 24Vdc, 120Vac, 220Vac.

 CPU (Central Processing Unit) This is a computer where ladder

logic is stored and processed.

 I/O (Input/Output) A number of input/output

PLC Hardware terminals must be provided so
that the PLC can monitor the
process and initiate actions.

 Indicator lights These indicate the status of the

PLC including power on, program
running, and a fault. These are
essential when diagnosing
problems.
  Inputs to, and outputs from, a PLC are necessary to monitor and control a
process. Both inputs and outputs can be
categorized into two basic types:
1- logical
Inputs & Outputs 2- continuous.
Consider the example of a light bulb. If it
can only be turned on or off, it is
logical control. If the light can be
dimmed to different levels, it is continuous.
  Inputs come from sensors that translate physical phenomena into electrical
signals. Typical examples of sensors are listed below in relative order of
popularity.
 Proximity Switches use inductance, capacitance or light to detect
an object logically.
Inputs  Switches mechanical mechanisms will open or close
electrical contacts for a logical signal.
 Potentiometer measures angular positions continuously,
using resistance.
 LVDT measures linear displacement continuously
using magnetic coupling.
  Inputs may be classified as :
1- AC Input Card
2- DC Input Card
Inputs OR
1- Sinking Input (Positive Logic) (NPN)
2- Sourcing Input (Negative Logic) (PNP)
  In smaller PLCs the inputs are normally built in and are specified when
purchasing the PLC. For larger PLCs the inputs are purchased as modules,
or cards, with 8 or 16 inputs of the same type on each card. For discussion
purposes we will discuss all inputs as if they have been purchased as cards.
The list below shows typical ranges for input voltages, and is roughly in
order of popularity.
 12-24 Vdc
 100-120 Vac
Inputs  10-60 Vdc
 12-24 Vac/dc
 5 Vdc (TTL)
 200-240 Vac
 48 Vdc
 24 Vac
Inputs
  There are many trade-offs when deciding which type of input cards to use.

 DC voltages are usually lower, and therefore safer (i.e., 12-24V).

Inputs  DC inputs are very fast, AC inputs require a longer on-time. For example,
a 60Hz wave may require up to 1/60sec for reasonable recognition.

 AC power is easier and less expensive to supply to equipment.

 AC signals are very common in many existing automation devices.

  PLC inputs must convert a variety of logic levels to the 5Vdc logic
levels used on the data bus. This can be done with circuits similar to
those shown below. Basically the circuits condition the input to drive
Inputs an opto-coupler. This electrically isolates the external electrical
circuitry from the internal circuitry. Other circuit components are
used to guard against excess or reversed voltage polarity.
Inputs
Inputs
Inputs
Inputs
Inputs
Sinking & Sourcing
Sinking & Sourcing
Sinking Input
Card
Sourcing Input
Card
  Outputs to actuators allow a PLC to cause something to happen in
a process. A short list of popular actuators is given below in order
of relative popularity.
 Solenoid Valves logical outputs that can switch a hydraulic or
pneumatic flow.
 Lights logical outputs that can often be powered
Outputs directly from PLC output boards.
 Motor Starters motors often draw a large amount of current
when started, so they require motor starters,
which are basically large relays.
 Servo Motors a continuous output from the PLC can
command a variable speed or position.
  As with input modules, output modules rarely supply any power, but instead
act as switches. External power supplies are connected to the output card
and the card will switch the power on or off for each output. Typical output
voltages are listed below, and roughly ordered by popularity.

 120 Vac
 24 Vdc
Outputs  12-48 Vac
 12-48 Vdc
 5Vdc (TTL)
 230 Vac
  These cards typically have 8 to 16 outputs of the same type and can be purchased
with different current ratings.

 Dry contacts a separate relay is dedicated to each output. This allows

mixed voltages (AC or DC and voltage levels up to the
maximum), as well as isolated outputs to protect other
outputs and the PLC. Response times are often greater
than 10ms. This method is the least sensitive to voltage
Outputs variations and spikes.

 Switched outputs a voltage is supplied to the PLC card, and the card
switches it to different outputs using solid state circuitry
(transistors, triacs, etc.) Triacs are well suited to AC
devices requiring less than 1A. Transistor outputs use
NPN or PNP transistors up to 1A typically. Their response
time is well under 1ms.
Outputs
Sinking & Sourcing
Output
Sinking Output
Card
 Sourcing
Output Card
Relay Output
Card
  The central processing unit (CPU) is built into single unit fixed PLCs while
modular rack types typically use a plug-in module. CPU, controller, and
processor are all terms used by different manufacturers to denote the
same module that performs basically the same functions. Processors vary
The Central in processing speed and memory options. A processor module can be
Processing divided into two sections: the CPU section and the memory section .
Unit (CPU) The CPU section executes the program and makes the decisions needed
by the PLC to operate and communicate with other modules.
The memory section electronically stores the PLC program along with
other retrievable digital information.
The Central
Processing
Unit (CPU)
  The CPU of a PLC system may contain more than one processor. One
advantage of using multiprocessing is that the overall operating speed
is improved. Each processor has its own memory and programs, which
operate simultaneously and independently. In such configurations the
The Central scan of each processor is parallel and independent thus reducing the
Processing total response time. Fault-tolerant PLC systems support dual processors
Unit (CPU) for critical processes. These systems allow the user to configure the
system with redundant (two) processors, which allows transfer
of control to the second processor in the event of a processor fault.
 • Memory is a component that stores data , Program and information
in PLCs.The Process of putting new information in memory location
called Writing. The Process of retrieving information from memory
location called Reading.

• The common types of memories is

RAM (Random Access Memory)
Memory Type this memory is fast, but it will lose its contents when power is lost,
this is known as volatile memory. Every PLC uses this memory
for the central CPU when running the PLC.
ROM (Read Only Memory)
this memory is permanent and cannot be erased. It is often used
for storing the operating system for the PLC
 • The common types of memories is
EPROM (Erasable Programmable Read Only Memory)
this is memory that can be programmed to behave like ROM, but it can
be erased with ultraviolet light and reprogrammed.

EEPROM (Electronically Erasable Programmable Read Only

Memory Type Memory)
This memory can store programs like ROM. It can be programmed
and erased using a voltage, so it is becoming more popular than
EPROMs.
  Memory is the element that stores information, programs, and data in
a PLC. The user memory of a PLC includes space for the user program
as well as addressable memory locations for storage of data. Data are
stored in memory locations by a process called writing. Data are retrieved
Memory Design from memory by what is referred to as reading . The complexity of the
program determines the amount of memory required. Memory elements
store individual pieces of information called bits (for binary digits ). The
amount of memory capacity is specified in increments of 1000 or in “K”
increments, where 1 K is 1024 bytes of memory storage (a byte is 8 bits).
  The program is stored in the memory as 1s and 0s, which are
typically assembled in the form of 16-bit words. Memory sizes are
commonly expressed in thousands of words that can be stored in
the system; thus 2 K is a memory of 2000 words, and 64 K is
a memory of 64,000 words. The memory size varies from as small
as 1 K for small systems to 32 MB for very large systems Memory
capacity is an important prerequisite for determining whether a
Memory Design particular processor will handle the requirements of the specific
application. Memory location refers to an address in the CPU’s
memory where a binary word can be stored. A word usually
consists of 16 bits. Each binary piece of data is a bit and eight bits
make up one byte .Memory utilization refers to the number of
memory locations required to store each type of instruction.
Inputs Memory
Mapping
Inputs Memory
Mapping
Inputs Memory
Mapping
Inputs Memory
Mapping
Inputs Memory
Mapping
Scan Cycle
  The scan is normally a continuous and sequential process of reading the status
of inputs, evaluating the control logic, and updating the outputs. shows an
overview of the data flow during the scan process. For each rung executed,
the PLC processor will:
• Examine the status of the input image table bits.

Scan Cycle • Solve the ladder logic in order to determine logical continuity.
• Update the appropriate output image table bits, if necessary.
• Copy the output image table status to all of the output terminals.
Power is applied to the output device if the output image table bit
has been previously set to a 1.
• Copy the status of all of the input terminals to the input image
table. If an input is active (i.e., there is electrical continuity), the
corresponding bit in the input image table will be set to a 1.
Scan Cycle
  The time it takes to complete a scan cycle is called the scan cycle
time and indicates how fast the controller can react to changes in
inputs. The time required to make a single scan can vary from
about 1 millisecond to 20 milliseconds. If a controller has to react
to an input signal that changes states twice during the scan time,
it is possible that the PLC will never be able to detect this change.
Scan Cycle For example, if it takes 8 ms for the CPU to scan a program, and an
input contact is opening and closing every 4 ms, the program may
not respond to the contact changing state. The CPU will detect a
change if it occurs during the update of the input image table fi le,
but the CPU will not respond to every change.
  The scan time is a function of the following:
• The speed of the processor module
Scan Cycle Time • The length of the ladder program
• The type of instructions executed
• The actual ladder true/false conditions