Programmable Logic Controllers

Prof. Alok Kanti Deb

Dept of Electrical Engineering
IIT Kharagpur
e-mail: [email protected]
Programmable controllers (PCs), sometimes called Programmable logic
controllers (PLCs), are largely used in process industries and they are also
applied in power station sequence control systems.

What are PLCs ?

A digitally operating electronic system, designed for use in an industrial

environment, which uses a programmable memory for the internal storage of
user oriented instructions for implementing specific functions such as logic,
sequencing, counting and arithmetic.

They are used in control, through digital or analog inputs and outputs, various
types of machines or processes.

The PLC and its associated peripherals are designed to be easily integrated
into an industrial control system and easily used for all other intended
functions.

Car Wheel Manufacturing

 PLC Manufacturers
• ABB Kent Taylor
• Allen Bradley
• Aromat
• Bailey Controls
• Robert Bosch Corp
• Control Technology
• Eason > 400 PLC Manufacturers
• GE Fanuc
• Honeywell
• Mitsubishi
• Omron
• Siemens Industrial Automation
• Toshiba
• Westinghouse
 Advantages

• Flexibility
• Implementing Changes and correcting errors
• Large Quantities of Contacts
• Lower Cost
• Pilot Running
• Visual Observation
• Speed of Operation
• Ladder or Boolean Programming Method
• Reliability and Maintainability
• Simplicity of Ordering Control System Components
• Documentation
• Security
• Ease of Changes by Reprogramming
 Disadvantages / Precautions

• Newer Technology – Technicians are unwilling to adopt newer

technology

• Fixed Program Applications – Multiprogramming capabilities of

PLCs are unutilized for fixed-program applications.

• Environmental Considerations – High heat and vibration interfere

with the PLC electronics.

• Fixed-Circuit Operation – For a fixed control system, PLC may be

costly. PLCs are most effective when periodic changes in operation
are made.
 Overall PLC System
PM
Programmer/
Monitor

CPU

Microprocessor
Input Output
Module Memory Module

Power
Supply

Rack & Chassis

 Central Processing Units
The brain of the system, containing
• Microprocessor: carries out mathematic and logic operations
• Memory: data and information are stored and retreived; holds
the system software and user program.
• Power Supply: converts AC line voltage to various
operational DC values.

Programmer / Monitor
Used to communicate with circuits of the PLC.
e.g. Hand-held terminals, industrial terminal, personal computer etc.

I/O Modules
Input Module has terminals into which outside process electrical
signals, generated by sensors and transducers are entered.
Typically 4,8,12 or 16 terminals per module.
Often input and output modules have different terminals.
 Some Input Field devices

Push Button Position Limit Switch Level Limit Switch

Temperature Limit Switch Pressure Limit Switch

 Some Output Field devices

M
SOL AH
PL

Motor Solenoid Pilot Lamp Alarm Horn

NO NC

Heater Relay Contact Relay Contact

(Normally-Open) (Normally-Closed)
 Counter

Count Input Counter

Reset Input
Set Value

• Counts down from Set Value when its execution condition (count
input) goes from OFF to ON.

• When the value reaches ZERO, the counter contact point is

turned ON.

• Its is reset with a reset input.

• Set value decided by the Programmer.

 Timer

Start Input Timer

Set Value

• Activated when its execution condition goes ON and starts

decreasing from the Set Value.

• When the value reaches ZERO, the timer contact point is turned
ON.

• Its is reset to Set Value when the execution condition goes OFF.

• Set value decided by the Programmer.

 Memory Map
Memory maps vary with different PLC manufacturers. In general, all PLCs
must have memory allocated for following 4 items.

Executive: Executive software is a permanently stored collection of system

programs. Performs system activities like execution of control programs,
communication with peripheral devices etc. Not accessible to user.

Scratch Pad: Temporary storage used by CPU to store relatively small

amount of data for interim calculations or control.

Data Table: Stores any data associated with the control program such as
timer/counter set values and any other stored constants or variables that
are user by the control program. Retains the status of system inputs once
they have been read, and the system outputs once they have been set by
the control program. Accessible to user.

User program: Provides storage for any programmed instructions entered

by the user. Accessible to user.
 Data Table Memory Area
Input Table: Array of bits that stores the status of discrete inputs, which are
connected to input interface circuits. Maximum number of inputs in the input
table is the maximum number of field inputs that can be connected to the PLC.

If a PLC system has 8 input modules, each with 16 terminal points, then the
input table in PLC memory (assuming 16 bit word length) will look as below:

Rack
Terminal 12

Slot
Input
15 13 10 08 06 04 02 00
0 0 0 1 000

002
Bit
address 004

007
Input module
with 16 terminals
Word
address
Limit switch has an address of 00012 for its corresponding bit in input table.
If limit switch is ON (closed), the bit 00012 will be 1; if the limit switch is OFF (open), bit will be 0.
Output Table: Array of bits that controls the status of the output devices, that
are connected to output interface circuits. Maximum number of bits in the
output table is the maximum number of field devices that can be interfaced to
the PLC.

Each connected output has a bit in the output table that correspond exactly to
the terminal to which the output is connected.

Bits of the output table are controlled (ON/OFF) by the processor as it

interprets the control program logic. If a bit in the table is turned ON (logic 1) /
OFF (logic 0), then the connected output is switched ON/OFF.

The output of timers or counters are used as internal outputs which are
generated after a time interval has expired or a count has reached a set
value.
 Ladder Diagrams
Most logic control systems may be implemented with 3 basic logic functions
AND, OR, and NOT.

Either singly or in combination they determine if an output field device is to be

switched ON or OFF.

Most widely used language for implementing these instructions are ladder
diagrams.

The AND function

A B

A B
Y A.B=Y
Y

Switch Interpretation Ladder diagram Boolean expression

 The OR function
A

A
B

B Y A+B = Y
Y

Switch Interpretation Ladder diagram Boolean expression

The NOT function

A
B A B
B

Switch Interpretation Ladder diagram Boolean expression

 Proper Construction of PLC Ladder diagrams
• A contact must always be inserted in slot 1 in the upper left.
• A coil must be inserted at the end of a rung.
• All contacts must run horizontally. No vertically oriented contacts are allowed.
A B

D E

No vertically oriented contacts allowed

A B
Y
D C C E

D E

One solution to vertically oriented contact problem

• The number of contacts per matrix is limited, depending on the
manufacturer. e.g. 11 across by 7 down
• Only one output may be connected to a group of contacts.

Y
• Contacts must be “nested” (a branch circuit programmed within a branch
circuit) properly or, not at all.

A A
Y Y

B B

C D C D

Incorrect Correct
• Flow must be from left to right.

A B
Y
C D
Not
“legal”
E

A B
Y
E C C D

The addition of 2 contacts (E and C on the left) adds the path E-C-B
• Contact progression should be straight across.

A B
Y
C D E

Incorrect

Use the topmost available junctions

A D B
Y
C E
 Process Scanning Considerations
PLCs function by scanning their operational programs. Each PLC operational
cycle is made up of three separate parts:

• Input scan
• Program scan
• Output scan

INPUT OUTPUT
INPUT USER OUTPUT
STATUS STATUS
TERMINALS PROGRAM TERMINALS
TABLE TABLE

Input Scan Program Scan Output Scan

 Start/Stop Pushbutton System
000 – word address of input module
100 – word address of output module
Each module has 16 terminals: 00 to 15
Start & Stop pushbuttons connected to terminal 00 & 01 of 000.
Signal from terminal 00 of 100 controls the machine.
00000 10000
As pushbutton is released
machine comes to the OFF state.

00000
10000
Machine ON if it is already ON.
10000 How to put OFF the machine ??

00000
00001 10000

10000
 Forward / Reverse Control
Each directions coil has its own start button. The single stop button
stops either coil’s operation. STOP must be pushed before changing
direction. Interlocks are provided so that both outputs cannot be
energized at the same time. It can also be used for low-speed/high-
speed or part-up/part-down control system.
00001 – stops operation in either direction
00002 – starts forward motion (10007)
00003 – starts reverse motion (10008)

00001 00002 10008 10007

10007

00001 00003 10007 10008

10008
 Automatic Weigh Station
Consider a conveyor system in which an automatic weigh station activates a
trap door or diverter in the event an overweight item passes over the weigh
station. The trap door opens immediately and remains open for 4 seconds to
allow sufficient time for the item to drop through to the overweight track (For
the system to work properly, it is necessary for successive items on the
conveyor to be separated by distances of at least 5 seconds or so).

Trap door

Input Variables.
00000 – pressure switch connected to terminal 00 of input module

Output Variables
10000 – solenoid connected to terminal 00 of output module
 00000
TIM000 10000

10000

10000
TIM000
# 0040

Timer TIM000 counts time based intervals of 0.1 sec (40 counts will
mean an elapsed time of 4 sec)
 Automatic Bottle Filling Control
To implement a control program that will detect the position of a bottle
via a limit switch, wait for 5 secs, and then fill the bottle until the photo
sensor detects the filled position. After the bottle is filled, it will wait for
7 secs to continue to the next bottle. The start and stop circuits will
also be included for the outfeed motor and for the start of the process.

Filling
Arrangement
(Solenoid
operated)
Photoelectric
Empty bottles sensor Filled bottles

Conveyor LS Conveyor

Motor 1 Rollers Motor 2

 00000
00001 10001

The I/O assignments are as below: 10001

Start process pushbutton : 00000 00002

10001 10000
Stop process pushbutton : 00001
01000
Limit switch (position detect) : 00002
00002 10001
Photo sensor (level detect) : 00003 TIM000
# 0050
Feed-motor drive : 10000
TIM000 00003 10001 10002

Outfeed-motor drive : 10001

00003 10001 01000
Solenoid control : 10002 TIM001
# 0070
Timer for 5 sec delay : TIM000 TIM001

00002 10001 01001

Timer for 7 sec delay : TIM001
01000
 Applications

• PLC with analog input and output modules for driving analog valves and
actuators using the PID control algorithms are being used in process
industries.

• Large PLCs are used for complicated control tasks that require analog
control, data acquisition, data manipulation, numerical computations and
reporting. They can be interfaced with applications where LAN may be
required.

• Some PLCs offer the ability to program in other languages besides the
conventional ladder language. eg. using BASIC

• Some PLCs use Boolean algebra to enter and explain the control logic.
Scope of Application in Thermal Power Plant

• Ash Handling System

• Coal Handling Plant

• Chemical Treatment Plant

• Compressor House

• Pump House

• Turbine House

• Fire Water System

• Similar subsystems
 Alternate Programming Languages
80 % of PLC Programming is Ladder diagrams, the language of the
“electricians”.

Vision: To have a higher level programming language for future PLCs with
requirement of,

• demand for elaborate machine and process control

• need to reduce programming time

• necessity of communicating program to a wider spectrum of

company personel.

• trend towards use of high level, user friendly, graphics based

programming language
Real world machine and control process involve sequential/concurrent
or Series/Parallel activity.

eg. A machine may involve the following steps:

Load → Punch → Stamp → Fasten → Eject

in a sequence

If only one part is run → No concurrent processing

If parts are passed continuously, where loader and puncher are all
operating simultaneously (though in different parts) – concurrent
processing occurring.

With latching contact, ladder logic becomes a concurrent processing

language.

Complex ladder logic programs are also confusing.

Need for a language that allows both sequential & concurrent processing !
BASIC: A STEP UP

10 READ X Acts like a NO and a Coil.

20 IF X=0, THEN Y=0

X
Y
30 IF X=1, THEN Y=1

BASIC – sequential language

Ladder Logic – good for parallel programming

 IEC 61131-3 Programming
IEC-International Electrotechnical Commission
- Complete collection of Standards on Programming Controllers and their
associated peripherals.

PART 1: General Information

PART 2: Equipment requirement and tests.

PART 3: Programming Languages.

PART 4: User Guidelines

PART 5: Communication

PART 6: Reserved for Future Use

PART 7: Fuzzy Control Programming

PART 8: Guidelines for the Application and Implementation of Programming

IEC 61131-3 emerged to establish a standard for programming.

It specifies the following programming languages

• Ladder Diagram (Graphics based)

• Instruction List (Text based)

• Function Block Diagram (Graphics based)

• Structured Text (Text based)

• Sequential Function Chart (Graphics based)

References :
1. Webb and Reis, “Programmable Logic Controllers”, 2003.
2. John R Hackworth, “Programmable Logic Controllers: Programming Methods and
Applications”, 2004.
3. M Gopal, “Digital Control and State Variable Methods”, McGraw Hill, 2005
4. William Bolton, “Programmable Logic Controllers”, 2011
5. Jon Stenerson, “Fundamentals of Programmable Logic Controllers, Sensors and
Communication”, 2005
Thank You