Subject: IoT Automation Lab

Experiment No. 06

Title: : PROGRAMMABLE LOGIC CONTROLLER

Aim:Introduction to PLC and Introduction to digital I/O interface to PLC Theory

Introduction
A programmable logic controller (PLC) is a device which is used to provide control for an automated process.
Using PLC's to achieve automation has many advantages like:
1.Consistency in manufacturing can be easily achieved.
2.Complete control of the manufacturing process can be achieved.
3.Accuracy and quality can be improved.
4.Productivity can be improved.
5.Makes it easy to work in difficult or hazardous environment.
Basic block diagram : A PLC has following sections and each section has unique job to perform.

The sensing section :

This section consists of limit switches, photoelectric sensors, push buttons etc. These incoming hardware devices provides input
signal to the PLC. These devices are also called as field input devices. The term “field input " is used because this device provides
incoming signals that are tangible items that you physically connect to PLC.
Input section : This section is majorly divided into 2 parts: First, the physical screw terminals, where incoming signal (i.e. input),
from the field input devices (e.g. limit switch) are connected to the PLC. The second portion of them input section is the PLC's
internal conversion electronics. This section converts and isolates the high-voltage input level from field input devices. High-
voltage signals from field input devices are converted to +5 volts direct current (VDC) for a valid ON input signal,
and a 0 VDC for a valid OFF input signal. Incoming signal conversion and isolation is necessary because microprocessor
components operate on +5 VDC, whereas an input signal may be of 24 VDC, 120 volts alternating current (VAC), or 220 VDC. If
120 VAC signal is inputted, for example, into 5 VDC, circuit will quickly destroy your PLC.

Controller : The controller is also known as central processing unit (CPU), or simply as the processor. Central processing unit
controls or supervises the entire process. The central processing unit solves the user program and apparently updates the status
of the outputs. Programmer :The programmer is a device used by the programmer or operator to enter or edit
program instructions or data. The programmer can be handheld unit, a personal computer, or an industrial computer
programming terminal.

Output section: The ON or OFF status of the inputs are read and the information is used to solve the user ladder program and
the updated signals is sent to the output section. The output section is simply a series of switches, one for each output point,
that are controlled by CPU and are used to turn output field devices ON or OFF.

Field hardware devices : The devices that are controlled by the PLC's output section screw terminals are the field hardware
devices.
Fixed and modular PLC hardware : There are two types of physical configurations, fixed and modular. In a fixed PLC, all of its
components like, the input section, power supply, CPU and associated memory and output section - is built into one self -
contained unit. All the input and output screw terminals are built into the PLC package and are fixed, which cannot be moved i.e.
not removable. This type of PLC is also called as a packaged controller. The modular PLC comes as separate pieces. All the parts
of modular PLC are purchased separately i.e. piece by piece. It’s like customizing , we may have 2 or 3 power supplies to choose
from , a handful of different processors(CPU's) , many separate input modules , many separate output modules and a selection
of assemblies , called racks , chassis , or baseplates to hold the pieces together.

How does a PLC work?

Microprocessor is the heart of any computer, it is also called as processor, or CPU. The central processing unit supervises system
control through the user program. After reading the input signal, the CPU follows the instructions, that a programmer or
operator has stored in the PLC's memory. Depending upon the result of the solved program, the field control devices or outputs
are turned ON or OFF. When the PLC is running and following the programmer's instructions, it is called as solving the program.

How do PLC's know what they are supposed to do?

A PLC just follows the instructions stored in memory. Each instruction given by the programmer is placed in PLC memory in
ascending order. A list of instruction is called as the user ladder program.

NOTE :
When the PLC is switched into the program mode, all outputs from the PLC are forced OFF regardless of their rung logic status,
and the ladder I/O scan sequence is halted. Run mode is used to execute the user program. Input devices are monitored and
output devices are energized accordingly. Test mode is used to operate or monitor the user program without energizing any
outputs. Remote mode allows the PLC to be remotely changed between program and run mode by a personal computer
connected to the PLC processor.

INTRODUCTION TO DIGITAL PLC INTERFACE :

Introduction :
There are 16 point, 8 point and 32 point input module. As, an example, Fig (a), let us take a standard input module with 16
points. Each 16 point input module corresponds to one 16-bit word of data. Also, each input point corresponds to 1 bit in the 16-
bit word associated with the input module.

Note:- A bit position cannot be empty, there is either 1 or 0 value in each position all the times.

In the above figure, input three is a closed switch, which is going into the input screw terminal 3. As we can see the switch is
closed, an ON (1) signal is sent to the input word, in bit position 3 Also from the figure, we can see input 4 is an open switch
going into the input screw terminal 4. Since the switch is open, an OFF (0) signal is transferred to the input word, in bit position 4.
The above figure represents a four -slot modular PLC, which contains a power supply, a CPU module, and three output modules.
Here also each slot of the chassis has a corresponding number. The CPU is in slot zero, while output modules reside in slots one
through four. The slot number corresponding to a particular output module identifies in which 16-bit word the output status file
will store that particular module's ON or OFF output data. After solving user ladder program, the CPU sends each 16-bit output
status file word to its associated output module by way of backplane. Each output module takes the low-voltage ON or
OFF signal, which is represented as 0 or 1 bit in the 16-bit word, isolates it, and turns on or turns off the associated output's
switching device. Each output module has one switching device for each output point. These switching devices may be small
mechanical relays, as shown in fig (f), or solid state devices. The output status file bits electrical signal is sent from the status file
to power the relay coil output three's relay output point.

Fig (d) and fig (e) illustrated PLC's with either all input or all output modules. These examples were created to help you
understand how status file words correlate with input and output modules. Actual applications will have a mix of input and
output modules in the same PLC chassis. One of the major advantages of a modular PLC is the ability to place input and output
modules in the selected chassis in the input or output designation required for a specific application.
For example, let us take a seven slot chassis. Here, CPU is placed in slot zero and then, you are free to place any mix of input and
output modules you need in the remaining six slots.
Few observations :
In slot 3, 2 input words are assigned to the 32 - point input module. The first word is I: 3.0 and I: 3.1 is the second word. The
lower 16 input addresses, screw terminals 0 through 15, are in the first word. These addresses are I:3.0 / bits 0 through 15.
For example: I: 3. 0 / 0 is input module in slot 3, bit or screw terminal 0. I: 3. 0 / 5 is input module in slot 3, bit or screw terminal
5.The addresses for the upper 16 inputs on 32-point module are as follows: I: 3. 1 / 0 is input module in slot 3, bit or screw
terminal 16. Since the lower 16 - bit word contains input points 0 through 15, the second word contains screw terminals or input
points 16 through 31.
Remember, the second word is I: 3. 1, so the first bit is I: 3 .1 / 0, or input point 16.
I: 3 .1 / 1 is the input module in slot 3, bit or screw terminal 17.
I: 3 .1 / 2 is the input module in slot 3, bit or screw terminal 18.Fixed I/O addressing :
In fixed PLC manufactured by various companies, the CPU is residing in slot zero, also all I/O screw terminals must also be in slot
zero.
The addressing for a fixed PLC is as follows:
•I: 0 / 3 for input screw terminal 3.
•I: 0 / 8 for input screw terminal 8.
•O: 0 / 7 for output screw terminal 7.
•O: 0 / 0 for output screw terminal 0.

Conclusion:
PLCs and digital I/O modules are essential for industrial automation, providing reliability, flexibility, and seamless integration.
Understanding them is crucial for designing, programming, and troubleshooting industrial control systems