BASICS OF PLC

Prepared
By:
JAY BHAVSAR
 Contents
 History

 Introduction  PLC Programming language

 Ladder logic
 Difference between PLC and DCS and PC
 Advantage and disadvantage
 Data flow overview
 Application

 Major components

 PLC scan cycle

 PLC communication
 History of PLC
 Devloped to replace relays in late 1960’s.

 In 1970’s PLC become most common choice for manufacturing controls

 Plc was first design and developed by modicon as a relay replacer for
general motors
 INTRODUCTION

What is PLC?
 PLC is a continuously monitor the status of devices connected as
inputs. Based upon a user written program ,stored in memory it
control the status of devices connected as output
 A programmable logic controller (PLC) is an industrially computer-
based unit that performs discrete or continuous control functions in
a variety of processing plant and factory environments.
What is PLC?

 It is capable of storing instructions to implement control functions

such as sequencing, timing, counting, arithmetic, data manipulation
and communication.
 The I/O interfaces provide the connection between the PLC and the
information providers (inputs like pushbuttons, sensors,…) and the
controllable devices (outputs like valves, relays, lamps,…).
What is PLC?
Components of automation

Sensor: Produce the input value for the controller as feedback. For
example, RTD, strain gauge.

Controller: Controls the process by sending the particular value

according to the set value and feedback coming from the sensor.
Difference between them called feedback. According to the behavior of
error, control strategies is being decided. Controllers can be Digital
controllers, PLCs etc.

Actuators: Component which is acting on the response of the

controller. And as a result process value will be effected.
comparison between PLC and PC
Difference between PLC and DCS
 PLC is usually used for controlling medium or large scale
application

 Whereas DCS is used for controlling entire plant

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

EUROPEAN
1. Siemens
2K&M
3. Festo
Selecting a PLC

Criteria


• Number of logical inputs and outputs.
• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
 PLC Size
1. SMALL
 it covers units with up to 128 I/O’s and memories up to 2
Kbytes.

2. MEDIUM
 It 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.
PLC SCAN CYCLE

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
CYCLE TIME DEPENDS ON THE SIZE OF THE PROGRAMS,
NO. OF I/O’S AND AND AMOUNT OF COMMUNICATION
REQURIED

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

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.
 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.
DATA FLOW OVERVIEW
DATA FLOW OVERVIEW
DATA FLOW OVERVIEW
PLC SCAN PROCESS
PROGRAMING DEVICE
HAND-HELD UNIT
WIH DISPLAY
Hand held units are often used on the factory
floor for troubleshooting, modifying programs,
and transferring program to multiple machines
It is not able to display long programming so its
not widely used in industy
PROGRAMING DEVICE

PC WITH APPROPRIATE
SOFTWARE
The software allows users to create ,edit and store
program

The plc is communicate with PC via a serial or

parallel data communication
 Major components of 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
Solenoids,
contactors,
Pushbuttons, alarms
contacts, etc.
limit switches, PROGRAMMING
etc. DEVICE
Major components of PLC
1. Power supply :
 The power supply converted line voltage commonly 120 or 240
volts AC
 AC Voltage converted into commonly 24v To power on the PLC and
its components

2. I/O MODULES :

 Provides signal conversion and isolation between the internal logic-

level signals inside the PLC and the field’s high level signal.
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.
INPUT MODULE

 These module act as interface between real time status of process

variable and the CPU
 Analog input module : typically input to these module is 4-20mA, 0-
10v
 Example - level Tx , RTD , thermocouple
 Digital input module : input to these modules is 24V DC 115V AC
230VAC
 switch , pushbuttons relays
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PLC

PUSHBUTTONS
OUTPUT MODULE

 These module act as a link between the CPU and the output
devices

 Analogoutput module : typically output to these module is 4-

20mA, 0-10v
 Ex – control valves, speed, vibration
 Digital
output module : output to these modules is 24V DC 115V
AC 230VAC
 Ex – solenoid valve, actuator, lamp, on off control
PLC SCAN PROCESS
RUNG

RAIL
PLC SCAN PROCESS
PLC SCAN PROCESS
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

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.
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.
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.
PLC PROGRAMMING LANGUAGE
 Ladder diagram (LD)
 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)
IEC 1131-3 is the international standard for programmable controller
programming languages. The following is a list of programming languages
specified by this standard:

5 types of programming language used in PLC

 1. Ladder diagram (LD)
2.Sequential Function Charts (SFC)
3.Function Block Diagram (FBD)
4.Structured Text (ST)
5.Instruction List (IL)

 One of the primary benefits of the standard is that it allows multiple

languages to be used within the same programmable controller. This
allows the program developer to select the language best suited to
each particular task.
Ladder Logic

 Ladder logic is the main programming method used for PLC's. As

mentioned before, ladder logic has been developed to relay logic
 XIC - Examine if Closed
 XIO - Examine if Open
 OTE - Output Energize
 OTL - Output Latch
XIC Examine if Closed
XIC Examine if OPEN
OTE Output Energize

Definition
Turns a bit on or off
Use OTE instruction in your
ladder logic to turn on a bit
when rung condition is
evaluated as true

EXAMPLE
Light
Motor run signal
Internal bits
Output Energize
TIMER

 TON - Timer On Delay

 TOF - Timer Off Dealy
 RTO - Retentive Timer
 Definition
TON Timer On Delay Count time base intervals when the
Symbol instruction is true.
The Timer On Delay instruction
begins to count time base intervals
when rung conditions become true.
As long as rung conditions remain
true, the timer adjust its
accumulated value (ACC) each
evaluation until it reaches the
preset value (PRE). The
accumulated value is reset when
rung conditions go false, regardless
of whether the timer has timed out.
TOF Timer Off Delay
DEFINATION:
Counts time base intervals when the
instruction is false.
The Timer Off Delay instruction begins to
count time base intervals when the rung
makes a true to false transition. As long as
rung conditions remain false, the timer
increments its accumulated value (ACC each
scans until it reaches the preset value (PRE).
The accumulated value is reset when rung
conditions go true regardless of whether the
timer has timed out.
RTO Retentive Timer
DEFINATION:
Counts time base intervals when the
instruction is true and retains the
accumulated value when the
instruction goes false or when power
cycle occurs.
The Retentive Timer instruction is a
retentive instruction that begins to
count time base intervals when rung
conditions become true.
 RTO Retentive Timer

 The Retentive Timer instruction retains its accumulated value when

any of the following occurs:
 Rung conditions become false.
 Changing Processor mode from run /Test / program mode.
 The processor loses power while battery back up is still
maintained.and a fault occurs.
COUNTERS
COUNTERS

 CTU - Count Up
 CTD - Count Down
 RES - Reset
CTU Count UP
Increments the accumulated value at each false
to true transition and retains the accumulated
value when the instruction goes false or when
power cycle occurs.
The CTU is an instruction that counts false to
true transition. When this transition happens the
accumulated value is incremented by one count.
A CTU accumulation is reset by the RES
instruction.
If the accumulation value is over the maximum
range then the overflow (OV) bit will be true.
RES Reset
Resets the accumulated value and status bit
of a timer or counter.
Use a RES instruction to reset timers or
counters. When the RES instruction is
enabled, it resets the Timer On Delay,
Retentive Timer, and Counter Up, Counter
Down instruction having the same address
as the RES instruction.
VARIOUSSYMBOL USED
IN LADDER LOGIC
 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.

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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.
Function Block Diagram
 Function Block diagram (FBD) is used for PLC programs described
in terms of graphical blocks.

 Functional blocks can have standard functions, such as those of

the logic gates or counter or timers or have functions defined by
the user, e.g. a block to obtain an average value of inputs.
Statement List

 In statement-list programming approach, an instruction set similar to

assembly language for a microprocessor is used. Statement lists,
available on few brands of PLCs, are the most flexible form of
programming for the experienced user but are by no means as
easy to follow as ladder diagrams or logic symbols.
DIGITAL OPERATION
Different Logic Gates Circuit Diagrams

 a logic gate is an idealized or physical device implementing a

Boolean function; that is, it performs a logical operation on one or
more logical inputs, and produces a single logical output
 Logic circuits include such devices as multiplexers, registers,
arithmetic logic units (ALUs), and computer memory, all the way up
through complete microprocessors, which may contain more than
100 million gates. In modern practice, most gates are made from
field-effect transistors (FETs), particularly MOSFETs (metal–oxide–
semiconductor field-effect transistors)
Combinational Logic

 Combinational Logic Circuits are made up from basic logic NAND,

NOR or NOT gates that are “combined” or connected together to
produce more complicated switching circuits. These logic gates are
the building blocks of Combinational Logic Circuits.
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).
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).
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.
Programing example
ADVANTAGE

 Very High Accuracy

 Low Power Consumption (Energy Saving)
 Small in Size (Required Lased space)
 Easily programmable
 Easy Maintenance
Disadvantages

 High Skilled Engineering Required for that high skilled person

required
 Difficulty with changes or replacements
 Some high Initial Cost.
 74
Areas of Application
 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical

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THAN
K YOU