Industrial Automation

EE11405

PLC
• In old days, electrical control was mostly based on relays
(Contactors) (i.e. Relay logic). Since from 1970 PLCs
(Programmable Logic Controllers) have become most
common choice for manufacturing / process control.
• Advantages of PLCs over Relay logic:
– PLCs are programmbale
– Many control relays can be replaced by software,
which means less hardware failure,
– It is easier to make changes in software than in
hardware.
– Special functions such as time delay actions,
counters are easy to produce in software.
– Reliability is more.
– There is almost no task limit to tasks for which PLCs
can be used.
– It is cost effective control system
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• Disadvantages of PLCs:
– PLC were Designed for Relay Logic Ladder and have
Difficulty with some Smart Devices.
– To maximize PLC performance and Flexibility, a
number of Optional Modules must be added

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 1
Industrial Automation
EE11405

PLC Vs PC
• PLCs are designed to be operated in industrial
environment with wide range of ambient temperature,
vibration and humidity conditions. It is not effected by the
electrical noise present in the industrial environment.
• In computer, the inputs are floppy drives and CD Roms
and output is a printer, but in PLC the inputs are signals
from control elements like push-buttons, limit switches,
temperature switches, pressure switch and transducer
etc., installed on the machines to be controlled. Also the
output are final control elements like contactors,
solenoids, positioning valves, indication lights, an so
forth.
• The PLC is not a disc based system like PC. With a disc
based system there is a continuous checking of what to
do next. With a PLC the answer of what to do next is
inherent, there is no consulting. The PLC program is
stored in battery backed RAM or EPROM.
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• Another important difference between PLC and PC is

that the PLC contains the operating systems and
application programs in ROM memory. The operating
system does not have to load an application program, as
it is already in ROM. It is difficult to differentiate between
PLCs, ‘BIOS’, operating system and application
program.
• Another major difference between PLC and computer is
the programming language. PLC is not programmed in
one of the high language used for programming a
computer. As PLC is designed to be operated by plant
engineers and maintenance personnel with limited
knowledge of computers, it is designed to be
programmed using RELAY LADDER LOGIC. However
some PLCs are available which can be programmed
using FORTRAN and BASIC, but relay ladder logic
programming is the most popular. Some PLCs are also
programmed using, Boolean Algebra, Statement lists
and Control system flow chart languages. 4

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 2
Industrial Automation
EE11405

• Another major difference is that troubleshooting is

simplified in most PLCs because they include fault
indicators, blown-fuse indicators, input and output status
indicator, and written fault information that can be
displayed on the programmer.

Block Diagram of PLC

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 3
Industrial Automation
EE11405

• A typical PLC can be divided into five components. These

components consist of the processor unit, memory, power
supply, input/output section (interface) and the programming
device. Some manufacturers refer to the processor as a
C.P.U. or central processing unit. The components are
shown in previous Fig.
• The power supply is required to convert 240 volts AC
voltage to the low voltage DC required for the logic circuits
of the processor and the internal circuits of the input and
output modules. DC power for the input and output devices,
if required is generally provided from a separate source.
• The input module and output modules are referred to a I/O
section (I for input and O for output). The real word input
devices like push buttons, limit switches, analog sensors are
wired to input module and real word output devices like
contactors, solenoid valves indicator lights, positioning
valves etc., are wired to the output modules. Real word
input and output devices are of two types: discrete and
analog. Discrete I/O devices are either ON or OFF (open or
closed), while analog devices have infinite number of 7
possible values.

• Examples of discrete input devices are pushbutton and

limit switch while analog input device are temperature
probes, Pressure transducers etc. which gives varying
voltage and current. The input from the analog input
device is converted by the analog module called Analog-
to-Digital Convener (ADC) into a proportional binary
number and stored in memory of the PLC for further use
by the processor
• Discrete output devices like contactors, solenoid valve
coils, indication lamps are either energised or de-
energized, but Analog output devices require varying
current or voltage to control the output. Example of
analog output device is the positioning valve, which
gives variable opening of the valve depending upon the
variable voltages/current applied to the valve which is
obtained using the Digital-to Analog Converter (DCS) as
the output module.

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 4
Industrial Automation
EE11405

• The processor unit operates on low DC voltage of 5

volts. Input modules thus contains circuitry that converts
input voltages of 120-240 V AC or 0-24 DC, etc., from
discrete input devices to low level DC voltage typically 5
V DC. Analog input modules converts the 4 -20 milli
ampere signals from sensors to low-level DC voltages
for the processor unit. Similarly, the output modules
change low level DC signals from the processor to 120-
240 AC or low level DC voltages or give output currents
in range 4-20 milli ampere.
• The programming device for a PLC can be a Hand-held
programmer, Dedicated programmer or Personal
computer. The program is entered using Relay Ladder
Logic, Statement Lists or Control System flow charts but
the most popular method of programming is the Relay
Ladder logic.

Control Panel with PLC

10

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 5
Industrial Automation
EE11405

Components

Central Processing Unit (CPU)

Input Output Modules , Remote Input Output
Modules

Power Supply

Bus system

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Central Processing Unit

It is a micro-controller based circuitry. The CPU consists of
following blocks :
• Arithmetic Logic Unit (ALU),
• Program memory
• Process image memory (Internal memory of CPU)
• Internal timers and counters
• Flags

CPU performs the task necessary to fulfill the PLC
functions. These tasks include Scanning, I/O bus traffic
control, Program execution, Peripheral and External device
communication, special functions or data handling
execution and self diagnostics.

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Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 6
Industrial Automation
EE11405

Input module

These modules act as interface between real-time status of
process variable and the CPU.

Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
(mV)

Digital input module : Typical input to these modules is 24 V
DC, 115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off
status

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Output module

These modules act as link between the CPU and
the output devices in the field.

Analog output module : Typical output from these
modules is 4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration

Digital output module : Typical output from these
modules is 24 V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers,
Pump valve on off control
Remote I/O module

These modules are attached to computers which
are connected to network

14

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 7
Industrial Automation
EE11405

Power Supply

The power supply gives the voltage required for
electronics module (I/O Logic signals, CPU, memory
unit and peripheral devices) of the PLC from the line
supply.

The power supply provides isolation necessary to
protect the solid state devices from most high voltage
line spikes.

As I/O is expanded, some PLC may require additional
power supplies in order to maintain proper power levels.

15

Bus System

It is path for the transmission of the signal . Bus system
is responsible for the signal exchange between
processor and I/O modules

The bus system comprise of several single line i.e. wires
/ tracks

16

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 8
Industrial Automation
EE11405

Different PLCs available in market

• Siemens
– S5 -110U, 115U, 135U
– S7 - 200, 300, 400
• Allen Bradley
– Micrologix 1000, 1200, 1500
– SLC 5/01, 5/02, 5/03
– PLC 5/10, 5/25 and 5/40
• Modicon
– Nano
– Micro
– Premium
– Quantum

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Origins of Ladder Diagram

• The Ladder Diagram (LD) programming
language originated from the graphical
representation used to design an
electrical control system
– Control decisions were made using relays
• After a while Relays were replaced by
logic circuits
– Logic gates used to make control OR
AND
decisions
• Finally CPUs were added to take over the
function of the logic circuits
– I/O Devices wired to buffer transistors
– Control decisions accomplished through CPU
programming
• Relay Logic representation (or LD) was
developed to make program creation and
maintenance easier
– Computer based graphical representation
of wiring diagrams that was easy to
understand 18
– Reduced training and support cost

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 9
Industrial Automation
EE11405

What is a Rung?
• A rung of ladder diagram code can contain both
input and output instructions
– Input instructions perform a comparison or test and
set the rung state based on the outcome
• Normally left justified on the rung
– Output instructions examine the rung state and
execute some operation or function
• In some cases output instructions can set the rung state
• Normally right justified on the rung

Input Instruction Output Instruction

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Series Vs Parallel Operations

• Ladder Diagram input instructions perform logical AND and OR
operations in and easy to understand format
– If all Input Instructions in series must all be true for outputs to
execute (AND)
– If any input instruction in parallel is true, the outputs will execute
(OR)
• Paralleling outputs allows multiple operations to occur based on the
same input criteria

A C D E

B AND F

Branches
OR
IF ((A OR B) AND (NOT C) AND D) THEN E=1; F=1 END_IF
20

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 10
Industrial Automation
EE11405

Ladder Logic Execution

• Rungs of Ladder diagram are solved from Left to

right and top to bottom
• Branches within rungs are solved top left to
bottom right
Ladder Rung

A D E
Left Power Rail Right Power Rail
B G
Branch
F H
I J
P S
K
R 21

22

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 11
Industrial Automation
EE11405

Starting of an Induction Motor

23

Starting of an Induction Motor

24

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 12
Industrial Automation
EE11405

25

Here Time delay is provided by timers TD1 and TD2

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Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 13
Industrial Automation
EE11405

Ladder diagram for PLC

Steeper Motor Driver circuit :

27

Students Notes _Compiled By

Dr.M.S.Narkhede, LEE, GP Mumbai 14