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semiconductor textile Power supply is provided to the processor unit, input and output
module unit. Power supply may be integral or separately mounted
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CATEGORIES  Home / Electronics Articles / Block diagram of programmable voltage voltage regulator
Memory section
logic controller (PLC)
voltage regulators zigbee
The memory section is the area of the CPU in which data and
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Block diagram of programmable information is stored and retrieved.  Data Memory is used to store
Cement-Ceramic logic controller (PLC) numerical data required in math calculation, bar code data etc.
Civil Engineering User memory contains user’s application program.
Author: Technical Editor
Category: Electronics Articles
24 Apr 17
Electrical Articles
Electronics Articles The block diagram of programming logic controller (PLC) is shown Programming device

Information in above figure. The PLC has following basic sections are, Programming devices are dedicated devices used for loading the
Mechanical Articles user program into the program memory or edit it and to monitor

Polytechnic Colleges List the execution of the program of the PLC. It is also used to
troubleshoot the PLC ladder logic program. Hand held terminal
Textile
(HHT) or dedicated terminal or personal computer are
Uncategorized
programming devices commonly used in most of the PLCs.

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Building capacitor current Processor section (CPU)

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sink and what factors What is simple
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affect its… mechanisms
operation within PLC. The CPU makes decision and executes
IC-741 IGBT transistor
control instructions based on the program instruction in memory.
inductor inductors

Integrated circuits LED Input and output module

light LVDT meter The input module is a mediator between input devices and central
Are There Any Benefits of
microcontroller processing unit (CPU) which is used to convert analog signal into
Using Exam Dumps for
digital signal.

Microprocessor MOSFET Passing… Theory of machine

The output module is a mediator between output devices and
motor photodiode PLC
central processing unit (CPU) which is convert digital signal into
PN junction Power analog signal. Tags: PLC, power supply
power supply rectifier
 Pages X X
Types of Industrial Control Systems What is PLC Redundancy? P LC TUTO RI AL S

PLC Redundancy Systems may utilize a warm standby,

Inst Tools
P LC TUTOR I ALS
Menu Industrial Control Systems Different Types of Industrial
hot standby, or voting configuration as per the design
consideration of  specific industrial a…
Control Systems are Distributed Control System (DCS),
Remote terminal unit (RTU) and Programm…

Components of PLC
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The recommended controller for SCADA systems is the programmable logic controller
(PLC). PLCs are general-purpose microprocessor based controllers that provide logic,
(1) Power supply :
timing, counting, and analog control with network communications capability.
The power supply converts facility electrical distribution voltage, such as 230 VAC, 120

Components of PLC VAC or 125 VDC to signal level voltage used by the plc processor and other modules.

A PLC consists of the required quantities of the following types of modules or cards,
mounted on a common physical support and electrical interconnection structure known
as a rack.
(2) Processor :
The processor module contains the microprocessor that performs control functions and
computations, as well as the memory required to store the program.

A typical PLC rack configuration is shown in below figure.

(3) Input/Output (I/O) :
These modules provide the means of connecting the processor to the field devices.
Examples of these modules are Analog Input Module, Analog output module, Digital
input module, Digital output module etc.

These are used to connect devices between plc and field devices like flow transmitters,
pressure transmitters, control valves, analyzers, substation feeders for motor control etc.

(4) Communication :
Communications modules are available for a wide range of industry-standard
communication network connections. These allow digital data transfer between PLCs and
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to other systems within the facility.
Types of Industrial Control Systems
X
What is PLC Redundancy? P LC TUTORI AL S
X
Types of Industrial Control Systems
X
What is PLC Redundancy? P LC TUTO RI AL S
X

P LC TUTOR I A L S
Industrial Control Systems Different Types of Industrial
Most commonly used modules are
Control Systems are Distributed Control System (DCS),
Remote terminal unit (RTU) and Programm…
communication.
PLC Redundancy Systems may utilize a warm standby, P LC TUTOR I ALS PLC Redundancy Systems may utilize a warm standby,
hot standby, or voting configuration as per the design hot standby, or voting configuration as per the design
Industrial Control Systems Different Types of Industrial
Modbus communication cards
consideration or Serial
of  specific industrial a… consideration of  specific industrial a…
Control Systems are Distributed Control System (DCS),
Remote terminal unit (RTU) and Programm…

Some PLCs have communications capability built-in to the processor, rather than using
separate modules.

(5) Communication Media and Protocols :

The most common communication media used are copper-wire, coaxial, fiber-optics, and
wireless. The most common “open” communication protocols are Ethernet, Ethernet/IP,
and DeviceNet.

“Open” systems generally provide “plug and play” features in which the system software
automatically recognizes and communicates to any compatible device that is connected PLC Software and Programming
to it.
All software and programming required for the PLC to operate as a standalone controller

Other widely accepted open protocols are Modbus, Profibus, and ControlNet. is maintained on-board in the processor.

(6) Redundancy : PLCs are programmed with one of the following standard programming languages:

Many PLCs are capable of being configured for redundant operation in which one (1) Ladder Diagrams :
processor backs up another.
Used primarily for logic (Boolean) operations and is easily understood by electricians and

This arrangement often requires the addition of a redundancy module, which provides control technicians. This is the most commonly used language in the United States and is

status confirmation and control assertion between the processors. In addition, signal supported by all PLC suppliers.

wiring to redundant racks is an option.

(2) Function Block Diagrams :
Used primarily for intensive analog control (PID) operations and is available only in “high-
end” PLC’s. It is more commonly used outside the United States.

(3) Sequential Function Chart :

It Used primarily for batch control operations and is available only in “high-end” PLC’s.

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Types of Industrial Control Systems
X
What is PLC Redundancy? P LC TUTORI AL S
X

P LC TUTOR I A L S PLC Redundancy Systems may utilize a warm standby,

It is Used
Industrial primarily
Control by PLC
Systems Different Typesprogrammers
of Industrial with a computer language
hot standby, or votingbackground and
configuration as per is
the design
consideration of  specific industrial a…
Control Systems are Distributed Control System (DCS),
Remote terminal unit (RTU) and Programm… PLC’s.
supported only in “high-end”

SCADA

SCADA PLCs should be specified to be programmed using ladder diagrams. This

language is very common, and duplicates in format traditional electrical schematics,
making it largely understandable by electricians and technicians without specific PLC
training.

The ladder logic functions the same as equivalent hard-wired relays. The PLCs in a SCADA
system will be networked to one or more central personal computer (PC) workstations,
which provide the normal means of human machine interface (HMI) to the system.

These PCs will be provided with Windows-based HMI software that provides a graphical
user interface (GUI) to the control system in which information is presented to the
operator on graphic screens that are custom-configured to match the facility systems.

For example, the electrical system status may be shown on a one-line diagram graphic in
which open circuit breakers are colored green, closed breakers are colored red, and
voltage and current values are displayed adjacent to each bus or circuit breaker.

PLCs are recommended for the following reasons :

(1) They were developed for the factory floor and have demonstrated high reliability and
tolerance for heat, vibration, and electromagnetic interference.

(2) Their widespread market penetration means that parts are readily available and
programming and technical support services are available from a large number of control
system integrators.

(3) They provide high speed processing, which is important in generator and switchgear
control applications.

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 Its input and output modules can be extended depending upon the requirements

PLC Architecture:
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Understanding a Programming Logic Co

(PLC)
PLC stands for Programmable Logic Controllers. They are basically used to control auto
PLC Internal Architecture
industries. They are one of the most advanced and simplest forms of control system
replacing hard-wired logic relays at a large scale.
A basic PLC system consists of the following sections:

Input/ Output Section: The input section or input module consists of devices like s
and many other real-world input sources. The input from the sources is connected to
the input connector rails. The output section or output module can be a motor or a sol
a heater, whose functioning is controlled by varying the input signals.
CPU or Central Processing Unit: It is the brain of the PLC. It can be a hexa
microprocessor. It carries out all the processing related to the input signals in order to
signals based on the control program.
Programming Device: It is the platform where the program or the control logic is w
handheld device or a laptop or a computer itself.
Power Supply: It generally works on a power supply of about 24 V, used to powe
Programming Logic Controller (PLC) devices.
Memory: The memory is divided into two parts- The data memory and the prog
Advantages: program information or the control logic is stored in the user memory or the prog
where the CPU fetches the program instructions. The input and output signals and the
Before getting into details about PLCs, lets us know 3 reasons why PLCs are being w
signals are stored in the input and output external image memory respectively.
days

Working of a PLC
They are user friendly and easy to operate
They eliminate the need for hard-wired relay logic
They are fast
It is suitable for automation in industries.
 The execution results are then stored in the external image memory which controls the
The CPU also keeps a check on the output signals and keeps updating the contents
memory according to the changes in the output memory.
The CPU also performs internal programming functions like setting and resetting of t
the user memory.

Programming in PLC
The basic functioning of the PLC relies on the control logic or the programming
Programming can be done using flowcharts or using ladder logic or using statement logic

Interlinking all these, let us see how we can actually write a program in PLC.

PLC Working Schematic

Compute the flowchart. A flowchart is the symbolic representation of the instructions. I
and simplest form of control logic which involves only logic decisions. Different symbol
below:

Working of PLC

The input sources convert the real-time analog electric signals to suitable digital e Write the Boolean expression for the different logic. Boolean algebra usually involves l
these signals are applied to the PLC through the connector rails. like AND, OR, NOT, NAND and NOR. The different symbols are:
These input signals are stored in the PLC external image memory in locations know
done by the CPU +   OR operator

The control logic or the program instructions are written onto the programming device .     AND operator

or through mnemonics and stored in the user memory. !     NOT operator.
The CPU fetches these instructions from the user memory and executes the
manipulating, computing, processing them to control the output devices.
 Install & Configure

Chrome
Streamline updates across

your fleet and automatically

create & save secure

Writing Mnemonics: Mnemonics are instructions written in symbolic form. They are als
Google passwords. Opcode and are used in handheld programming devices. Different Symbols are as giv

Ldi – Load Inverse

Write the instructions in simple statement forms like below: Ld- Load

AND- And the logic

IF Input1 AND Input2 Then SET Output1 ELSE SET Output OR- Or logic
ANI – NAND logic

Write the ladder logic program. It is the most important part of PLC programming.
ORI- NOR logic

about ladder logic programming, let us know about few symbols and terminologies
Out – Output
Rung: One step in the ladder is called a rung. In simpler words, the basic stateme
A Simple PLC Application
logic is called a Rung.

Y- Normal Output signals

So, now that we have had a brief idea about programming in PLC, let’s get into deve
M – Motor symbol
application.
T – Timer

C – Counter
Problem: Design a simple line follower robotic system to start a motor when a

Symbols: simultaneously switch on the LED.  The sensor on the motor detects any obstacle and an
to indicate the presence of the obstacle and the motor is simultaneously switched off
switched on and LED is off.

Solution:

Basic Logic Functions using Ladder Logic

 Solution
Flow Chart

Let us first assign our symbols or tags to the inputs and outputs
Next Step is writing the Boolean expressions

M – Motor,
M = A. (! B)

A – Input Switch 1,
L = C. (! B)

B- Input Switch 2,
Bu = B. (! A.! C)

L – LED,
The next step involves drawing the ladder logic program

Bu –Buzzer

Now let us design the Flow Chart

Ladder Logic Program

The final step involves writing the mnemonics to be fed to the handheld device
Ld A ANI Ldi B

Ld C ANI Ldi B

Ld B ANI Ldi A AND Ldi C

So, now that I have demonstrated the basic control function using PLC, do let me know m
ideas of control designs using PLC.

Photo Credits:

Programmable Logic Controllers by wikimedia

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Characteristics of a Microcontroller
Search any part number or keyword Search any part number or keyword
CART ACCOUNT Not sure if a device in question is a microcontroller or another kind of computer? Let’s take a Clook
ART at aO U N T
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few characteristics that set it apart.

Home White Papers
Microcontrollers Versus PLC’s: A Detailed Comparison
Embedded

A microcontroller embeds inside another device. They help control the device’s actions or features. For
MICROCONTROLLERS VERSUS that reason, you may hear people refer to a microcontroller as an “embedded microcontroller.”

PLC’S: A DETAILED
Task-Dedicated

Microcontrollers are only dedicated to one certain task, designed to run one specific program. As
opposed to RAM, this program remains in Read-Only Memory (ROM), where it does not change.
COMPARISON Low-Power

A general purpose computer, which stays plugged into a wall socket, will use around 50 watts of
electricity. A microcontroller will only use around 50 milliwatts.

Dedicated Input/Output Device

A microcontroller will have a dedicated input device and in most cases, an output device (such as an LCD
Microcontrollers Versus PLC’s: A Detailed Comparison
or LED display).

In addition, the microcontroller will accept input from the device that it’s controlling and sends signals to
Introduction other components within it to help control it.
As open-source electronic prototyping platforms such as Arduino, BeagleBone, and Raspberry Pi
Take the microcontroller within a television, for example. It accepts input from the remote control and
continue to widen the realm of possibilities for digital device and interactive object development, there’s
then displays the output on the television screen. Inside, the controller controls the speaker system,
more interest than ever before in microcontrollers and their related components.
channel selector, and picture tube electronics such as brightness.
Yet, this industry is so nuanced that it’s easy to confuse microcontrollers with their larger-scale
Or, consider a microwave oven. The oven’s controller accepts input from a keypad and displays output
counterparts, Programmable Logic Controllers (PLCs). Similar in nature but stronger in capacity, PLCs
on an LCD display. In addition, it controls the relay that manages on/off power for the microwave’s
offer myriad of benefits and uses in their own right.
generator.
Today, we’re delving into the difference between microcontrollers and PLCs. We’ll explain what each
Economical and Small

system does and who uses it to help differentiate the unique characteristics of each.
A microcontroller won’t break the bank. In most cases, users seek out the smallest and most affordable
Ready to learn more? Let’s get started! one that can get the job done.

Ruggedized

What is a Microcontroller? Many microcontrollers can withstand high heats and rougher conditions than general purpose
Let’s begin on the smaller side of the equation. In short, a microcontroller is a computer. However, it’s computers can handle.
different than the laptop or personal computer you’re used to, though all computers share the same
For instance, the microcontroller that manages your car’s engine has to hold up against extreme
features:
temperatures that range from below freezing in Alaska to over 100 degrees Fahrenheit in Nevada.
A Central Processing Unit (CPU)
While this scenario requires a ruggedized microcontroller, not all require this characteristic. The
Program-loading capabilities (e.g. Desktop computers load browsers from the hard disk)
microcontroller embedded in a Blu-ray Disc player, for instance, has no need for ruggedization.
Random-Access
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thousands of programs and are useful for a variety of purposes. On the other hand, a microcontroller is
 As microcontrollers are so cost-effective and include such a wide variety of accessory components, their To facilitate this function, most PLCs include multiple ports and communication protocols to ensure that
uses have become more mainstream. For years, their use centered on the maker world, including MENU the device can communicate with other systems. MENU

automation clubs and personal robot builders. Yet, as they expand in functionality, manufacturers are
considering
Search anyusing them
part in industrial
number applications, as well.
or keyword CART ACCOUNT Comparing Microcontrollers
Search any part number or keyword and PLCs: A Scenario CART ACCOUNT

Is this a wise move? Are the two the same? Next, let’s take a look at what sets a PLC apart from a While there may be some applications in which a microcontroller can do a similar job as a PLC, users
microcontroller. should consider each scenario to determine which system is best.

For the purpose of this paper, let’s use a common industrial application to illustrate the point. Say, for
What is a PLC? instance, a user wanted to perform a small automated task.
Now that we’ve covered the basics of a microcontroller, let’s compare it to a PLC.
He wants to use a few sensors and an actuator to provide the output. He also needs a reporting function
The most basic definition? A PLC is a larger-scale microcontroller. It’s an industrial digital computer that’s to “speak” to a larger control system. What’s needed is a basic operating program.
ruggedized and adapted to facilitate tough manufacturing processes.
A small PLC will work, in this case. Yet, is it the smartest and most economical decision? What about an
Its most common applications include: open-source, board-level microcontroller? If you’re in a similar dispute, here are a few factors to
consider.
Assembly lines
Robotic and machine learning devices I/O Compatibility

Any function that requires high-reliability control or process fault diagnosis Once you know your required number of inputs and outputs, check to see if the microcontroller in
How does it work? question includes the required number of I/Os.

A PLC accepts information from connected sensors and input devices. Then, it processes that data and Keep in mind that the type of I/Os matter. You may be able to find a microcontroller with the right
creates outputs based on preset parameters. Depending on the exact setup, a PLC can even monitor and number of discrete and analog I/Os, but they may not be the correct type for your application.
record run-time data, analyzing machine line productivity or operating temperature, for example.
In some cases, you can convert them to match your needs.

Characteristics of a PLC Take a 4-20 mA current loop, for instance. A user may be able to convert this to a 0-5 V voltage loop in a
What sets a PLC apart from a microcontroller, larger-scale industrial PLC or any other industrial control cinch. Yet, if the PLC includes a more specific type, such as an analog output with pulse-width modulation
solution? Let’s take a look at a few key characteristics. (PWM), you’ll be harder-pressed to convert it to anything, though you can purchase a signal converter to
facilitate the process.
Inputs/Outputs

A PLC includes a CPU that stores and processes program data. Yet, it relies on input and output modules This is where a PLC can shine.
to connect it to the rest of the machine. These I/O modules send information to the CPU, triggering
Designed to work with industrial sensors, most will offer a wider range of I/O choices. This cuts down on
certain results.
the need for external conversion. In addition, most PLCs will build in isolation for I/O points, which can
The PLC I/O controls can be analog or digital. Inputs can range from sensors and switches to meters, and help protect those devices and circuits.
outputs include relays, valves, drives, and lights. One advantage that PLCs offer is that users can
Mounting and Housing

customize their I/Os to meet configuration requirements for their application.

Most microcontrollers look like a naked board with pins available for connections. This can make
Human Machine Interface
mounting and housing more difficult, as the user will need to provide his own power and make terminals
When humans want to interact with a PLC in real-time, they rely on a Human Machine Interface (HMI) to if he wants to connect an external device.
do so. These can range in scale from a simple display with a keypad and text to a smart, touchscreen
Operating Systems and Watchdogs

panel akin to modern consumer electronics.

A microcontroller may be less expensive, but users get what they pay for. Their bare-bones nature
Communications
means that the user will be responsible for coding everything but the simplest capabilities.
While I/O devices are a start, the PLC may also need to connect to different kinds of systems. For
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instance, a user may need to export recorded application data from the PLC and send it to a Supervisory
useData
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siteas
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Control and Acquisition (SCADA)that you are happy with it.

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 A PLC also requires simple application writing, though there is more going on inside that neither the However, as long as they choose the right components, users can install a PLC in an outdoor enclosure
programmer nor the user sees. Housekeeping programs and watchdogs help monitor the systems and
MENU that’s subjected to extreme temperatures without concern. MENU

equipment to ensure protection and data integrity.

Industry Standards for Testing

Search any part number or keyword Search any part number or keyword
Take the for/next loop within a PLC, for instance. If there’s an issue with it and the program gets
CART
stuck, it
ACCOUNT
Unsure how to test for each of the above characteristics? The International Electrotechnical Commission
CART ACCOUNT

could hinder performance and pose a safety concern.
The software watchdog will kick in and begin to time each scan of the program. If one scan doesn’t finish
in the allotted time, it will bark. This faults the PLC and places it into safe mode while notifying the user.
At the same time, there are hardware watchdogs that monitor the devices that connect to the PLC. As the
PLC shakes hands with its I/O modules or external devices (such as switches, sensors, or actuators), the
watchdog counts each scan as it occurs.
If any scan count starts to lag, it signals an issue with the PLC. In most cases, this will trigger the system
into safe mode and alert the user.
Can you add this functionality onto a microcontroller? The short answer is “yes” although it isn’t easy.
Users would have to write these programs from scratch or reuse existing software modules, neither of
which is a simple step. From there, the user would also need to test and verify the software for the given
application, which is also laborious.
(IEC) and Underwriters Laboratories (UL) include standards to go by. Each PLC system will include
documentation that lists the tests completed and the methodology used.
Most microcontrollers don’t undergo such extensive testing, which can make it more difficult to know
their capabilities. There are also differences between generic boards and brand-specific ones.
Understanding Microcontrollers vs PLCs in Your
Application
Depending on your use case scenario, budget and program expectations, you may be able to use either a
microcontroller or a PLC.
Remember that while microcontrollers offer costs savings, they’re more limited in nature than PLCs. This
means if you’re looking for a system to go into a larger industrial network, it may not be up to the task.
However, it could be perfect for DIY projects and other teaching tools that aren’t as complicated.

Want more information on industrial controls? That’s why we’re here.

Specific Industrial Conditions to Consider
What about specific industrial conditions? Are PLCs better able to withstand rugged requirements than We’re the global leader in this industry and offer a wide range of products to fit your needs. From motor
microcontrollers? Here are a few environments to compare. controls to relays, you’ll find it in our online shop.

Shock and Vibration

Contact us for more information and let us help you power up your next project.
A PLC is capable of withstanding the strong amounts of both shock and vibration common to warehouse
Disclaimer:

environments. A microcontroller may work too, though it will require special mounting and connection
The content provided in this white paper is intended solely for general information purposes and is
considerations designed to hold up to this abuse.
provided with the understanding that the authors and publishers are not herein engaged in rendering
Corrosion
engineering or other professional advice or services. The practice of engineering is driven by site-specific
In some environments, equipment is around vapors and fumes that can corrode wiring and other circumstances unique to each project. Consequently, any use of this information should be done only in
components. consultation with a qualified and licensed professional who can take into account all relevant factors and
desired outcomes. The information in this white paper was posted with reasonable care and attention.
Most PLCs include coatings that cut down on the amount of bare, exposed metal on their boards. However, it is possible that some information in these white papers is incomplete, incorrect, or
Likewise, their wires include corrosion-resistant materials. inapplicable to particular circumstances or conditions. We do not accept liability for direct or indirect
losses resulting from using, relying or acting upon information in this white paper.
Noise

In almost every industrial environment, you’ll find systems that create electronic noise, along with
magnetic fields. Can the equipment withstand it? An inexpensive microcontroller could go into fault
mode or lose its program if the interference is significant enough.
OUR PRODUCTS
Yet, a PLC has a better level of protection. It can stand standard electronic noise without issue.

Temperature Levels
13mm Pilot Lights
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Most microcontrollers operate best in a benign, temperature-controlled environment, though certain
useones
ruggedized this site
can we will assume
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or higher happy with it.

ranges. OK PRIVACY POLICY 16mm

use this site we will assume that you Pilot Lights
are happy with it.
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© 1976-2021 c3controls (724) 775-7926 © 1976-2021 c3controls (724) 775-7926
22mm IEC Pilot Devices
 recording, as well as the simple processing of signals in binary code are required.

The principle of operation of CPU can be briefly described as fallow.

The CPU accepts (reads) input data from various sensing devices, executes the user program from memory and sends appropriate output
commands to control devices.
A direct current (DC) power source is required to produce the low-level voltage used by processor and I/O modules. This power supply can be
housed in the CPU unit or may be a separately mounted unit, depending on the PLC system manufactures. The CPU contains various electrical
parts and receptacles for connecting the cables that go to the other units as well as to operational key switches.

Typical operation key switch positions are.

GoDaddy Domain Transfers Off: system cannot be run or programmed.

Run: allow the system to run, but no program alterations can be made.
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Program: disables output and allows creating modifying, and deleting of programs.
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Programmable Logic Controller - PLC

PLC stands for programmable logic control. It is computer designed to be used in industry. It controls the different process and is programmed GoDaddy Learn More
According to the operational requirement of that process.

Several industries utilize sequential industrial process which is respective in nature. For such processes industries have to depend upon use of relays,
stepping drum, timers and controls considerable difficulties experienced in reprogramming necessitated due to change in the nature of production. Often
the whole system has to be scrapped and a redesigned is required.
To overcome these problems PLC control system was introduced. The PLC can be described as a control ladder comprising a sequence program.PLC
sequence program consists of normally open and normally closed contacts connected in parallel or in series. It also has relay coils, which turns ON and
OFF as the state of these contacts change.
Input & Output Modules of PLC
Input/output modules are used for interfacing between input devices (e.g start and stop push buttons, sensers, limited switch, selector switch) and
microprocessor. And also used for interfacing between output devices (e.g electrical heater, lights, solenoid valve, relays, buzzer, fan) and
microprocessor. The input information is transfer to the processor through input module and output information from the processor to load is transform
through output module.
The input/output module use for providing the isolation between input devices and process. And also to provide isolation from processor to output

PLC Programmable Logic Concept devices. For isolation modules use the opto coupler.

Programmable logic controller is a microprocessor based programming technique, which is used to perform many functions in industrial process.
Programmable logic controller operates similar to the ordinary controller. But in this system different operation are performed by software. If we want to
change program it is only needed to change the program in the software. PLC takes input instructions in the form of ladder diagram or computer
software instructions.
These instructions are decoded in CPU and CPU provides differed signals to control or to operate many devices of system.
Input devices such as push buttons, limited switches, sensors and selector switches are hard-wired to terminals on the input modules. Output devices
such as small motor, motor starters, solenoid valve, and indictor lights are hard wired to the output modules.
Input interface modules accept signals from the machine or process devices (e.g 220V AC) and convert them into signals (e.g 5VDC) that can be used
by the controller, or processor output interface modules converts controller or processor signals (e.g 5VDC) into external signals (e.g 220 v AC) used to
control the machine or process.

When these devices change their position or cause to change controlled variable. A sample of controlled variable is given to CPU indicate that change The simplified circuit and block diagram of input modules is shown in fig. input modules perform four basic tasks in PLC system.
in controlled variable has been eliminated. PLC basically consists of a ladder network, which is performed according requirements of the system.
They sense when signal is received form the sensor on the input of the machine,
They convert the input voltage to the correct voltage level for the PLC
Basic Parts of the PLC
They isolate PLC from fluctuation in the input signal voltage or current.
A typical block diagram of PLC is show in Fig. as clear from fig PLC consists of following basic parts. At end  they send the signal to the PLC.

CPU (Central processing unit)

Programming device
Input & output module.

PLC Input Module Block Diagram

PLC Block Diagram

PLC Block Diagram

The central processing unit is the heart of the PLC system. The CPU is a microprocessor based control system that replaces central relays, counters,
timers and sequencers. A processor appears only once in a PLC and it can be either a one-bit or a word processor. One bit processors are adequate for
dealing with logic operations. PLCs with word processors are used when processing text and numerical data, calculations, gauging, controlling and
 The Figure shows the block diagram of microprocessor based control system. Data acquisition system (DAS) takes information signals form sensor
which is in the form of analog and change it into digital value which can be read in and processed by the microprocessor. A key-board and display in the
system allow the user to set-point values, to read the current values of process variables, and issue commands. Relays, D/A converters,

PLC Input Module Circuit Diagram

It is clear form the above figure that the input module is consist of two section one is power section  while the other is logical section, which are
electrically isolated from each other. When push button is closed 220V AC is applied to the bridge rectifier, through resisters R1 & R2. rectifier convert
AC Signal into DC signal and zener diode ZD gives low voltage to the LED. When light from LED strikes the phototransistor it become in conduction
region and give DC voltage to the processor. Optical isolator also helps to reduce the effects of electrical noise, which can produce error.

PLC Output Module

Output module is use for interfacing between output load and processor, the output modules has a function similar to that of the input modules except in PLC Microprocessor Based Control System Block Diagram

reverse order.

The fig shown the block and circuit diagram of output module. It consists of two sections, one is logic section second is power section. Solenoid valves and other actuators are used to control process variables under program direction. A programmable timer in the system determines the
rate at which control loops are serviced.

Microprocessor-based control system range from a small Programmable controller which might be used to control a machine on Factory floor to large
computers used to control an entire fractionating column in an oil refinery.

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PLC Output Module block Diagram

When logic high signal comes from the processor the LED is on & light strike to phototransistor. Which become in conduction region & give a triggering
pulse to at the gate of triac. The triac conducts-and load lamp is energized through it as clear from fig.

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The interfacing is providing by opto-coupler (LED, Phototransistor) as in the input module.

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PLC Isolated Circuit Diagram

Motion Selector | D&E notes

Programming device (Keyboard Monitor)

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Keyboard and monitor is used for programming a PLC. The data is inter in the PLC processor with the help of Keyboard in the form of ladder diagram.
This ladder diagram can be see on the monitor screen. The programmer can communicate with PLC processor with help of programming devices. The
programming unit communicates with processor if PLC via a serial or parallel data communication link. The personal computer can be used for
programming of PLC if it has required software. Privacy & Disclaimer Terms of Service Sitemap

Micro processor Based PLC Control System

A Developer's Perspective of PLC Configuration and Programming using
FBD and ST
G. Karmakar, Ashutosh Kabra, R. K. Patil
Bhabha Atomic Research Centre
Mumbai, India
Abstract:
This paper attempts a journey right from configuring a PLC,
writing application program to code generation along with run-
time configurations and RTOS abstraction for embedding it into
PLC hardware using a typical control Logic application. The IEC
61131-3 languages Function Block Diagram (FBD) and the
corresponding ST (Structure Text) has been used as vehicles for
this tour.
INTRODUCTION
Programmable Controllers (PLC) are the backbone of most
automation projects. PLCs are used for controlling purposes in
various industries like power generation, steel production,
chemical, petrochemical, Nuclear Power plants etc. A
Programmable Controller (PLC) is an industrial computer control
system that continuously monitors the state of input devices and
makes decisions based upon a program to control the state of
output devices. PLC is an example of a real time system since
output results must be produced in response to input conditions
within a bounded time. In the past many vendors for PLC systems
used their own programming languages which were incompatible
with others. To enhance reusing of components, compatibility and
interoperability among different product, the IEC 61131 standard
was introduced to unify the main different approaches. Third part
of IEC 61131 standard specifies the syntax and semantics of a
unified suite of programming languages for programmable
controllers (PCs), of which most widely used are Function Block
Diagram (FBD) and Structured Text (ST). In this paper, we
describe a typical control Logic application for demonstration of
configuring a PLC, writing application program and code
generation along with run-time configurations and RTOS
abstraction for embedding it into PLC hardware. The
programming language ST (Structured Text) and the
corresponding FBD have been used throughout the paper.
THE STUDY EXAMPLE
A. Problem Definition
A simple example of controlling a pump P1 and its discharge
valve V1 and sending information to any device (say a SCADA
station) on demand has been taken as the study example.
The following Use Cases specifies the requirement:
Use Case1: Read Inputs
Read the following field Inputs
1. P1 START Push Button (PB) status
2. P1 STOP Push Button (PB) status
3. V1 OPEN Push Button (PB) status
4. V1 CLOSE Push Button (PB) status
5. P1 ON/OFF status
6. Read P1 discharge pressure
It is a time driven task: Read every 10 ms Use Case2: Control
Interlocks
1. The pump P1
1. Will start if START PB is actuated and will be latched.
2. Will stop either if the STOP PB is actuated or if the P1 discharge
pressure is high. Obviously, any of these conditions will de-latch
the START PB actuation event.
2. The Valve V1
1. Will open either if the V1 OPEN is actuated OR (if the Pump is
started AND 3 second has been elapsed).
2. Will close if the V1 CLOSE is actuated provided the pump P1 is
not running.
Use Case3: Communication Slave/Server
On Query from any external device it will send Response data.
The protocol details are not part of this high level programming.
THE DOMAIN MODEL OF PLC
The domain model of a PLC in figure 1 below depicts the various
software modules that make a PLC.
Figure 1: PLC domain model
SOFTWARE MODEL AND BUILDING BLOCKS OF IEC 61131-
3
IEC 61131-3 software model consist of elements which are
programmed using the languages defined in this standard and
configuration elements, namely configurations, resources, tasks,
global variables and instance-specific initializations, which support
the installation of programmable controller programs into
programmable controller systems. Software Architecture of IEC
61131-3 PLC is shown in fig. 2.
Figure 2: Software Architecture of IEC 61131-3 PLC
A. Configuration, Resource and Task
At the highest level, the software for a particular control
application is contained in a configuration. Configuration is used
to group all resources of the PLC system together. It also
provides means for data exchange between them.
A resource is the processing facility, able to execute IEC
programs. It is defined in order to assign task to the physical
resources of a PLC system. One or more resources can be defined
within a configuration. Configuration and resources do not contain
instructions like POUs, but solely define the relations between
their elements.

Configurations and resources can be started and stopped via the

“operator interface”, “programming, testing, and monitoring”, or
“operating system” functions defined in IEC 61131- 1. The
starting of a configuration shall cause the initialization of its
global variables, followed by the starting of all the resources in
the configuration. The starting of a resource shall cause the
initialization of all the variables in the resource, followed by the
enabling of all the tasks in the resource. The stopping of a
resource shall cause the disabling of all its tasks, while the
stopping of a configuration shall cause the stopping of all its
resources. Figure 3a depicts the PLC configuration for our study example in
FBD.

Task is defined as an execution control element which is capable

of invoking, either on a periodic basis or upon the occurrence of Figure 3a: Configuration ProcessCtrl in FBD The configuration
the rising edge of a specified Boolean variable, the execution of a written in ST is shown in figure 3b.
set of program organization units, which can include programs
and function blocks whose instances are specified in the
declaration of programs. Like any PLC application, other than
assigning Programs and/or functions to tasks, we also need to
configure the requirement of I/O hardware and its type. For our
study example, one Digital Input Card, One Digital Output Card
and one Analog Input Card are required.
 Chapter 7: Internal Relays

This chapter continues on from the previous chapters on programming and

introduces internal relays. A variety of other terms are often used to describe these
elements, e.g. auxiliary relays, markers, flags, coils, bit storage. These are one of
the elements giving special built-in functions with PLCs and are very widely used
in programming. A small PLC might have a hundred or more internal relays, some
of them being battery backed so that they can be used in situations where it is
necessary to ensure safe shutdown of plant in the event of power failure. Later
chapters consider other common built-in elements.

7.4 Internal Relays

In PLCs there are elements that are used to hold data, i.e. bits, and behave like
relays, being able to be switched on or off and switch other devices on or off.
Hence the term internal relay. Such internal relays do not exist as real-world
switching devices but are merely bits in the storage memory that behave in the
same way as relays. For programming, they can be treated in the same way as an
external relay output and input. Thus inputs to external switches can be used to
give an output from an internal relay. This then results in the internal relay contacts
being used, in conjunction with other external input switches to give an output, e.g.
activate a motor. Thus we might have (Figure 7.1):

 On one rung of the program:

 Inputs to external inputs activate the internal relay output.

Figure 3b: Configuration ProcessCtrl in ST

 Let’s take a more in-depth look at each one of these languages, go over their applications,
general structure, and use cases.

What is the most popular programming language for a PLC?

This question is debated among PLC programmers across the world. The consensus is that the
most utilized language for PLC programming is ladder logic. This is due to the fact that it's highly
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flexible, easy to learn and very well understood by electricians who have worked with
schematics that model the same architecture.
Learning Tips
However, over the last decade, a younger workforce has entered manufacturing. These

Top 5 Most Popular Types of PLC engineers and technicians have been primarily taught modern languages such as Java, Python
and Javascript. These languages have a closer resemblance to Strcutured Text [ST] and thus

Programming Languages promote its usage.

It's also important to consider the industry at question. A chemical process is typically designed
used Piping & Instrumentation Diagrams (P&ID). These specific schematics are easily replicated
By Vladimir Romanov through the use of Function Block Diagrams [FBD].

PLC Programming Languages - An example of a chemical process that would be easier to implement in Function
Block Diagrams (FBD) PLC programming

Ladder Logic PLC Programming

Before Programmable Logic Controllers became popular, relay-based controls were the norm at
most manufacturing sites. Relays drove loads based on the simple logic that was implemented
through the physical wiring of the devices. The wiring of these devices was specified in
PLC Programming Language Specifications electrical drawings that assumed the layout resembling a ladder. As the most basic PLCs were
introduced into the field, ladder logic PLC programming was designed to mimic the layout of
The 5 most popular types of PLC programming languages of 2020 are: relay-based circuits. In other words, ladder logic was one of the first PLC programming
languages that’s still used today due to simplicity.
Structured Text (ST)

Sequential Function Charts (SFC)

Ladder Logic Diagram (LD)

Function Block Diagram (FBD)

Instruction List (IL)

The International Electrotechnical Commission 61131-3 outlines 5 different PLC Programming

languages: ladder logic, structured text, function block diagrams, sequential function charts,
and instruction lists. Each one of these languages has advantages, weaknesses, and best use
cases. As a competent PLC programmer, it’s essential to be aware of these options to
troubleshoot existing code, utilize the right tool for the job, and have a different perspective on
how problems may be solved. Furthermore, depending on the PLC platform of choice, specific
languages may come at a premium or not be available at all. For example, only the full license of
RSLogix 5000 will have access to languages beyond Ladder Logic.

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 for electrical engineers and those with basic knowledge of assembly programming.

Slow Deployment | Because of the visual nature of ladder logic, it takes longer a programmer
to create the logic they’ve envisioned. There’s a need to drag and drop elements that slow
down the development process versus other modern programming languages.

Unintuitive for Complex Applications | Ladder Logic shines when it comes to sequential
boolean tasks. However, when it comes to modern control theory that involves PIDs, flow
control, analog sensors, and feedback loops, it’s not always easy to implement and decipher.

Ladder Logic is the most used PLC programming language around the world. It’s easy to work
with and maintain for those who don’t have constant exposure to PLC programming. We
recommend that you begin your PLC programming journey by learning ladder logic first.

Structured Text PLC Programming

Structured Text is a PLC programming language that closely resembles C or assembly. The user
enters lines of code that execute sequentially, evaluate specific functions, boolean checks, and
energize appropriate outputs of the PLC. Structured Text provides a simple transition into PLCs
for those who have a background in a traditional programming language such as C, C++, Java, or
Python. Furthermore, it can be easily manipulated in text processors, thus making it fast to
implement without the need for hardware.

PLC Programming Languages - PLC Schematics Leading to Ladder Logic PLC Programming

‍
Since its inception, ladder logic has evolved significantly. However, the basic principles of
operation remain the same. Ladder logic PLC programming evaluates each rung of a ladder in
sequential order assesses conditional instructions, and if the result evaluates to “TRUE,” the
output instructions are executed.

PLC Programming Languages | Ladder Logic PLC Programming Example in RSLogix 5000

Advantages of Ladder Logic PLC Programming

Simple to Implement and Troubleshoot | Ladder Logic is a visual language that provides
confirmations of status for most instructions. In other words, it’s easy for someone with little
knowledge of a specific process to walk through the program and understand the logic.
Structured Text PLC Programming | Example in Studio 5000 CompactLogix PLC
Modular Design | Ladder Logic can be easily modified through the addition or subtraction of
logic. Each rung is a separate condition and can be removed or added as needed. Advantages of Structured Text PLC Programming
Resilience and Consistency | Ladder Logic allows the user to implement many functions.
Intuitive to Other Programming Languages | As mentioned above, Structured Text is easy to
However, the language is heavily standardized and doesn’t give full flexibility, thus keeping the
learn for those who are looking to transition from a software engineering background. It
code consistent between different implementations.

features the same structures, programming paradigms, and functions that one would expect
to see in C or Java.

Drawbacks of Ladder Logic High Complexity | Structured Text allows for greater flexibility than other languages and thus
makes it easier to implement advanced functionality for those who master the language.
Steep Learning Curve | Ladder Logic is a simple language, yet not very intuitive to those who
Transferability | Structured Text is standardized among most PLC systems, thus making it
come with backgrounds in C, C++, Java, or Python. That being said, it may be easier to grasp
37 37 easy to migrate between platforms. You’ll find significant differences in other languages
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 between platforms, yet structured Text can be implemented in hardware and software Troublesome at Scale | FBD shines when it comes to small implementations of specific areas
platforms.
of a process. However, as the program becomes complex, it’s easy to get lost in all the sheets.

Disadvantages of Structured Text
Difficult to Troubleshoot | When compared to ladder logic programming, structured Text is
much more complex from a troubleshooting standpoint. There are no visual queues, less
visual aids, and typically more code on a single line. Those who aren’t comfortable with this
language will have a hard time figuring out the process flow.
Function Block Diagrams are critical in analog scaling, PID loops, and Motion Control
sequences. As you learn about these topics, you should start exposing yourself to this type of
PLC programming. Before then, we would recommend mastering ladder logic.
Sequential Function Charts PLC Programming

Error-Prone | Structured Text provides greater flexibility to the user. However, this flexibility
comes at the cost of standardization. Users must use software engineering best practices to
create safe fallbacks and trap any potential failures of the software.
process. For those who aren’t familiar with this notion, an example would be a chemical
We typically recommend that you learn Structured Text only after you’ve mastered Ladder
Logic unless you have a background in another programming language. It’s not often seen in
production environments due to the drawbacks mentioned above. However, it’s an excellent way
to manipulate data, implement FOR loops and other structures that require extra steps in Ladder
Logic.
Language
As the name implies, sequential function charts, or SFC, shine when it comes to a subsequent
transformation from raw materials into the finished product. Let’s take a simple brewing process
as an example.
Picture a large beer brewing facility with numerous tanks, valves, pressure sensors, heating
elements, and a packaging section. When an operator initiates the production of a new batch,
the process goes through the following sequence of steps. Note that these steps are simplified.
Step 1 - The system is verified for readiness. Are all the appropriate ingredients available? Are

Function Block Diagrams PLC Programming the tanks empty? Are the valves in the right state? If the answer is valid to all checks, proceed. If

Language
not, abort.

Function Block Diagram, of FBD,  is a programming language developed with chemical
processes in mind. It allows the user to create a visual representation and flow of the process
with appropriate transitions between the instructions. The visual editor is user friendly, intuitive,
and creates a natural way to implement specific flows.
The most common application we’ve used Function Block Diagrams in our PLC programs is to
establish PID controllers. The visual aspect of FBD makes the PID easy to implement, visualize,
tune, and troubleshoot in the field.
Step 2 - Initiate a tank filling sequence that may call on multiple ingredients (water, sugar, salt,
yeast, etc.). Validate the state and proceed once the tank is full.
Step 3 - Initiate the brewing process. Raise and maintain the temperature for a specified period.
Monitor tank pressure and react accordingly. Add ingredients if necessary. Proceed to the next
step after brewing is complete.
Step 4 - Initiate transfer to holding tank. Our batch is ready; verify that all the appropriate valves
are set to the right position, the holding tank is empty and begin the transfer process.

Step 5 - Transfer the batch to the bottling facility.

As you can see from the example outline above, the process steps are executed in a sequence,
have defined start conditions and flow as the process would run in the production facility. In
ladder logic, this process can be implemented through an SQI/SQO Instruction. However, a
better approach would be to utilize SFC.

Function Block Diagram PLC Programming | Analog Signal Scaling Example in RSLogix 5000

Advantages of Function Block Diagrams PLC Programming

Flexible Visual Editor | The editor for Function Block Diagram programming is very user
friendly and provides a simple way to create any layout.

Ideal for Complex Programming Structures | In ladder logic, the user will have to use multiple
rungs for what’s possible to accomplish on a single page of FBD. The instructions can be
brought directly into complicated PLC Instructions that implement PID loops, Motion Control,
and Add-On-Instructions (AOIs).

User Friendly | The visual editor of FBD, comes naturally for most users. The layout of the
process can be re-created through a drag-and-drop methodology that leaves little to
guesswork.

Disadvantages of Structured Text

Hard to Standardize | Due to the flexibility in the layout, it’s challenging to standardize
programs written in FBD. Each PLC programmer will have an approach that’s different from
others. Those who come behind will have a hard time understanding the flow of information.‍ Sequential Function Charts PLC Programming | Sequential Process Example in RSLogix 5000

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 Advantages of Sequential Function Charts PLC
Programming
Mimic Process Flows of Most Chemical Processes | Batching is a common chemical process
approach that takes a set number of raw ingredients and transforms them into the final
product. SFCs shine in these applications.

Combined with ST | Most SFC editors allow the use of Structured Text in specific cases to
create advanced logic flows.

Disadvantages of Sequential Function Charts

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Inapplicable in Most Applications | It’s challenging to apply sequential function charts to a

process that isn’t sequential. In other words, it has a limited number of use cases.‍

Parallel Flows are Difficult to Implement and Troubleshoot | You may implement an unlimited
amount of process flows through SFCs. However, as the process paths split into multiple
flows, it becomes difficult to implement separate flow paths that would result in a robust
sequence.

Sequential Function Charts are extremely useful in specific cases. However, trying to fit this type
of programming language into a case that isn't sequential quickly leads to frustration. As you
work in a manufacturing environment, we recommend that you become familiar with the
process, understand the flow of the product and seek to build a model on paper before diving
into SFC programming.

Instruction Lists PLC Programming Language

Instruction Lists are often confused with Structured Text due to their similar editors. These two
PLC programming languages are typically seen on different platforms as their flow is similar. For
example, Codesys based controllers would allow users to implement logic in Instruction Lists,
while RSLogix 5000 based controllers only have access to Structured Text.

In terms of program flow, each line specifies instruction as well as the conditions and outcomes
of the execution. In many aspects, Instruction Lists are closer to how you’d implement ladder
logic programs than structured text. However, either language is capable of creating the same
process flow.

Advantages of Instruction Lists PLC Programming

Highly Standardized | Instruction Lists follow a tight structure that requires the user to create
variables explicitly, specify conditions, and list every instruction. There’s little variation between
program implementation which leads to easy to understand code.

Instruction Focused | As the name would suggest, there’s a high level of importance placed on
instructions rather than data flow. This style of programming creates a level of clarity of how
data is processed in the program.

Disadvantages of Instruction Lists

Unavailable on Most PLC Platforms | As mentioned above, Instruction Lists aren’t a popular
method of programming as they come unnaturally to most programmers. They’re closer to what
one would see in assembly rather than any other programming language on the market.

Conclusion
The five most popular PLC Programming Languages are Ladder Logic, Structured Text,
Function Block Diagrams, Sequential Flow Charts and Instruction Lists. These methods of
programming are available on most platforms. However, certain PLCs will restrict user access to
certain languages unless the user pays a premium.

We recommend that every PLC programmer starts with ladder logic as this method is most
common in the industry. That being said, as the person is exposed to advanced programming

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