Introductory PLC

Programming

Introduction

What is a Programmable Logic

Controller (PLC)?

A Programmable Logic Controller, or PLC,

is more or less a small computer with a
built-in operating system (OS). This OS is
highly specialized and optimized to handle
incoming events in real time, i.e., at the
time of their occurrence.

The PLC has input lines, to which sensors

are connected to notify of events (such as
temperature above/below a certain level,
liquid level reached, etc.), and output lines,
to which actuators are connected to affect
or signal reactions to the incoming events
(such as start an engine, open/close a
valve, and so on).

The system is user programmable. It uses

a language called "Relay Ladder" or RLL
(Relay Ladder Logic). The name of this
language implies that the control logic of
the earlier days, which was built from
relays, is being simulated.

Some other languages used include:

1. Sequential Function chart

2. Functional block diagram
3. Structured Text
4. Instruction List
5. Continuous function chart

A programmable logic controller, PLC, or

programmable controller is a digital
computer used for automation of typically
industrial electromechanical processes,
such as control of machinery on factory
assembly lines, amusement rides, or light
fixtures. PLCs are used in many machines,
in many industries. PLCs are designed for
multiple arrangements of digital and
analog inputs and outputs, extended
temperature ranges, immunity to electrical
noise, and resistance to vibration and
impact. Programs to control machine
operation are typically stored in battery-
backed-up or non-volatile memory. A PLC
is an example of a "hard" real-time system
since output results must be produced in
response to input conditions within a
limited time, otherwise unintended
operation will result.
Before the PLC, control, sequencing, and
safety interlock logic for manufacturing
automobiles was mainly composed of
relays, cam timers, drum sequencers, and
dedicated closed-loop controllers. Since
these could number in the hundreds or
even thousands, the process for updating
such facilities for the yearly model change-
over was very time consuming and
expensive, as electricians needed to
individually rewire the relays to change
their operational characteristics.

Digital computers, being general-purpose

programmable devices, were soon applied
to control industrial processes. Early
computers required specialist
programmers, and stringent operating
environmental control for temperature,
cleanliness, and power quality. Using a
general-purpose computer for process
control required protecting the computer
from the plant floor conditions. An
industrial control computer would have
several attributes: it would tolerate the
shop-floor environment, it would support
discrete (bit-form) input and output in an
easily extensible manner, it would not
require years of training to use, and it
would permit its operation to be
monitored. The response time of any
computer system must be fast enough to
be useful for control; the required speed
varying according to the nature of the
process.[1] Since many industrial
processes have timescales easily
addressed by millisecond response times,
modern (fast, small, reliable) electronics
greatly facilitate building reliable
controllers, especially because
performance can be traded off for
reliability.

In 1968 GM Hydra-Matic (the automatic

transmission division of General Motors)
issued a request for proposals for an
electronic replacement for hard-wired relay
systems based on a white paper written by
engineer Edward R. Clark. The winning
proposal came from Bedford Associates
of Bedford, Massachusetts. The first PLC,
designated the 084 because it was
Bedford Associates' eighty-fourth project,
was the result.[2] Bedford Associates
started a new company dedicated to
developing, manufacturing, selling, and
servicing this new product: Modicon, which
stood for MOdular DIgital CONtroller. One
of the people who worked on that project
was Dick Morley, who is considered to be
the "father" of the PLC.[3] The Modicon
brand was sold in 1977 to Gould
Electronics, later acquired by German
Company AEG, and then by French
Schneider Electric, the current owner.

One of the very first 084 models built is

now on display at Modicon's headquarters
in North Andover, Massachusetts. It was
presented to Modicon by GM, when the
unit was retired after nearly twenty years
of uninterrupted service. Modicon used the
84 moniker at the end of its product range
until the 984 made its appearance.

The automotive industry is still one of the

largest users of PLCs.

Early PLCs were designed to replace relay

logic systems. These PLCs were
programmed in "ladder logic", which
strongly resembles a schematic diagram
of relay logic. This program notation was
chosen to reduce training demands for the
existing technicians. Other early PLCs used
a form of instruction list programming,
based on a stack-based logic solver.

Modern PLCs can be programmed in a

variety of ways, from the relay-derived
ladder logic to programming languages
such as specially adapted dialects of
BASIC and C. Another method is state
logic, a very high-level programming
language designed to program PLCs
based on state transition diagrams.
Many early PLCs did not have
accompanying programming terminals
that were capable of graphical
representation of the logic, and so the
logic was instead represented as a series
of logic expressions in some version of
Boolean format, similar to Boolean
algebra. As programming terminals
evolved, it became more common for
ladder logic to be used, for the
aforementioned reasons and because it
was a familiar format used for
electromechanical control panels. Newer
formats such as state logic and Function
Block (which is similar to the way logic is
depicted when using digital integrated
logic circuits) exist, but they are still not as
popular as ladder logic. A primary reason
for this is that PLCs solve the logic in a
predictable and repeating sequence, and
ladder logic allows the programmer (the
person writing the logic) to see any issues
with the timing of the logic sequence more
easily than would be possible in other
formats.

PLC usage scenarios

A PLC is primarily used to control

machinery. A program written for a PLC
consists basically of instructions to turn
on and off outputs based on input
conditions and the internal program. In this
respect, it is similar to how a standard
computer application is used. Once a PLC
program is activated, however, it will
typically run continuously as a loop for an
indefinite period. PLC-based systems are
frequently used not only to control simple
devices such as a garage door opener, but
also for solving complex application
scenarios, such as controlling a whole
house, including switching lights on or off
at certain times, monitoring custom built
security system, and so on.

Most commonly, a PLC is found inside of a

machine in an industrial environment. A
PLC can run an automatic machine for
years with little human intervention. They
are designed to withstand most harsh
environments.

History of PLCs

Evolution of PLC started from the proposal

by GM to develop a Standard Machine
Controller to alleviate the problems related
to the Electro-mechanical circuits.

When the first electronic machine controls

were designed, they used relays to control
the machine logic (i.e. press "Start" to start
the machine and press "Stop" to stop the
machine). A basic machine might need a
wall covered in relays to control all of its
functions. There are a few limitations to
this type of control.

Relays fail.
The delay when the relay turns on/off.
There is an entire wall of relays to
design/wire/troubleshoot.

A PLC overcomes these limitations, it is a

machine controlled operation.
Recent developments

PLCs are becoming more and more

intelligent. In recent years PLCs have been
integrated into electrical communications
such as Computer network(s) i.e., all the
PLCs in an industrial environment have
been plugged into a network which is
usually hierarchically organized. The PLCs
could be supervised by a control center or
a supervisory system known as SCADA
and often are connected to Human
Machine Interfaces (HMI). There exist
many proprietary types of networks based
on serial communication and Ethernet
communication.
Basic Concepts

How the PLC operates

The PLC is a purpose-built machine control

computer designed to read digital and
analog inputs from various sensors,
execute a user defined logic program, and
write the resulting digital and analog
output values to various output elements
like hydraulic and pneumatic actuators,
indication lamps, solenoid coils, etc.

Scan cycle

Exact details vary between manufacturers,

but most PLCs follow a 'scan-cycle'
format. PLC scans programme top to
bottom & left to right.

Overhead - Overhead includes testing I/O

module integrity, verifying the user program
logic hasn't changed, that the computer
itself hasn't locked up (via a watchdog
timer), and any necessary
communications. Communications may
include traffic over the PLC programmer
port, remote I/O racks, and other external
devices such as HMIs (Human Machine
Interfaces).

Input scan
A 'snapshot' of the digital and analog
values present at the input cards is
saved to an input memory table.

Logic execution
The user program is scanned element by
element, then rung by rung until the end
of the program, and resulting values
written to an output memory table.
Diagnosis and communication
is used in many different disciplines with
variations in the use of logics, analytics,
and experience to determine "cause and
effect". In systems engineering and
computer science, it is typically used to
determine the causes of symptoms,
 mitigations, and solutions. It
communicates with the input module
and sends a message to the output
module for any incorrect data files
variations.

Output scan
Values from the resulting output
memory table are written to the output
modules.

Once the output scan is complete the

process repeats itself until the PLC is
powered down.

The time it takes to complete a scan cycle

is, appropriately enough, the "scan cycle
time", and ranges from hundreds of
milliseconds (on older PLCs, and/or PLCs
with very complex programs) to only a few
milliseconds on newer PLCs, and/or PLCs
executing short, simple code.

Basic instructions
Be aware that specific nomenclature and
operational details vary widely between
PLC manufacturers, and often
implementation details evolve from
generation to generation.

Often the hardest part, especially for an

inexperienced PLC programmer, is
practicing the mental ju-jitsu necessary to
keep the nomenclature straight from
manufacturer to manufacturer.

Positive Logic (most PLCs follow this

convention)
True = logic 1 = input energized.
False = logic 0 = input NOT energized.

Negative Logic
True = logic 1 = input NOT energized
False = logic 0 = input energized.

Normally Open
(XIC) - eXamine If Closed.
This instruction is true (logic 1) when the
hardware input (or internal relay
equivalent) is energized.
Normally Closed
(XIO) - eXamine If Open.
This instruction is true (logic 1) when the
hardware input (or internal relay
equivalent) is NOT energized.

Output Enable
(OTE) - OuTput Enable.
This instruction mimics the action of a
conventional relay coil.

On Timer
(TON) - Timer ON.
Generally, ON timers begin timing when
the input (enable) line goes true, and
reset if the enable line goes false before
setpoint has been reached. If enabled
until setpoint is reached then the timer
output goes true, and stays true until the
input (enable) line goes false.

Off Timer
(TOF) - Timer OFF.
Generally, OFF timers begin timing on a
true-to-false transition, and continue
timing as long as the preceding logic
remains false. When the accumulated
time equals setpoint the TOF output
goes on, and stays on until the rung
goes true.

Retentive Timer
(RTO) - Retentive Timer On.
 This type of timer does NOT reset the
accumulated time when the input
condition goes false.

Rather, it keeps the last accumulated time

in memory, and (if/when the input goes
true again) continues timing from that
point. In the Allen-Bradley construction,
this instruction goes true once setpoint
(preset) time has been reached, and stays
true until a RES (RESet) instruction is made
true to clear it.

Latching Relays
(OTL) - OuTput Latch.
(OTU) - OuTput Unlatch.
Generally, the unlatch operator takes
precedence. That is, if the unlatch
instruction is true then the relay output is
false even though the latch instruction may
also be true. In Allen-Bradley ladder logic,
latch and unlatch relays are separate
operators.

However, other ladder dialects opt for a

single operator modeled after RS (Reset-
Set) flip-flop IC chip logic.

Jump to Subroutine
(JSR) - Jump to SubRoutine
For jumping from one rung to another
the JSR (Jump to Subroutine) command
 is used.

Programmable Logic

External links
Wikipedia:

Programmable logic controller

Ladder logic
IEC 61131-3 PLC programming language
standards
SCADA

Wikiversity:

Automation template

by philip
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