Programmable Logic Controller

(PLC)

MG5018/DE5402
 PLC

 PLC (Programmable Logic Controller) is a digitally

operating electronic apparatus which uses a
programmable memory for the internal storage of
instructions for implementing specific functions, such
as logic, sequencing, timing, counting and arithmetic,
to control through digital or analogue input/output,
various types of machines or processes.
 In other words, a PLC is used to control automatic
machines and processes, particularly where mass
production over longer periods of time are required.
 History of PLC
In the late 1960's PLCs were first introduced. The primary reason
for designing such a device was eliminating the large cost involved
in replacing the complicated relay based machine control systems.
“Relay is an electrically operated (electromechanical) switch
consisting of a coil of wire surrounding a soft iron core.”
Bedford Associates (Bedford, MA) proposed something called a
Modular Digital Controller (MO-DI-CON) to a major US car
manufacturer.
The MODICON 084 (Bedford’s 84th Project) brought the world's
first PLC into commercial production. One of the people who
worked on that project was Dick Morley, who is considered to be
the “Father" of the PLC. (father-of-the-plc)
The Automation industry is still one of the largest users of PLCs.
Advantages of PLC over Relay Control
Systems

The PLCs offered the following advantages over Relay control

systems -
 higher reliability than electromechanical devices
 many more “contacts” than electromechanical devices
 a wide variety of inbuilt control tasks (timers, counters etc)
 control wiring was reduced, reducing installation time and costs
 space & electrical energy requirements were reduced
 fault finding & commissioning was easier and less time
consuming because PLCs are Soft Wired as compared to Hard
wired Relays
 they conveniently permitted process sequence modification and
duplication
 they were reusable
 on-line monitoring, control and documentation
 PLC Hardware

In general terms, the PLC consists of the

following components:
 an Input and Output (I/O) Module system,
 a processor module or central processing
unit (CPU),
 a memory unit,
 a power supply unit,
 and a programming device.
 Input and Output Devices

The Input and Output (I/O) Module system provides

the physical connection between the process
equipment and the processor.
Input devices can be switches, sensors etc which are
used to sense / measure physical quantity e.g.
Motion, level, temperature, pressure etc.
Output devices can be valves, motors, pumps,
alarms, lights etc which act depending upon the
signals from the processor.
 The Processor Module

 The Processor Module or CPU consists of

one or more Microprocessors and other ICs
that executes arithmetic & logical
calculations and performs memory functions
of the PLC. The CPU reads the inputs,
executes logic as determined by the
application program, performs calculations,
and controls the outputs accordingly, and
controls the overall operation of the PLC.
 Memory Unit

There are different types of Memories used in

a PLC such as RAM, ROM, PROM, EPROM,
EEPROM etc.
 RAM, ROM AND PROM
 RAM: Random Access Memory is designed to allow
data to be written to it and read from it continually. It
is “Volatile” i.e. it requires power to hold the data. If
power is removed, data is lost.
 ROM: Read Only Memory is designed to store
information that can only be read by the PLC. The
ROM chip is written in the factory and cannot be
changed.
 PROM: Programmable Read only Memory can be
written to (programmed) only once or added to until
all memory locations are full.
 EPROM & EEPROM
 EPROM: Erasable Programmable Read only
Memory is similar in operation to PROM with a major
difference of being able to be erased by exposing it
to UV light through a window in the chip case.
 EEPROM: Electrically Erasable Programmable Read
only Memory is again non Volatile and does not
require battery backup. The big advantage of
EEPROM over EPROM is that data can be
electrically over-written.
 MEMORIES

In a PLC Memories are required for:-

 Application program (RAM or EEPROM)
 Diagnostics (ROM or EPROM)
 PLC overall operation (RAM)
 Data (RAM & ROM)
 Communications (RAM & ROM)
Memory Characteristics
 Power Supply Module

Power Supply, as the term says, provides the power

voltage to the PLC. Most PLC’s have a dedicated
power supply that supplies power for the internal
workings of the PLC itself as well as providing power
that can be used to supply some field devices. When
installing a PLC system it is important to allow a
power supply with enough current capacity to supply
all the needs of the installation and it must survive
hostile industrial environments.
 PLC Programming

 Most PLCs are programmed by a PC or

Laptop using a software e.g. ZelioSoft or
Multisim via a special lead e.g. RS – 232.
There is a range of programming methods and devices as
shown below.
 PLC Programming Languages

There are 5 standard languages:

 Ladder Logic or Ladder diagram (LD),
 FBD (Function Block Diagram),
 SFC (Sequential Function Chart),
 ST (Structured Text) and
 IL (Instruction List).
 Ladder Diagram
 Ladder Diagram is a PLC programming
language which represents a program by a
diagram similar to a relay logic (ladder)
diagram. The name “ladder” is derived from
the fact that both diagrams resembles a
ladder, with two vertical rails and a series of
horizontal rungs between them. The left
vertical rail is the positive bus and all
horizontal rungs are derived from this.
 Ladder Diagram (contd.)

 Ladder Diagram programming incorporates

the fundamental logic gates and elements.
Logic gates such as AND, OR, NOT, NAND,
NOR and XOR functions can be
implemented in LD programming. Elements
such as counters, timers, data shifting &
other elements are also provided in LD
programming.
Function Block Diagram (FBD)
Programming.
 Programs
 PROGRAM 1: This program uses 1 NO Input and 1 Output
Lamp. Lamp is On (energised) when NO Input is closed. Lamp
stays On as long as NO Input remains closed.
 PROGRAM 2 – AND: This program uses 3 NO inputs and 1
Output Lamp. Lamp is On (energised) if all 3 NO inputs are
closed. Lamp stays On as long as all 3 NO Input remains
closed.
 PROGRAM 3 – OR: This program uses 3 NO Inputs and 1
Output Lamp. Lamp is On (energised) when any one of 3 NO
Inputs are closed. Lamp stays On as long as any one of NO
Input remains closed.
 PROGRAM 4 – NOT: This program uses 1 Input and 1 Output
Lamp. Lamp is On (energised) when the Input is at logic 0 state
otherwise its Off.
 Programs (contd.)
 PROGRAM 5 – NAND: This program uses 2 Inputs and 1
Output Lamp. Lamp is Off (de-energised) only when both the
inputs are at logic 1 state, otherwise its On (energised).
 PROGRAM 6 – NOR: This program uses 2 Inputs and 1 Output
Lamp. Lamp is energised only when both the Inputs are at logic
0 state, otherwise its Off (de-energised).
 PROGRAM 7 – XOR: This program uses 2 Inputs (4 switches)
and 1 Output Lamp. Lamp is energised only when one of the 2
Inputs are at logic 1 state otherwise its Off (de-energised).
 PROGRAM 8 – XNOR: This program uses 2 Inputs (4 switches)
and 1 Output Lamp. Lamp is energised only when both the
Inputs are at logic 0 or 1 state otherwise its Off (de-energised).