Unit IV

PLC Programming
Contents

 Introduction to PLC

 Architecture of PLC

 Selection of PLC

 Ladder Logic Programming for different gates

 Latching

 Timers

 Counters

 Practical Example of PLC

Introduction

 PLC is digital computer for automation of Electromechanical Industry

 E.g. Assembly Lines

Heating, Ventilation and Air conditioning

Plastic Injection Moulding Machines

Domestic & Commercial Washing Machine

 PLC: Member of Computer Family

 PLC: Uses IC instead of electromechanical devices to implement control

functions
Introduction

 Capable of storing instructions

Timing

Counting

Arithmetic logic

Data Manipulation

Communication

To control machines & Processes

Introduction
Introduction: Why PLC?

 Hard wired panels/ Relay logic are time consuming

 Hard wired panels : Wiring and Repairing are main issues

 Controllers: Faster

Operates in real time

Withstands vibrations, temperature, humidity, noise

Inbuilt interfacing input and output

Flexible, easy to reprogramme

Easy to maintain, less space, less wiring, cheaper

Selection criterion for PLC

 Application Requirement

 Input / Output Requirement

 Memory Requirement

 CPU Requirement

 Software Requirement

 Operate interface

 Communication requirement

 Environmental Requirements
Components of PLC
Input Devices

 Provides input to control system

 Limit Switches: Open or Closed

 Comparators

 Push Buttons: Pressed or Not Pressed

Output Devices

 Accept Output from the control system

 Lights: ON/ OFF

 Motors: Rotating or Non Rotating

 Solenoids: Engaged or Not Engaged

Input Output Devices

Input Output
Relay Sequencers

 Control, Sequencing, Safety, Central Locks in Automobiles

 Before PLC: Relays, Cams, Timers etc.

 Physical relays used in circuit instead of Ladder Diagram

 Event sequence is done through wires, relays and circuits

 For changing Event sequence rewiring requires

 Sometimes it is necessary to add or remove relays

 Video
From Relay to Computer Based
Controllers
 Input and output variables are binary in nature

 Control relays can be replaced by Software

 Less hardware control

 Program sequence can be changed through software only

 Special Functions e.g. time delay, counters are easy to change through

software
Architecture of PLC
Components of PLC

 Input Module

 Output Module

 CPU

 Memory

 Power Supply

 Programming Device

 Communication

Channel
Input Module of PLC
 Module Examines state of physical switches

Other Input Devices

Conversion of signal into form suitable to processor

 It can accommodate number of input channels
Input Module of PLC
 Conversion of real world voltage & current that PLC can understand

 Different types of input devices hence different types of input modules

 Digital Module, analog module

 Discrete / Digital Module: Use 0 or 1 to show state

 Analog Module: Use Number to show state e.g. 30 Degrees

Output Module of PLC
 Output Module supplies AC Power to devices like Motors, Lights,

Solenoids
 It accepts 0 or 1 from the processor and uses it to turn ON or OFF Motors,

Lights, etc.
 Output module channel has indicator to show ON/OFF of operations
Processor

 Processor is computer

 It executes a program to perform operations given in the ladder diagram

 Performs arithmetic and Logical operations

 Output given by the processor depends on input variable data

CPU

 Brain of PLC

 Logic and Sequencing functions

 Uses Microprocessor
Memory

 Contains Program of logic, sequencing, other input and Output operations

 Memory ranges from 1K to 48K words

 RAM, ROM, EPROM (Erasable & Programmable)

Power Supply

 115 Volts Power Supply for PLC and Other modules

 Types

Fits into one slot of chassis

External power supply- outside of the chassis

Stand alone supply- Connected to PLC or Input/Output through power

cable

Embedded power supply as part of PLC Block

Programmable Device

 Detachable from the PLC

 Can be shared with different controllers

 Types

Simple teach Pendant type devices

PLC Programming keyboards and CRT Displays

Communication Channel

 Buses: Paths used for communication within PLC

 Information is transmitted in binary form

 Data Bus: Sending data between constituent elements

 Address Bus: To send addresses of locations for accessing stored data

 Control Bus: For signal related to internal control actions

 System Bus: Communications between the I/P O/P ports & I/P O/P unit
Communication Channel
Types of PLC

 Single Box Type (Brick)

 For Small Programmable controllers

 Internal compact package with power supply, processor, memory

 6, 8, 12 or 24 Inputs & 4, 8 or 16 outputs

 Stores memory from 300 to 1000 instructions

Types of PLC

 Modular (Rack)

 Separate module for Power Supply, Memory, Input / Output module,

Processor
Types of PLC

Brick Type PLC

Rack Type PLC

PLC Operation

 Two modes of operation

 The I/O Scan Mode

 The Execution Mode

PLC Operation

 The I/O Scan mode

 Processor updates state of all outputs and inputs

 One channel at a time is scanned

 Time required for this depends upon speed of processor

PLC Operation

 The Execution mode

 Processor evaluates each rung of ladder diagram sequentially

 After evaluation of Rung, last known state of each switch & relay contact is

considered
 If any true path to the output device is detected then O/P is said to be

energized (It is set to ON)

Use of NC Push Button

(a) Wrong: Button turns light OFF

(b) With Relay logic: Light turns ON

(c) With PLC: Button turns light ON

Programming of PLC

 Ladder Logic used for Machine Control and Process Control

 Ladder: Resemble Ladder

 Vertical Rails are Power Supply

 Horizontal Lines are Rungs

Ladder Diagram Scanning
Ladder Diagram: Rung
Elements of Ladder Diagram
Elements of Ladder Diagram
Ladder Diagram: AND Logic

Lamp will be ON only if contact A & B simultaneously actuated

Ladder Diagram: OR Logic

Lamp will be ON only if either of the contact A & or contact B actuated

Ladder Diagram: NOT Logic

Lamp will be ON if contact A is not actuated

Lamp will be OFF when contact A is actuated

Ladder Diagram for AND Gate
Ladder Diagram for OR Gate
Ladder Diagram for NOT Gate
Latch to turn ON & OFF a motor
using 2 NO Push button Switches
Example
Bank with Three Bank Officers having three unique key of vault

Bank Rule: To open the vault at least two officers must be present

Develop the ladder diagram to unlatch the door and turn ON the light when two

keys are inserted

Solution:

1,2,3: Officers’ Key

Example
Small House with 3 Windows and 2 doors

Develop ladder diagram to turn on a light

if one or more windows are open or if both doors are open

PLC Timer Function
 To provide needed delays in the PLC applications

 To specify period of time that some operation is to last

 Timer is activated by true path

 Timer begins to accumulate time in form of “ticks”

 Each tick is certain amount of time

 Timers are preloaded with certain no of ticks

 When accumulated time ticks = preload value; timer itself becomes true
PLC Timer Function

 EN =Enabled
 DN =Done
 Timer =T: 1

 Time Base =Each count means

0.01 seconds
 Preset =0.01 s x 500 = 5 s

 Accumulator =Holds the value of

current count
Example: Traffic Light
Red Light on for 31 seconds, Green light on for 28 seconds, amber light is on

for 6 seconds.
PLC Counter Function
 Counter counts input changes from False to True

 In one scan Input is False

 In next scan Input is True

 No further count takes place until input goes False again

 Counter has preset number of counts

 After accumulating preset number of counts counter becomes TRUE

 After becoming TRUE it actuates some other part of the Ladder Diagram
PLC Counter Function

 EN =Enabled
 DN =Done
 Counter =C: 1
 Preset =Counter gets to

preset value makes DN bit go

TRUE
 Accumulator =Holds the value of

current count
SCADA
 Supervisory Control and Data Acquisition

 Industrial control system

 Monitors and Controls industrial processes

 Manufacturing,

 Production

 Power Generation

 Fabrication

 Refining

 Continuous, Batch, Repetitive, Discrete

Components of SCADA
 Human Machine Interface (HMI)

 Operator monitors and controls the process

 Supervisory system (Computer)

Acquires Data of the process

Sends command to process

 RTU (Remote Terminal Units)

Connects sensors to Process

Converts Sensor Signal to Digital Data

Sending Digital Data to Supervisory System

 PLC: Economical, Versatile, Flexible
Components of SCADA

• RTU: Remote Terminal Unit

• MTU: Master Terminal Unit
• DAS: Data Acquisition
System
• HMI: Human Machine
Interface
Components of SCADA
PLC Examples
Draw a PLC ladder diagram for a motor with:
NO start button
NC stop button
Thermal overload limit switch opens on high temperature
Green light while running
Red light for thermal overload.
PLC Examples Level Control
A process tank (Figure) to mix the liquid fertilizer:
A start pushbutton to start the operation
Valve V1 to fill the tank to preset level sensed by level switch A
As tank fills level switch closes and NO contact energize stirrer motor to
start automatically and operate it for 5 sec to mix the fluid
When stirrer stops valve V2 is energized to empty the tank.
When tank is empty switch B is opened and de-energized valve V2
A stop button to stop the operation
A start pushbutton to start the operation
Valve V1 to fill the tank to preset level sensed by level switch A
As tank fills level switch closes and NO contact energize stirrer motor to start
automatically and operate it for 5 sec to mix the fluid
When stirrer stops valve V2 is energized to empty the tank.
When tank is empty switch B is opened and de-energized valve V2
A stop button to stop the operation
P1 P2 CR 1

CR 1

CR 1 LA V1

CR 1 LA T:1
Time base 0.01
Preset 500
Accum 00

T1 M

T1 LB P2

P2

P2 V2
PLC Examples Conveyor
Start Push Button to start the conveyor motor
Bottles move past the photosensor & conveyor motor automatically after
the count of 25 Bottles
Counter to be set at zero after 25 counts
Conveyor motor can be stopped manually at any time
Count of the counter is reset manually by means of count reset button
Start Push Button to start the conveyor motor
Bottles move past the photosensor & conveyor motor automatically after the count of
25 Bottles
Counter to be set at zero after 25 counts
Conveyor motor can be stopped manually at any time
Count of the counter is reset manually by means of count reset button

X100 Reset Resetting counter

X200 Sensor
X300 Start
X400 Stop
C100 Counter Counter Value 25
M100 Relay
M200 Relay Start Stop, Relay with
Y100 Motor counter

Motor Start

Resetting Relay
(Rung 1)