AN

INTRODUCTION
TO
PLC PROGRAMMING

BY
INDO GERMAN TOOL ROOM,
AURANGABAD

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 WHY TO LEARN PLC ??
 The participants will
understand the things happens
in a process industry daily.

 They will understand about the

electrical hardware devices.

 Students will get the

knowledge how to study an one
line diagram used in the
industry for control circuit of
electrical drives.
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 What is a control ??

Control means to make an

output on and off by help of
controlling devices.

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 Types of control

 On Off control
 Sequential control

 Feedback control

 Motion control

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 EXAMPLE OF
AN
UNCONTROLLED CIRCUIT.

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 A CONTROLLED CIRCUIT

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 EXAMPLE
OF MANUAL CONTROL
 Manual Control circuits use
components that require human
interaction in order to operate.

Toggle switch

AC
source

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 EXAMPLE
OF MANUAL CONTROL
After the toggle switch is made on
manually the bulb gets ON.

Toggle switch
AC
source

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 ELECTRO MECHANICAL CONTROL
DEVICES
 TOGGLE SWITCHES,
PUSH BUTTON S,
EMERGENCY STOP S,
LIMIT SWITCHES,
SELECTOR SWITCHES ,
RELAY S,
TIMERS,
MINIATURE CIRCUIT BREAKERS (MCBS) ,
RESIDUAL CURRENT CIRCUIT BREAKERS
(RCCBS),
PROXIMITY , LIQUID
SENSORS/ACTUATORS,
MAGNETIC CONTACTORS,
SOLENOID VALVES .
ETC …………….
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  Application of
Electrical Devices on
Control Circuits (One
Line Diagram)

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 ELECTRICAL SYMBOLS

ABOUT THE
ELECTRICAL
SYMBOLS
&
ONE LINE
DIAGRAM
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 AN EXAMPLE OF ONE LINE DIAGRAM

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 What is Automation?
Automation is basically the delegation
of human control functions to technical
equipment towards achieving

 Higher productivity.
 Superior quality of end product
 Efficient usage of energy and raw
material.
 Improved safety in working condition.

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AUTOMATION APPLICATION
 Power generation :- hydro, coal, gas, oil, shale, nuclear,
wind, solar
 Transmission :- electricity, gas, oil
 Distribution :- electricity, water
 Process :- paper, food, pharmaceutical, metal,
processing, glass, cement, chemical, refinery, oil
& gas
 Manufacturing :- computer aided manufacturing (CAM),
flexible fabrication, appliances, automotive, aircrafts
 Storage :- silos, elevator, harbor, deposits, luggage
handling
 Building :- heat, ventilation, air conditioning (HVAC),
access control, fire, energy supply, tunnels,
highways,....
 Transportation :- rolling stock, street cars, sub- urban
trains, busses, cars, ships, airplanes, satellites,...

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 APPLICATION OF PLC IN
INDUSTRIAL AUTOMATION.
 When PLCs are connected with
industry (may it be an
electrical industry or may it be
a mechanical industry) to
control its various functions
that happens daily in an
automatic manner, it is called
Industrial Automation or an
Automated Industry.
 Where every control is done
by the Application of PLCs.
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 WHAT IS A PLC ??
 A Programmable Logic Controller
(PLC for short) is simply a special
computer device used for
industrial control systems.
 They are used in many industries
such as oil refineries,
manufacturing lines, conveyor
systems and so on.
 Where ever there is a need to
control devices, the PLC provides
a flexible way to "software" the
components together.
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 WHY PLC ??
 PLCs were invented as replacements for
automated systems that would use
hundreds or thousands of relays, timers,
and drum sequencers.
 Often, a single PLC can be programmed to
replace thousands of relays.
 Programmable controllers were initially
adopted by the automotive manufacturing
industry, where software revision replaced
the re-wiring of hard-wired control panels
when production models changed.
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 DETAILS OF PLC ??

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 PLC OVERVIEW

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PLCs are used in many different
industries and machines such as
packaging and semiconductor machines.
Well known PLC brands are:-
ABB Ltd.
Koyo
Honeywell
Siemens
Modicon
Omron
Allen-Bradley
General Electric,
(Panasonic,Matsushita),
Mitsubishi.

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 BASIC REQUERIMENTS
FOR A PLC PROGRAMMING

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 MODELS OF DIFFERENT
PLCS.
ALLEN BRADLEY MICRO PLC

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SIEMENS PLC WITH ITS RELATED
SOFTWARE

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  SOME OF THE POPULARLY
USED PLC BRANDS AND ITS
RELATED SOFTWARES ARE
…..

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  PLCS SOFTWARES
SIEMENS SIMATICMANAGER
MITSUBISHI GX DEVELOPER.
ABB CONTROL BUILDER.
ALLEN BRADLEY RS VIEW.
GEFANUC SIMPLICITY,
VISA PRO.
MODICON CONCEPT.
WANDER WAVE IN TOUCH.
INTELLUTION FIX 32.
SCHNEDIER PL7, UNITY.
WAGO WAGO-IO-PRO.
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  PROGRAMMING
LANGUAGES

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  LADDER LOGIC

 FBD LOGIC (FUNCTIONAL

BLOCK DIAGRAM)

 STL LOGIC(STATEMENT
LIST)

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 WHAT IS A
LADDER LOGIC ??
 The reason it’s called ladder logic is
the program is drawn graphically and
it looks like a ladder.
 Ladder diagrams are used to describe
the logic of electrical control
systems.
 There are differences in the way
ladder logic was implemented in
computerized form as compared to
hard wire.

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 SIMATIC MANAGER
SOFTWARE SCREEN
Example pro je c t – S te p7

Os lo Univ ers ity Colle ge

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