https://www.youtube.com/watch?

v=w9t_34JfR8Y&t=118s •

https://www.youtube.com/watch?v=U-OHSIxGrOw

https://www.youtube.com/watch?v=iJFRu6ID4EY&t=73s
 Automatic Bottle Filling

https://www.youtube.com/watch?v=JdXzMI1PXcs&t=32s

Pick and Place Robot Control using PLC

https://www.youtube.com/watch?v=JeXkhfr5Fmw

Sorting the objects

https://www.youtube.com/watch?v=O0tGIq22CBQ

https://www.youtube.com/watch?v=TdDVM_3bhTk
 Oil &Gas Industry- ABB
https://www.youtube.com/watch?v=WnD04J324UU •

https://campaign-mo.abb.com/farm-to-fork-bakeries?utm_source=abb-website&utm_medium=abb-website-banner
 Lesson Outcomes

• Explain the structural components of PLC

• Explain the concept of current sourcing and
sinking in PLC
• Understand the working of CPU and its
components
 The PLC ( programmable logic controllers ) was defined by the National
:Manufacturers Association (NEMA) in 1978 as
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
 Advantages of PLC over Relays
Higher reliability than electromechanical devices •
Reduced wiring, installation costs, space, energy requirements •
Fault finding & Commissioning was easier •
Modification easier •
 PLC Intro
https://www.youtube.com/watch?v=2vvqyQavxs4 •
 Development in PLC technology
,Real time programmable timers •
Programmable counters •
Arithmetic, bit & data manipulation & processing •
PID capability (usually via a special module) •
Expanded fault diagnostics capabilities •
Common data highway or LAN communications interfacing •
.between PLC modules & a main computer or control console
Operator display/control interfacing or HMI (Human Machine •
Interface)
https://www.youtube.com/watch?v=ReTtgzN-Dmc&list=PLln3BHg93SQ85ymy4VvtmRGxo2Stps2Iv
A programmable logic controller (PLC) is an industrial
solid-state computer that monitors inputs and outputs,
and makes logic-based decisions for automated
processes or machines.

Components of PLC
There are four components of PLC as follows:

1. Processor or Central Processing Unit (CPU)

2. Programming unit, Software

3. Input module

4. Output module
Input
Input Devices
Devices Input
Input Module
Module Micro-
Micro- Output
Output Output
Output Devices
Devices
Processor
Processor Module
Module

Memory
Memory

Power
Power Supply
Supply

CPU

Fig 2 : Components of PLC

Fig : PLC system
 Major Components of a Common PLC
POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR & T D
From T L Memory P U
SENSORS E U L To
T E OUTPUT
,Pushbuttons
,contacts
,limit switches Provides isolation Lamp, Fan,
Provides isolation And signal conditioning
ProximityAnd signal conditioning Motor,
PROGRAMMING
,Switches Solenoids,
DEVICE
Sensors (Temp, contactors,
pressure, flow,
alarms,
level, optical,
,magnetic etc) Valves, VFD
Smart Devices Smart Devices
.etc .etc
/https://ladderlogicworld.com/plc-architecture
 Fig : PLC Block Diagram
/http://eu.mouser.com/applications/industrial_application_logic_controller
/https://www.equustek.com/industrial-automation-plc-programming-basics
 Input and Output Modules
• Discrete input and output
• Analog input and output
• Specialty I/O modules
• Communication modules
• The discrete I/O interface module connects field
input devices of the ON/OFF nature to PLC.
• Analog input signals are values (Voltage or
current):
• – 0 to 10 volts DC –
• -10 to +10 volts DC –
• 4 to 20 milliamps
 Input module
• The input/output module connects PLC with outside
world.
• The input module connects the input terminals to
the rest of the system.
• Each input point has a unique address.
• It provides isolation and signal conditioning
functions.
Isolation:
• Each terminal is usually electrically isolated from the
internal electronics by Opto couplers or OPTO
ISOLATORS.
• Sinking and sourcing are two important terms
when discussing input and output connections of
PLCs; the way in which d.c. devices are connected
to a PLC. .
Sourcing : The input module provides current to the
input device i.e. the input module is the source of the
current (Figure 1.11(a)).

If the current flows from the output module to an

output load then the output module is referred to as
sourcing (Figure 1.11(b)).
• With sinking, the input module takes the current from
the input device i.e sink for the current (Figure 1.12(a)).
• If the current flows to the output module from an output
load then the output module is referred to as sinking
(Figure 1.12(b)).
D.C. digital input circuits: (a) sink input (b) source input
https://instrumentationtools.com/plc-digital-input-and-output-modules
 • Signal Conditioning would include filtering,
amplification, Analog to digital conversion, level
shifting etc
Types of Voltages:
DC: 12V, 24V, 48V
AC: 120V/220V

Input Devices:
Pushbuttons
Sensors
Relay Contacts
Switches etc…
 Central Processing Unit (CPU)

 CPU is the “brain” of PLC system.

 CPU has three main parts:
1. Microprocessor
2. Memory
3. Power supply
 Microprocessor

• Microprocessor is a multipurpose and

programmable device that performs the
following actions:
• Read the input.
• Perform Arithmetic, logic and control
operations as per the program stored in
memory.
• Communicate the actions to the output device.
 Memory
• Memory is a set registers to store information.

Volatile Non-Volatile
Data is lost when power source is Data is retained even though
removed when power source is removed
Used to store temporary data Used to store system program,
operating system
 Memory Operation

• Write: The process of putting new information into a memory

location is called writing.
• Read: The process of retrieving information from a memory
location is called reading.

Read only Memory (ROM) Random Access Memory (RAM)

Only read operation Can be read or write
Used to store operating system Used to store user program,
temporary data
• Memory in PLC is used to store
instructions(or programs) and execute them to
control the field devices.
• There are two memory sections in PLC:
1. Executive memory
2. Application memory
 PLC Memory

Executive Memory Application Memory

•Used to store operating system, firmwareUsed to store user program

•Permanent Memory Temporary data

•Not accessible to the user Accessible to the user

•Its ROM. Its RAM

 Memory capacity
• Data is stored in memory in the form of 0 or 1.
Single value is called bit.
• Memory capacity is expressed in terms of bytes
(B) or Kilo bytes (KB).
• 1 byte = 8-bits
• 1 KB= 1024 bytes (1024 x 8 = 8194 bits)
• 16 KB means 16 x 1024 bytes.
 Power supply

 It is very important part of PLC system.

 It provides internal DC voltages to the system
components.
 Most PLCs, however, require a 120 VAC or 220
VAC power source, while a few controllers will
accept 24 VDC.
 Programming Unit
• In order to direct PLC for action, one needs to feed the
program to PLC. This programming is done by
programming terminal which has necessary software.
• The software also aids in monitoring and debugging.
 Output of PLC
Types of Voltages:
DC: 12V, 24V, 48V
AC: 120V/220V
Output Devices:
• Relays (24V DC/AC, 120V/220V AC)
• Transistors MOSFET (24V DC)
• Valves
• Solenoids
• Light
• Fan etc….
*Output of a PLC can be Digital as well as Analogue
 Output Module
• The output module contains switches activated
by the CPU in order to connect two terminals and
so allow current to flow in the external circuit.
• The output device can be a valve
(hydraulic/pnuematic), motor, light/bulb.
• Output terminals are numbered and these
numbers are used in the program.
• The switch may be a transistor or a relay.
Device Name Input Output
Analog Digital Analog Digital
Push Button 
Thermocouple 
Relay Coil 
Linear control valve 
Alarm 
Limit Switch 
Pressure Sensor/Bourdon Tube 
Potentiometer 
Lamp 
ma transmitter 20 - 4 
Device Name Input Output
Analog Digital Analog Digital
Proximity Sensor 
Temperature Sensor 
Valve Positioner 
Variable Lighting 
Identify the input and output from
: the following figure
 Inputs
Input signals are provided by transducers / detectors that
convert physical quantities into electrical signals. Depending on
transducer used, the information detected can discontinues (binary) or
continuous (analog) representation of the input quantity

Transducers Measured Quantity Output Quantity

Switch Movement / Position Binary Voltage
Limit Switch Movement / Position Binary Voltage
Thermostat Temperature Varying Voltage
Thermocouple Temperature Varying Voltage
Thermistor Temperature Varying Resistance
Strain Gauge Pressure / Movement Varying Resistance
Photo Cell Light Varying Voltage
Proximity Cell Presence of Objects Varying Resistance
 Outputs
Output devices (like relays, pumps, motors..) are tools used by a
control system to alter certain key element or quantities within the
process.they are also transducers but contrary signals from the control
system into other necessary. There are also discontinuous (binary) or
continuous (analog) devices
Output device Quantity Produced Input
Motor Rational motion Electrical
Pump Rational motion + product Electrical
displacement
Piston Linear motion / pressure Hydraulic / pneumatic
Solenoid Linear motion / pressure Electrical
Heater Heat Electrical
Valve Orifice variation Electrical/Hydraulic/pneumatic
Relay Elec. Switching / limited physical Electrical
movement
• AC Input - Uses AC voltage for input field device status.
• DC Input (Discrete) - Uses DC voltage for input field
device status.
• DC Input (Analog) - The input is a variable DC signal level.
• AC Output - Controls the ON/OFF state of AC output field
devices such as relays, coils, and solenoids.
• DC Output (Discrete) - Discrete DC output modules
control the ON/OFF states of DC output field devices.
• DC Output (Analog) - Provides a variable DC level.
• Sinking and sourcing are two important terms
when discussing input and output connections of
PLCs; the way in which d.c. devices are connected
to a PLC. .
Sourcing : The input module provides current to the
input device i.e. the input module is the source of the
current (Figure 1.11(a)).

If the current flows from the output module to an

output load then the output module is referred to as
sourcing (Figure 1.11(b)).
• With sinking, using the conventional current flow
direction as from positive to negative, an input device
supplies current to the input module, i.e. the input
module is the sink for the current (Figure 1.12(a)). If the
current flows to the output module from an output load
then the output module is referred to as sinking (Figure
1.12(b)).
 PLC Types
There are three basic PLC types:

• Unitary PLC

• Modular PLCs

• Rack style PLCs

 Unitary PLC

It contains every feature(CPU , I/O boards, memory and Power supply )
of the system in one box usually attached with the system.
They have limited input-output terminals and memory.
Used for small system, fix and dedicated application that does not
require change.
Advantages: Cheaper, more compact, portable, fast, everything in one
unit
some very powerful units available with built in GSM, color screens,
and web servers.
Applications: Machine parts inspection, overhead door control, parts
counting and sorting, car park barrier, shop front window display
Example The Micrologix 1000 includes on-board memory for storing programs, 32 digital input and
output ports, and a communications port used to program the unit. This setup is typical of many unitary
 Compact PLC-
All components are in a single box
 Unitary PLC

Unitary PLC’s are fitted directly to the component or machine that they are
controlling.
 Such a PLC might have 6, 8, 12 or 24 inputs
and 4, 8 or 16 outputs and a memory which
can store some 300 to 1000 instructions.

Disadvantages:
Fig: Unitary PLC Can run only small programs
Can not expand
If one feature fails, the whole unit
need to be replaced,
 Modular PLCs

The CPU, Input and output

modules and power supply come as
a separate module and also
communication network.
Modular PLC has a range of
modules that slot together to form
the system.
The modules mount on a DIN rail.
It has more number of inputs and Allen-Bradley PLC installed in a control panel
Example: Allen Bradley Micrologix 1200
outputs as compared to Unitary
PLC.
 Fig: DIN rail

http://amci.com/specialty-io/specialty-io-anynet-io-ssi-interface-ane2.asp
http://www.tech-zephyr.com/programmable-logic-controllers-and-its-advantages/
 Modular PLCs
• Advantages:
 Flexibility
• The number of input and output can be expanded as per the requirement.
• Provides more flexibility to the user
 Easy upgradation and scalability
• An additional card say ADC/DAC or motion control card can be connected as a separate
module.
 Reduced Downtime
• Modules can be added/removed without affecting others so Less downtime
 Coast Effectiveness
• Fault detection is easier, less maintenance, highly reliable

https://forumautomation.com/t/what-is-a-modular-plc/10999
 Modular PLC Applications
 Useful for large system applications
 Manufacturing industry to control process lines (Plastic moulding
machine, dairy production, bottling plant, industrial automation
etc)
Disadvantage:
• Scan time increases when number of input and output increase
• Expensive
Example:
The Allen Bradley Micrologix 1200 is a commonly used example of
the modular PLC type. This unit is able to handle between 23 and
40 inputs and outputs. The actual number of connections can be
expanded easily by adding modules. This provides a wide range of
flexibility and is typical of a modular PLC.
 Fig: Modular PLC

http://www.advancedmrf.com/industrial-control-panel/programmable-logic-controller-plc/
http://www.motioncontroltips.com/2012/02/07/beckhoffs-din-rail-mountable-controller-
features-multi-optional-interface/
 DIN Rail Mount Signal Conditioners

Models Available for Thermocouples, RTDs, DC Voltage and Current, Frequency,

Strain Gage Bridge, AC Voltage and Current

http://www.omega.com/pptst/DRG-SC.html
https://www.slideserve.com/cholden/programmable-logic-controllers-powerpoint-ppt-presentation
Control panel with
PLC (grey elements
in the center). The
unit consists of
separate elements,
from left to
right; power supply,
controller, relay
units for in- and
output
 Rack-mounted PLC
Rack style PLC is a bit similar to modular PLC but implemented differently.
More powerful and complex than modular PLC used for complex and large
applications.
The modules are on standard cards that slots into a standard rack inside a cabinet and
communicate each other via rack.
 Whereas each module in a modular PLC connects to the base unit directly, a rack
mounting PLC keeps each module separate. All extra modules are connected through
a network, and modules are held in organized racks.
The number of I/Os are very high.( 1000 I/O points modular Vs 1,00,00 I/O
points Rack for the same brand)
It has its own integrated power supply.
The communication(or scan time) is faster between processor and module.
Some brands have multiple processors on board sharing inputs.
Redundant processor useful for systems such as waste water pump or fire
control system. Rack-style PLCs can communicate with other networks.
 Application of Rack-
style PLC

• Systems that require large number

of inputs and outputs
• Large automation process
• oil rig motor control center

Fig: Rack style PLC

Example: SLC 500
https://automationforum.co/difference-between-modular-plc-compact-plc/
 PLC selection criteria

In order to select a particular PLC for an application, there are many points/selection
criteria to be taken into account.
 Logical input and output: It is the number of inputs and outputs
that can be connected to PLC.
Memory: The size of the program and application decides the
memory requirement.
Number of I/O modules: The nature of application decides the
number and type of I/O modules.
Speed of operation/Scan time: The amount of time taken by
PLC to read input, process it and update the output is called scan
time. The length of program decides it. Typical values for this are
1 microsecond per simple ladder instruction.
Function: Depending on the requirement, a particular type of
PLC will be used that will be able to perform the job.
Type of communication: Various Communication standards like
Serial and networked (ModBus, Profibus, Ethernet /IP) will be
used depending on the requirement. For big processes, there may
be need of data communication between several PLCs then one
 has to select a particular network protocol.
 Software: The availability of programming software and other tools is of great
importance for system development and debugging.

 Cost: Depending on the application, the cost of the control system will vary.
However it must suit the budget. Unitary PLC suits small applications and it is
cheaper as compared to Rack mounted PLC which is used to control the entire
industrial process.
 Reliability: For certain high-end applications( like nuclear power plant or oil and gas
plant) its utmost important to have a very reliable control system(even if a minor
problem may create a big loss/damage)

 Environment: PLC must be suitable for the working environment (like temperature,
humidity/moisture, interference(electric/magnetic), vibration)
 HMI (Human Machine Interface): If the system needs operator control or interaction.
In order to convey information about machine or process status, or to allow an
operator to input data, many applications require operator interfaces. Traditional
operator interfaces include pushbuttons, pilot lights and LED numeric display.
Electronic operator interface devices display messages about machine status in
descriptive text, display part count and track alarms. Also, they can be used for data
 Points to be considered
 Is the application basic or complex ?
 How many input and output devices would be
required ?
 What are the types of input and output devices to be
used ?
 What are the voltage and power requirements ?
 What speed is required of the CPU?
 Will there be future expansion required ?
 Will the unit communicate with the other units or
computers ?
 What sort of communication will be used ?
 What kind of programming system will be used ?
 Siemens (Texas Instruments) 505 series PLC Municipal Waste Water Treatment

https://www.scribd.com/doc/84826551/BTEC-NC-Selection-and-Applications-of-Programmable-Logic-
Controllers-Understand-the-Selection-of-Hardware-and-Software
Allen-Bradley (Rockwell) PLC-5 system-to monitor and control the operation of
Natural Gas Compressor
http://iamechatronics.com/notes/general-engineering/257-plc-examples
Relay
,It is a electromechanical switch •
.It is used to switch large loads using small currents •
.Thus provides safety between high and low current circuits •
Works on DC and AC •
 ?How does a relay work
https://www.youtube.com/watch?v=n594CkrP6xE •
 Contactor
A contactor is a device that is for making and breaking an •
electrical power circuit. For example, we usually use a
.motor contactor for turning on and off an electrical
It is used to switch higher loads/currents (>15A) •
Contactor Terminals

A1 and A2 are coil terminals

Auxiliary (Feedback) contacts
https://www.realpars.com/blog/contactor
 pole contactor with main and auxiliary contacts-3

Auxiliary contacts are mainly used to signal switching or malfunction states, for
.interlocking circuits or logic and sequence controls with low to high loading
 Contactor when not energized

https://www.youtube.com/watch?v=8gpxXzNUaKU
Contactor when energized
 Contactor
terminals
Relay Logic Circuit
Motor
Basic PLC operation

Read
Read Inputs
Inputs

Solve
Solve Logic
Logic

Write
Write Output
Output

Fig: PLC scan cycle

 Data Bus

Data Bus
BUF BUF

C
BUF
R
Test Processor
W
C
R Clock
ALU
Test ID Reset
Write
Address Bus BUF
Read

A B
IR

PC AL

BUF BUF

Address Bus

Fig: Internal structure of the processor

 PLC Categories
• Depending upon size of PLC, input-out
numbers, memory requirement and
applications, there are four categories of PLC.
1. Micro PLC
2. Small PLC
3. Medium PLC
4. Large PLC
 Micro PLC
• Used for few numbers of discrete Inputs and
Outputs Applications
Features  Small Conveyer controls
 Up to 32 I/O  Monitoring of temperature
 16 bit processor  Activating an output
 Relay Replacer
 Memory up to 1K
 Digital I/O
 Built in I/Os in a compact unit
 Master Control Relays
 Timers and Counters
 Programmed with handheld
programmer
 Small PLC
 Single board controllers
 Mainly used for ON-OFF , timing and sequencing applications

Features Applications
 Up to 128 I/O
 16 bit processor
Relay Replacer  Small applications that require basic

 Memory up to 2K math, control, network interface
 Digital I/O and data handling capacity
 Local I/O only
 Ladder or Boolean language only
 Master Control Relays
 Timers / counters / shift registers
 Dram timer or sequencers
 Programmed with handheld
programmer
 Medium PLC
 These controllers use range of modules that slot together
to make the complete system
The number of inputs and outputs can be expanded.
• Features
 Up to 1024 I/O  Master Control Relays
 16 or 32 bit processor  Timers / counters / shift registers
 Relay Replacer and analogue control  Dram timer or sequencers
 Memory up to 4K words  Jump
 Digital I/O  Math capabilities
 Analogue I/O  Limited data handling
 Local and remote I/O  Special function I/O modules
 Ladder or Boolean language  RS-232 communication port
 Function block/ high level language  Local area networks
 Support I/O bus networks
 Large PLC
Features
 Up to 4096 I/O
 16 or 32 bit processor
 Relay Replacer and analogue
control
 Memory up to 12K words
 Expandable to 128K
 Digital I/O
 Analogue I/O
 Local and remote I/O
 Ladder or Boolean language
 Function block/ high level
language
 Master Control Relays
 Timers / counters / shift
registers
 Dram timer or sequencers
 Jump
 Subroutines, interrupts
 Math capabilities
 Extended data handling
 Special function I/O
modules
 RS-232 communication port
 Local area networks
 Support I/O bus networks
 Large PLC Applications
• There's a need for data acquisition, data
manipulation with complex numerical
calculations
PLC category by size