PLC Training – BASIC

Programmable Controller
Descriptions

This training introduces the basic hardware and software

components of a Programmable Controller (PLC). It
details the architecture and basic instruction set common
to all PLC’s. Basic programming techniques and logic
designs are covered. This training describes the
operating features of the PLC, the advantages of the PLC
over hard-wired control systems, practical applications
and troubleshooting of PLC’s.

2
 PLC - Introduction

What does PLC stand for?

• PLC - programmable logic controller

• PLC implements logic control functions
by means of a program

3
PLC Origin
•- Developed to replace relays in the late 1960s
•- Costs dropped and became popular by 1980s
•- Now used in many industrial designs
Historical Background
The Hydramatic Division of the General Motors
Corporation specified the design criteria for the first
programmable controller in 1968

Their primary goal

To eliminate the high costs associated with inflexible,

relay-controlled systems.

5
Historical Background
• The controller had to be designed in modular form, so
that sub-assemblies could be removed easily for
replacement or repair.

• The control system needed the capability to pass data

collection to a central system.

• The system had to be reusable.

• The method used to program the controller had to be

simple, so that it could be easily understood by plant
personnel.

6
 Generation of PLC
• The first PLC were introduced in the early 1960s, mainly by the automobile
industry.
• Up until then the automatic control of manufacturing equipment was achieved
by using hundreds , and even thousands , of relays enclosed in metal
cabinets.
• A lot of time, and errors often occurred when making connections.
• For these reasons, control engineers developed a computerized
programmable system to replace the relay racks.
• The annual automobile-model changes required frequent modifications to the
production lines and their associated relay-control systems.
• Because the control systems were complex, the modifications took a lot of
time, and errors often occurred when making connections.
• For These reasons, control engineers developed a computerized
programmable system to replace the relay racks.

7
 Capacity of Industrial PLCs
• In the beginning, PLC were mainly used to replace hard-
wired physical relays.

• This offered many advantages because the PLC took up

less space than conventional relay cabinets and consumed
much less energy.

• Today, thanks to the evolution in electronics and computer

technology, the performance of PLC is impressive.

• While they are still used to replace relays, PLCs can now
perform mathematical operations and control and regulate
industrial processes.
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Advantages of PLCs
• Less wiring.

• Wiring between devices and relay contacts are done

in the PLC program.

• Easier and faster to make changes.

• Trouble shooting aids make programming easier and

reduce downtime.

• Reliable components make these likely to operate for

years before failure.
 Programmable Controller Development
1968  Programmable concept developed
1969  Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974  Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976  Remote input/output systems introduced
1977  Microprocessors - based PLC introduced

11
Programmable Controller Development
1980  Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983  Low - cost small PLC’s introduced
1985 on  Networking of all levels of PLC, computer
and machine using SCADA software.

12
Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a

programming memory for the internal storage of
instructions for implementing specific functions such as
logic, sequencing, timing, counting and arithmetic to control
through digital or analog modules, various types of
machines or process.

13
Leading Brands Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer

EUROPEAN 1. Siemens
2. ABB
3. Festo
4. Telemechanique

JAPANESE 1. Toshiba
2. Omron
3. Keyence
4. Mitsubishi
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Areas of Application
 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical

15
PLC Size
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- these PLC’s are capable of providing
simple to advance levels or machine
controls.
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s
and memories up to 750 Kbytes.
- can control individual production
processes or entire plant.

16
Machine Control
To Learn about:

• What is Input and Output in machine control systems.

• Input and Output types.
• Machine controller types
• Important consideration when configuring input and output
interfacing.
• Typical Common Input and Output Devices
Example of Process that needs a Control Systems.

Tank Used to Mix Two Liquids

MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

SOLENOID
C
TIMER

1 -MINUTE
MACHINE CONTROL GENERAL LAYOUT

Input Processor Output

Input - Something going into a system in its operation to

achieve output or a result.
Output - Something going out from a system done by its
operation.
Processor - Something processing inputs data and producing
results as per programmed
Input and Output signals are divided into 2 types;

• Analog (continuous)
• Digital ( on/off or discrete )
Analog and Digital Data;

Digital data

Analog data

Typical analog inputs and outputs for Typical Digital inputs and outputs for PLCs;
PLCs;
Inputs:
Inputs: • Position Sensor
• oven temperature • Limit switch
• fluid pressure • Start/Stop Switch
• fluid flow rate
Outputs:
Outputs: • Motor On/Off
• fluid valve position • Valve On/Off
• motor position • Light On/Off
• motor velocity
To Control What? ..Output - based on
Input
Features

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 Example of PLC I/O LAYOUT Analog Input
Clam
Temper Motor Press Vibrati ping Liquid
ature Speed ure on Force Level

Digital Input
Sol Valve Sol Valve Start
Motor Motor Sensor1 Sensor2 Detect Limit Stop Pos Safety
INPUT
Sensor1 Sensor2 Sensor1 Switch Switch Sensor Sensor

Output
Unit

PLC: DATA PROCESSING

Input CPU
Unit Unit

Indexing Vacuum Motor Pump

Sol Sol Bulb Rotary AC Relay SSR
Cooling
Fan Speed Motor Pump Speed
Servo
Motor Speed OUTPUT
Valve1 Valve2 Sol Motor Coil

Digital Output
Analog Output
DC DC
Motor1 Motor2

What else Analog inputs that you know..

List out your Machine I/Os.. And discuss
Machine Control type :
• PC based – using high level language eg. VB, C++ etc.
- Use Industrial PC / Embedded PC to control machine.
- PCI Input and Output card
- PC architechture

• PLC control – Ladder programming

- Use Programming Logic Controller
- Traditionally, the PLC used discrete outputs to communicate
to the peripheral devices.
- extremely reliable and flexible devices for machine control.
- Simple ladder programming.

• Microcontrollerr – Assembly language, Hi-tech C, CCS, C+

• Relay Control System

MACHINE CONTROL TYPE

PC-Based Machine Control

Key Advantages With

This Control Scheme;
• Handles data intensive
applications
• Variety of connectivity
options
• Front end software can
be customized
• New engineers are more
familiar with PCs than
PLCs

Typical Applications;
• Data acquisition/processing in addition to machine control—handling large amounts of data
• Networking of many machines or to other factory activities - connectivity to plant information technology
system
• Need for central control of I/O devices distributed over a large area
Input and Output Unit (Board / Card). PC-Based Machine Control

Examples of I/O card using various device.

Relay I/O Card

24 channel Opto Coupler isolated I/O Card

Isolated digital I/O card

128 channel | PCI-1758UDO
 PC-Based Machine Control
Input and Output Unit. (examples)
Relay Control System
Input & Output contacts in series and/or parallel
 desired logic functions
Combinations of logic elements
 create complex control plans
Typical relay system
 several hundred or thousand switching contacts
Extremely difficult to change control function of panel
 complete re-wiring of system
Other disadvantages
 cost, speed & reliability
Replacement of relay control systems by modern alternatives based
on electronics & microprocessors
Convert small control signals to higher I/ V driving signals
 used extensively as output devices
Relay Control System
Example;

Elevator Control System

 PLC-Based Machine Control

Key Advantages
• High reliability
• Proven technology
• On line editing
Typical Applications
• I/O centric applications (I/O control is the most critical
criteria)
• Process control
• Greater than 500+ I/O points
 Require short installation & commissioning times

Specific features for industrial control:

• Noise immune equipment
• Modular plug-in construction
• Standard I/O connections & signal levels
• Easily understood programming language
• Ease of programming & reprogramming in-plant
• Capable of communicating & reprogramming in-plant
• Capable of communicating with other PLCs, computers &
intelligent devices
• Competitive in both cost & space occupied with relay &
solid-state logic systems

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 PLC COMPONENTS

 PLC Structure
 PLC’s CPU
 PLC’s Memory
  PLC Structure
Programming Terminal

Power CPU Memory

Supply

PLC Input
Module
Output
Module

Input Output
Devices Devices
PROCESS
  PLC Structure

Divided into 4 parts, I/O Modules, CPU, Memory and

Programming Terminal

Operates by examining the input signals from a process and

carrying out logic instructions

Producing output signals to drive process equipment

Standard interfaces built-in to PLC => directly connected to

process actuators & transducers without the need for
intermediate circuitry or relays
  PLC’s CPU

Controls & supervises all operations within PLC

Carrying out programmed instructions store in
memory
Communications highway
carries information to & from CPU
memory & I/O units under control of CPU
Modern PLCs microprocessors-based
Larger PLCs additional microprocessors to
control complex, time consuming
functions
  PLC’s Memory

(a) Executive Memory

Operating System
 ROM, rarely needs changing
Scanning in PLC
Helps the microprocessor to interpret
programmed symbols & instructions
Keeps track of all I/O status
Monitors the current status of health of system
  PLC’s Memory

(b) System Memory

• System administration  RAM
• Allotted for use of OS only & not available for programming
• Stores information which passes between programmer & OS
 during / before execution of user program

(c) Data Memory

• Timers, counters, & process parameters  set for data storage
• Any data manipulation in user program
• Two sub-memories, (i) fixed data (ii) variable data
• Fixed data  programmed via programming device
• Variable data  CPU for data storage
 The five IEC 61131-3 Programming languages
1. Function Block Diagram (FBD) graphical languages 4.Sequential Flow Chart (SFC)
AUTO CALC1
START STEP
DI CALC PUMP

V IN1 OUT >=1 DO T1

MAN_ON V N ACTION D1 D1_READY
STEP A
ACT IN2
D ACTION D2 D2_READY
T2
N ACTION D3 D3_READY
STEP B
2. Ladder Diagram (LD)
D ACTION D4 D4_READY
CALC1 T3

AUTO CALC PUMP

IN1 OUT
ACT textual languages 5. Structured Text (ST)
IN2
MAN_ON VAR CONSTANT X : REAL := 53.8 ;
Z : REAL; END_VAR
VAR aFB, bFB : FB_type; END_VAR

bFB(A:=1, B:=‘OK’);
3. Instruction List (IL) Z := X - INT_TO_REAL (bFB.OUT1);
A: LD %IX1 (* PUSH BUTTON *) IF Z>57.0 THEN aFB(A:=0, B:=“ERR”);
ANDN %MX5 (* NOT INHIBITED *) ELSE aFB(A:=1, B:=“Z is OK”);
ST %QX2 (* FAN ON *) END_IF
 Types of PLC Construction:

i. Compact PLC:

Compact PLC – MELSEC FX3U

ii. Modular PLC
iii. PLC Plug-in Card

Figure 3: Plug-in Card PLC

HOW to CONTROL INPUT /
OUTPUTs
HOW to CONTROL Input / Output?

Example of Motor Control

How if I/O is Large and Logic
Sequential?
We need Programmable Logic
Controller…
RELAY CONTROL
• This is how PLC
Technology is Developed.
GREEN
GREEN
Ladder Diagram of this circuit

Switch Relay Coil

NO Contact LED Green

NC Contact LED Red

Relay Coil
LED Green
LED Red
Standard Start / Stop Circuit
Standard Start / Stop Circuit
Standard Start / Stop Circuit
Standard Start / Stop Ladder Diagram
Convert this into Ladder Diagram
PLC Basic I/O Connections
76
PLC Programming Software
WIRING AND
COMMUNICATION
PROTOCOLS
CONCEPT
PLC INTER-CONNECTION : WIRING CONCEPTUAL
Example : Relay I/O type.
LOAD
Input Unit Output Unit
MY2
Ch I0.00
P
Ch I0.00
L
Ch 00.00
C

Ch I0.01
P
Ch I0.01 R
O Com
G LED
Light
R
A
M
/
C
P
Com U
Buzzer
PLC Communication
Protocols
Network Bus Cables
PLC Communication
Protocols
Network Bus Cables
 Hardwire Circuit
24+V

Lamp 1 Lamp 2 Solenoid

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CPU
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Switch

0V, common