PLC AND ITS

APPLICATIONS
Prof. Narendra Kumar
Electrical Engineering Department
Delhi Technological University
Delhi-110042
 Presentation Outline
 Evolution of Programmable Logic Controllers (PLC)
 Introduction to Programmable Logic Controllers
 Advantages of PLCs
 Functional Components of PLC System
 Relay Ladder Logic
 Central Processing Unit
 Input /Output System
 Programming and Peripheral Devices
 Programming Concepts
 Applications
 Manufacturers
PLC (Programmable Logic Controller)
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 Hydraumatic 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.

4
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.

5
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

6
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.

7
 Controllers

What type of task might a control system have?

• It might be required to control a sequence of events or
maintain some variable constant or follow some
prescribed change.
• For example, the control system for an automatic drilling
machine might be required to start lowering the drill
when the workpiece is in position, start drilling when the
drill reaches the workpiece, stop drilling when the drill
has produced the required depth of hole, retract the drill
and then switch off and wait for the next workpiece to be
put in position before repeating the operation.
What form might a controller have?

For the automatic drilling machine, we could

wire up electrical circuits in which the closing or
opening of switches would result in motors
being switched on or valves being actuated.
Thus we might have the closing of a switch
activating a relay which, in turn, switches
on the current to a motor and causes the drill
to rotate (See Fig.1).
Fig.1. A Control Circuit
 Microprocessor controlled system
• Instead of hardwiring each control circuit for each control situation we
can use the same basic system for all situations if we use a microprocessor
based system and write a program to instruct the microprocessor how to
react to each input signal from, say, switches and give the required outputs
to, say, motors and valves.
• Thus we might have a program of the form:
If switch A closes
Output to motor circuit
If switch B closes
Output to valve circuit
• By changing the instructions in the grogram we can use the same
microprocessor system to control a wide variety of situations.
 PLC(PROGRAMMABLE LOGIC
CONTROLLERS)
• A programmable logic controller (PLC) is a special form
of microprocessor-based controller (i.e. A digitally
operating electronic apparatus) that uses a
programmable memory to store instructions and to
implement functions such as logic, sequencing, timing,
counting and arithmetic in order to control machines and
processes.
Definition according to NEMA standard ICS3-1978,
USA.
•The term logic is used because programming is primarily
concerned with implementing logic and switching operations, e.g. if
A or B occurs switch on C, if A and B occurs switch on D.

Figure 1. A programmable logic controller

•Input devices, e.g. sensors such as switches, and output devices in
the system being controlled, e.g. motors, valves, etc., are connected
to the PLC.
•The operator then enters a sequence of instructions, i.e. a
program, into the memory of the PLC. The controller then monitors
the inputs and outputs according to this program and carries out
the control rules for which it has been programmed.
 ADVANTAGES OF PLCs

• The great advantage that the same basic controller can be used with a wide
range of control systems.
• To modify a control system and the rules that are to be used, all that is
necessary is for an operator to key in a different set of instructions. There is no
need to rewire.
• The result is a flexible, cost effective, system which can be used with control
systems which vary quite widely in their nature and complexity.
• 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.
 Functional Components of PLC system

Figure 2. Architecture of the PLC system

• The processor unit or central processing unit (CPU) is the unit containing the
microprocessor and this interprets the input signals and carries out the control
actions, according to the program stored in its memory, communicating the
decisions as action signals to the outputs.
• The power supply unit is needed to convert the mains A.C. voltage to the low D.C.
voltage (5 V) necessary for the processor and the circuits in the input and output
interface modules.
• The programming device is used to enter the required program into the memory of
the processor. The program is developed in the device and then transferred to the
memory unit of the PLC.
• The memory unit is where the program is stored that is to be used for the control
actions to be exercised by the microprocessor and data stored from the input for
processing and for the output for outputting.
• The input and output sections are where the processor receives information from
external devices and communicates information to external devices. The inputs
might thus be from switches or other sensors such as photo-electric cells,
temperature sensors, or flow sensors, etc. The outputs might be to motor starter
coils, solenoid valves, etc.
• Input and output devices can be classified as giving signals which are discrete, digital or
analogue . Devices giving discrete or digital signals are ones where the signals are either
off or on. Thus a switch is a device giving a discrete signal, either no voltage or a voltage.
Digital devices can be considered to be essentially discrete devices which give a
sequence of on−off signals. Analogue devices give signals whose size is proportional to
the size of the variable being monitored. For example, a temperature sensor may give a
voltage proportional to the temperature.

Figure 3. Signals: (a) discrete, (b) digital, (c) analogue

• The communications interface is used to receive and transmit data on
communication networks from or to other remote PLCs (Figure 4). It is
concerned with such actions as device verification, data acquisition,
synchronisation between user applications and connection management.

Figure 4. Basic communications model

Internal Structure of PLC

Figure 5. Architecture of a PLC

• The basic internal architecture of a PLC consists of a central processing unit
(CPU) containing the system microprocessor, memory, and input/output
circuitry.
• The CPU controls and processes all the operations within the PLC.
• It is supplied with a clock with a frequency of typically between 1 and 8 MHz.
This frequency determines the operating speed of the PLC and provides the
timing and synchronisation for all elements in the system.
• The information within the PLC is carried by means of digital signals. The
internal paths along which digital signals flow are called buses. In the physical
sense, a bus is just a number conductors along which electrical signals can flow.
It might be tracks on a printed circuit board or wires in a ribbon cable.
• The CPU uses the data bus for sending data between the constituent elements,
the address bus to send the addresses of locations for accessing stored data and
the control bus for signals relating to internal control actions. The system bus is
used for communications between the input/output ports and the input/output
unit.
I/O Module
• The I/O interface section of a PLC connects it to
external field devices.

• The main purpose of the I/O interface is to condition

the various signals received from or sent to the external
input and output devices.

• Input modules converts signals from discrete or analog

input devices to logic levels acceptable to PLC’s
processor.

• Output modules converts signal from the processor to

levels capable of driving the connected discrete or
analog output devices.
I/O Module
DC INPUT MODULE
IS NEEDED TO:
USED TO  Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL Helps reduce the
effects of
electrical noise

Current Buffer,
FROM Limiting OPTO-
Filter,
TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits

Figure 6. DC Input Module

I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC  Prevent voltage
INPUT TO DC AND transients from
DROPS THE damaging the
VOLTAGE TO LOGIC processor.
LEVEL Helps reduce the
effects of
electrical noise

Rectifier, Buffer,
FROM Resistor OPTO-
Filter,
TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits

Figure 7. AC Input Module

I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
 Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of
electrical noise

Amplifier
FROM OPTO-
RELAY
TTL TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

Figure 8. DC/AC Input Module

 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC
 Allen-Bradley 1746-1A16

L1 L2 I= Input
Module
I:2 slot # in rack

P. B SWITCH 0 Module
Terminal #
Address I:2.0/0

LADDER PROGRAM
INPUT
MODULE

WIRING DIAGRAM
 CONTACTOR
L2 L1 N.
O

MOTOR
L2
C •SOLENOID
L1
•VALVES
FIELD •LAMP
WIRING •BUZZER

OUTPUT MODULE
WIRING
L1 O:4 L2

CONTACTOR 0
LADDER PROGRAM
Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing, timing,
counting, and arithmetic.
•System memory is generally built from read-only memory
devices.

APPLICATION
•The application memory is divided into the data table area
•Data Table and user program area.
•The data table stores any data associated with the user’s
•User Program control program, such as system input and output status data,
and any stored constants, variables, or preset values. The
data table is where data is monitored, manipulated, and
changed for control purposes.
•The user program area is where the programmed
instructions entered by the user are stored as an application
control program.
PLC Communications
Common Uses of PLC Communications Ports

 Changing resident PLC programs -

uploading/downloading from a supervisory controller
(Laptop or desktop computer).
•

 Forcing I/O points and memory elements from a

remote terminal.
•

Linking a PLC into a control hierarchy containing

several sizes of PLC and computer.

Monitoring data and alarms, etc. via printers or

Operator Interface Units (OIUs).
•
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards

RS 232

 Used in short-distance computer communications,

with the majority of computer hardware and
peripherals.
 Has a maximum effective distance of approx. 30 m at

9600 baud.
PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all

devices plus providing overall data exchange
management or protocol, ensuring that each device can
“talk” to other machines and understand data received
from them.

LANs provide the common, high-speed data

communications bus which interconnects any or all
devices within the local area.

LANs are commonly used in business applications to

allow several users to share costly software packages
and peripheral equipment such as printers and hard disk 31
PLC Communications
RS 422 / RS 485

Used for longer-distance links, often between several

PCs in a distributed system. RS 485 can have a
maximum distance of about 1000 meters.
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
Examples of PLC Programming Software:
1. Allen-Bradley – Rockwell Software RSLogix500
2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be connected

to the controller. There should be sufficient I/O ports to meet
present requirements with enough spares to provide for
moderate future expansion.

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Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying

sufficient voltage and current to drive the output
peripheral connected to it.

SCAN TIME

This is the speed at which the controller executes the

relay-ladder logic program. This variable is usually
specified as the scan time per 1000 logic nodes and
typically ranges from 1 to 200 milliseconds.
Specifications
MEMORY CAPACITY
•The amount of memory required for a particular
application is related to the length of the program and
the complexity of the control system.
•Simple applications having just a few relays do not
require significant amount of memory. Program length
tend to expand after the system have been used for a
while.
•It is advantageous to a acquire a controller that has
more memory than is presently needed.

37
PLC Operation
Basic Function of a Typical PLC

•Read all field input devices via the input interfaces,

execute the user program stored in application memory,
then, based on whatever control scheme has been
programmed by the user, turn the field output devices
on or off, or perform whatever control is necessary for
the process application.

•This process of sequentially reading the inputs,

executing the program in memory, and updating the
outputs is known as scanning.
While the PLC is running, the scanning process
includes the following four phases, which are repeated
continuously as individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
PHASE 1 – Input Status scan

 A PLC scan cycle begins with the CPU reading the

status of its inputs.
PHASE 2– Logic Solve/Program Execution

 The application program is executed using the status

of the inputs

PHASE 3– Diagnostics/ Communication Execution

 Once the program is executed, the CPU performs

diagnostics and communication tasks
PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the
stored output values are sent to actuators and other
field output devices. The cycle ends by updating the
outputs.
As soon as Phase 4 are completed, the entire cycle
begins again with Phase 1 input scan.

The time it takes to implement a scan cycle is called

SCAN TIME. The scan time composed of the program
scan time, which is the time required for solving the
control program, and the I/O update time, or time
required to read inputs and update outputs. The program
scan time generally depends on the amount of memory
taken by the control program and type of instructions
used in the program. The time to make a single scan can
vary from 1 ms to 100 ms.
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.
Selecting a PLC

Criteria

• Number of logical inputs and outputs.

• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
A Detailed Design Process

1. Understand the process

2. Hardware/software selection
3. Develop ladder logic
4. Determine scan times and memory requirements
Tank Used to Mix Two Liquids

MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

SOLENOID
C
TIMER

1 -MINUTE
Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control circuit
operates as follows:

1. When the start button is pressed, solenoids A and B

energize. This permits the two liquids to begin filling the
tank.

2. When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used
to mix the liquids together.

3. The motor is permitted to run for one minute. After

one minute has elapsed, the motor turns off and
solenoid C energizes to drain the tank.
Tank Used to Mix Two Liquids
4. When the tank is empty, the float switch de-energizes
solenoid C.

5. A stop button can be used to stop the process at any

point.

6. If the motor becomes overloaded, the action of the

entire circuit will stop.

7. Once the circuit has been energized it will continue to

operate until it is manually stopped.
Discrete Input
A discrete input also referred as digital input is an input that
is either ON or OFF are connected to the PLC digital input.
In the ON condition it is referred to as logic 1 or a logic high
and in the OFF condition maybe referred to as logic o or
logic low.
Normally Open
Pushbutton
Normally Closed
Pushbutton
Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

 IN

OFF PLC
Logic 0
Input
Module
24 V dc

IN

ON PLC
Logic 1
Input
Module
24 V dc
Analog Input
An analog input is an input signal that has a continuous signal. Typical inputs
may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level transmitter
monitors the level of liquid in the tank. Depending on the level Tx, the signal to
the PLC can either increase or decrease as the level increases or decreases.

Level Transmitter IN

PLC
Analog
Tank Input
Module
 Digital Output
A discrete output is either in an ON or OFF condition. Solenoids, contactors
coils, lamps are example of devices connected to the Discrete or digital outputs.
Below, the lamp can be turned ON or OFF by the PLC output it is connected to.

OUT

PLC
Lamp
Digital
Output
Module
 Analog Output
An analog output is an output signal that has a continuous signal. Typical outputs
may vary from 0 to 20mA, 4 to 20mA or 0 to10V.

Electric to pneumatic transducer

OUT
E Supply air
PLC 0 to 10V P

Analog
Output Pneumatic control valve
Module

53
PROGRAMMING

Normally Open Normally Closed

(NO) (NC)

Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.

54
Coils

Coils represent relays that are energized when power flows to

them. When a coil is energized it causes a corresponding
output to turn on by changing the state of the status bit controlling
the output to 1. That same output status bit maybe used to control
normally open or normally closed contact anywhere in the program.

55
Boxes

Boxes represent various instructions or functions that are

Executed when power flows to the box. Some of these
Functions are timers, counters and math operations.

56
 AND OPERATION

A B C
Rung

Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).

57
 OR OPERATION

A C
Rung

In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).
 NOT OPERATION

A C
Rung

In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.
As an example, consider a system where there has to be no output when any one of
four sensors gives an output, otherwise there is to be an output. One way we could
write a program for this is for each sensor to have contacts that are normally closed
so there is an output. When there is an input to the sensor the contacts open and the
output stops. We have an AND logic situation. Figure 9 shows the ladder diagram of
a system that might be used.
Input Input Input Input Output
X400 X401 X402 X403 Y430

1 2 3 4
Sensors
END

Figure 9. Output switched off by any one of four sensors being activated
Areas of Application
 Manufacturing / Machining

 Food / Beverage

 Metals

 Power

 Mining

 Petrochemical / Chemical
Manufacturers (Leading Brands) Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi