Programmable

Logic Controller
(PLC)

Prepared by:
Mohd Azhar B Ibrahim
Petrochemical Engineering Department
Tun syed Nasir Syed Ismail
Polytechnic,Johor
What does PLC mean?

A PLC  is an industrial

computer used to monitor
inputs and the decisions
are made based on its
program or logic, to
control (turn on/off) its
outputs to automate a
machine or a process

Mohd Azhar Ibrahim

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Definition of PLC

According to The National Electrical Manufacturers Association

(NEMA), a programmable logic controller is defined 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 analog input/output modules,
various types of machines or processes.”

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Advantages of PLC control

Increased reliability- Once the program has been written and tested, it
can be easily downloaded to other PLCs. Since all the logic is
contained in the PLC’s memory, there is no chance of making logic
error. The program takes the place of much of the external wiring that
would normally be required for control of the process. Hardwiring,
though still required to connect field devices, is less intensive. PLCs
also offer the reliability associated with solid-state components.

More flexibility- It is easier to create and change a program in a PLC

than to wire and rewire a relay circuit. Original equipment
manufacturers can provide system update by simply sending out a
new program. End user can easily modify the program in the field.
 Advantages of PLC control

Lower cost - PLC was originally designed to replace relay control

logic, and the cost savings have been so significant that relay
control is becoming obsolete except for power applications.
Generally, if an application has been more than about a half-dozen
control relays, it will probably be less expensive to install a PLC.

Communication Capability - A PLC can communicate with other

controllers or computer equipment to perform functions as
supervisory control, data acquisition, monitoring devices and
process parameters, and download and upload of programs
 Advantages of PLC control

Faster response time- PLC is designed for high-speed and real-time

applications. The programmable controller operates in real time, which
means that an event taking place in the field will result in the execution
of an operation or output. Machines that process thousand of items per
second and objects that spend only fraction of a second (i.e. turbine
rotation, etc) in front of a sensor require PLC’s quick-response
capability.

Easier to troubleshoot- PLCs have resident diagnostics and override

functions that allow users to easily trace and correct software and
hardware problems. To find and fix problems, users can display the
control program on a monitor and watch it in real time as it executes.

Security- Most of the PLC manufacturer provide different of security to

protect the PLC from being accessed by unauthorized personnel. If
desired, security can be provided by hardware feature such as keylocks
and by software feature such as passwords
 The Elements

Basic structure consists the following elements:

1. CPU
2. Memory
3. Input/Output sections
4. Power supply
5. Programming Devices

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Basic structure of PLC

PLC Unit
Power Supply
Signal
Signal to
from input
Output
devices;
Input/ Output/ Devices;
switches, Center Processing
Signal Signal Motor,
sensors Unit
Module Module conveyer,
etc.
lamp etc.

Memory

Programming
Device

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Basic structure of PLC Siemens S7 1200

 A signal board (SB) Communication modules (CMs)

provides additional I/O for Signal modules (SMs) add and communications processors
your CPU. The SB connects additional functionality to the (CPs) add communication options
on the front of the CPU. CPU. SMs connect to the to the CPU, such as for
 A communication board right side of the CPU. PROFIBUS or RS232 / RS485
(CB) allows you to add  Digital I/O connectivity (for PtP, Modbus or
another communication port  Analog I/O USS), or the AS-i master. A CP
to your CPU.  RTD and thermocouple provides capabilities for other
 A battery board (BB) allows types of communication, such as
you to provide long term to connect the CPU over a GPRS
backup of the realtime clock network.
 The CPU supports up to 3 CMs
or CPs
 Each CM or CP connects to
the left side of the CPU (or
Lorothy to theBuah
Morrison
Electrical Engineering Department
left side of another CM or CP)
Kuching Polytechnic,Sarawak
 The Element cont...
Central Processing Unit, CPU
Under the default configuration, all local digital and analog I/O points are updated
synchronously with the scan cycle using an internal memory area called the process
image. The process image contains a snapshot of the physical inputs and outputs (the
physical I/O points on the CPU, signal board, and signal modules). The CPU performs
the following tasks:

● The CPU writes the outputs from the process image output area to
the physical outputs.
● The CPU reads the physical inputs just prior to the execution of the
user program and stores the input values in the process image input
area. This ensures that these values remain consistent throughout the
execution of the user instructions.
● The CPU executes the logic of the user instructions and updates the
output values in the process image output area instead of writing to
the actual physical output

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Central Processing Unit, CPU
The CPU has three modes of operation: STOP mode,
STARTUP mode, and RUN mode. Status LEDs on the front
of the CPU indicate the current mode of operation.

● In STOP mode, the CPU is not executing the program.

You can download a project.
● In STARTUP mode, the startup OBs (if present) are
executed once. Interrupt events are not processed during
the startup mode.
● In RUN mode, the program cycle OBs are executed
repeatedly. Interrupt events can occur and be processed at
any point within the RUN mode
Central Processing Unit, CPU
The system guarantees that the scan cycle will be completed in a
time period called the maximum cycle time; otherwise a time error
event is generated.
● Each scan cycle begins by retrieving the current values of the
digital and analog outputs from the process image and then writing
them to the physical outputs of the CPU, SB, and SM modules
configured for automatic I/O update (default configuration).
● The scan cycle continues by reading the current values of the
digital and analog inputs from the CPU, SB, and SMs configured for
automatic I/O update (default configuration), and then writing these
values to the process image.
● After reading the inputs, the user program is executed from the
first instruction through the end instruction. This includes all the
program cycle OBs plus all their associated FCs and FBs.
 Memory
The CPU provides the following memory areas to store the user
program, data, and configuration:
● Load memory is non-volatile storage for the user program, data
and configuration. When a project is downloaded to the CPU, it is
first stored in the Load memory area. This area is located either in
a memory card (if present) or in the CPU. This non-volatile
memory area is maintained through a power loss. The memory
card supports a larger storage space than that built-in to the CPU.

● Work memory is volatile storage for some elements of the user

project while executing the user program. The CPU copies some
elements of the project from load memory into work memory. This
volatile area is lost when power is removed, and is restored by the
CPU when power is restored.
● Retentive memory is non-volatile storage for a limited quantity
of work memory values. The retentive memory area is used to
store the values of selected user memory locations during power
loss. When a power down or power loss occurs, the CPU restores
Lorothy Morrison Buah
Electrical Engineering Department
these retentive values upon power up. Kuching Polytechnic,Sarawak
 The Element cont...
Memory

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 The Element cont...

Power Supply

Most PLC controllers works at 24 Vdc.

Some PLC controllers have electrical supply

as a separate module, while small and
medium series already contain the supply
module.

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Siemens S7 System
Requirement
 The Element cont...

I/O Sections

Input devices such as Sensors & Switches

Push button Proximity sensor

Limit switch

Lorothy Morrison Buah

Level sensor Flow sensor Electrical Engineering Department
Kuching Polytechnic,Sarawak
 The Element cont...

I/O Sections
Output devices such as Indicator lamps, Buzzer, Motors

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
SIEMENS S7 PLC Operation
Concepts
 Example of IO List in Industry..

IO LIST
Existing Tag Description        
           
    DO DI AO AI
RM1D AGITATOR(REACTOR D) x      
SSV7D VALVE(SST7 TO SWT1) x      
Jacket Heating/Cooling Control
TCV-IFS(C) valves     x  

LI_14D IMT Level SWITCH   x    

 The Element cont...

Programming Devices

The programming device is used to enter

the required program into the memory of
the processor.

The programming devices:

• Programming Console
• Personal Computer

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 PLC Operation

Internal Utility Relays

- Do not receive signals from the outside world.
- Do not physically exist.
- Simulated relays; enables a PLC to eliminate external relays.

Counters
- Do not physically exist.
- Simulated counters; can be programmed to count pulses.
- Counters can be count up, down or both up and down.

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 PLC Operation cont...

Timers
- Many varieties and increments.
- Most common type is an on-delay type.

Data Storage
Registers assigned to store data when the power is
removed from the PLC.

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 PLC Brand in Industry

 Allan Bradley
 Siemens S7
 Yokogawa
 Toshiba
 Emerson
 PLC
Programming
Session

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 PLC Programming

Ladder Diagram power rails

-consists of two
vertical lines (+) (-)
representing the I0.0 Q1.0
power rails.
I0.1
-Circuits are
I0.1 1001
connected as
horizontal lines
between these two END
verticals.

data

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 PLC Programming...

Ladder diagram features

- Power flows from left to right.

- Contact can not be placed on the right of output.
- Each rung contains one output at least.
- A particular input/output can appear in more than one
rung of a ladder.
- The inputs/outputs are all identified by their addresses,
the notation used depending on the PLC manufacturer

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Symbols of Ladder Diagram

Normally-opened
input

Normally-closed
input

Output

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Connection in Ladder Diagram

AND : Series
connection

OR : Parallel
connection

NOT : Normally-closed
input

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Connection in Ladder Diagram
A B

OR LD : Combines two parallel

C D
groups of conditions

A B

AND LD : Combines two group of

conditions in series.
C D
Examples of
Ladder
Diagram

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Examples

Construct a Ladder Diagram for the following circuits:

i. ii.
L1
S1 S2 L1
S1 S2

24V 24V
Answer……

i. ii.

S1 L1
S1 S2 L1

S2
END
END

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Exercise 1……

1 Develop a program that will cause

output D to go true when switch A
and switch B are closed or when switch
C is closed.

2 Develop a program that will cause

output D to be on when push button A
is on, or either B or C are on.
Answer :
1 A B D A
2 D

B C

C
B C
 Exercise 2……

1 Construct a ladder diagram for the following

problem.
i) there are three buttons A, B, C.
ii) the output is on if any two buttons are pushed.
iii) if C is pressed the output will always turn on.

Answer should consist of truth table , equation

and ladder diagram
Answer :

A B C L L = C+(A.B)
0 0 0 0
A B L
0 0 1 1
0 1 0 0
0 1 1 1
1 0 0 0 C
1 0 1 1
Ladder diagram
1 1 0 1
1 1 1 1
Mnemonic
Code

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 Statement List

Statement List Operations

• Statement list is a
programming language * LOAD (LD) instruction
used in PLC known as
Mnemonic Code. * AND instruction
* OR instruction

• A statement is an * Output ( OUT) instruction

instruction or a directive * END (FUN) instruction
for the PLC.
* NOT instruction
* AND LD instruction
* OR LD instruction

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
 I/O Data

Input Data Output Data

0000 ~ 0011
{
1000 ~ 1007

{
1st digit 3rd & 4th 1st digit 3rd & 4th
is ‘0’ to digits is ‘1’ to digits
represents represent represents represent
input data input bit on output output bit
the PLC data on the PLC
2nd digit 2nd digit
represents represents
channel channel

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
PLC Model - CPM 2A

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Programming
Console

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Ladder Diagram to Mn
emonic Code Conversi
on examples

Lorothy Morrison Buah

Electrical Engineering Department
Kuching Polytechnic,Sarawak
Convert the ladder diagrams given below to its
equivalent mnemonic codes.

0000 1000
01001

0001

0002
Answer……..

Address Instruction Data

00000 LD 0000

00001 OR 0001

00002 OR 0002

00003 OUT 1000

00004 END(01)
Convert the ladder diagrams given below to its
equivalent mnemonic codes.

0000 0001 1000

0002 0003
Answer……..

Address Instruction Data

00000 LD 0000

00001 OR 0002

00002 LD 0001

00003 OR NOT 0003

0004 AND LD -

0005 OUT 1000

00006 END(01)
 Exercise……

Convert the ladder diagrams given below to its

equivalent mnemonic codes.

0000 0001 0002 0003

01000
1000

0004

0005
 Answer…..

Address Instruction Data

00000 LD 0000

00001 AND NOT 0001

00002 LD 0002

00003 AND 0003

00004 OR 0004

00005 OR 0005

00006 AND LD ---

00007 OUT 1000

00008 END(01)
 Exercise……

Convert the ladder diagrams given below to its

equivalent mnemonic codes.
1000
0000 0004
01000

0001 1001
01000

0002
01000

0005 1002

0003
 Answer……

Address Instruction Data

00000 LD 0000

00001 OR 0001

00002 OR 0002

00003 OR 0003

00004 AND 0004

00005 OUT 1000

00006 OUT 1001

00007 AND 0004

00008 OUT 1003

Convert the ladder diagrams given below to its
equivalent mnemonic codes.

1 2

3
 Answer……

Addre Instructio Data

Addre Instructio Data Addres Instruction Data
1 2 ss n 3
ss n s
00000 LD X0 00000 LD X0
00000 LD X0
00001 AND X1 00001 LD X1
00001 AND X1
00002 LD X2 00002 OR X2
00002 LD X2
00003 OR X3 00003 AND LOAD -
00003 OR X3
00004 AND - 00004 LD X3
00004 AND X4
LOAD
00005 OR LOAD - 00005 AND X4
00005 AND X4
00006 AND X5 00006 LD X5
00006 OUT 1000
00007 OUT 1000 00007 AND X6
00008 OR LOAD -
00009 OR X7
00010 AND LOAD -
00011 OUT 1000
 Exercise question

1. Convert the ladder diagram to mnemonic code

2. Convert the mnemonic code to ladder diagram

3. Light control system using 1 input and 2 outputs; when the PLC
program is RUN, L2 will turn on first. When S1 is switched to on,
L1 will turn on hence L2 will turn off.
SET & RESET
TIMER
1. Condition : When the Push button, PB1 is on after delay for 5 seconds
L1
will turn on. PB2 is used to reset the timer. (Timer instruction as
ON-
Delay circuit)
2. When PB1 is on, L1 will on after delay for 5 seconds. Upon L1 on, Timer 2 will also
on, delay for 5 seconds. The normally closed contact (use TIM 2 data) is to reset
Timer 1 and the output will be off. When L1 off, the Timer 2 will also off hence
activate the normally closed contact after delay for 5 seconds and the L1 will be on
again. The process is continuous until PB1 is off.
COUNTER
Condition: Figure below is a Packaging Control System where 5 tinned
foods be packed in a box. Sensor 1(SE1) is used to sense the presence of a tin
on a running Tin conveyor. When SE1 is On, a counter used in the system will
start to count. Upon 5 counts, the Tin Conveyor controlled by Motor 1 (M1) will
stop. The Push button is used to reset the counter.

Push button (PB) (SE1) Sensor 1 (SE1)

Tin Conveyor

Motor 1 (M1)
Pilot Lamp (L1)

Box Conveyor
Motor 2 (M2)
Make some changes to practical A so that when conveyor (M1) stops,
delays for 5 seconds then the box conveyor (M2) moves. When M2
moves, the Pilot Lamp turns On to indicate the Box Conveyor is
moving. When the Push button is pressed, the counter will be reset.

Push button (PB) (SE1) Sensor 1 (SE1)

Tin Conveyor

Motor 1 (M1)
Pilot Lamp (L1)

Box Conveyor
Motor 2 (M2)
 EXERCISE

When input push button 0000 is being pressed 5 times, then the output
01000 will turn ON. When output 01000 is ON, TIM 001 will activate and
after 3 seconds, output 01001 will trun OFF. Use input 00001 as the reset
button

construct a ladder diagram that will sound a buzzer

after 15 seconds by using latching circuit

The light will turn ON after the switch 1 is pressed 5 times. It will turn
OFF after time delay of 5 seconds and switch 2 will deactivate all system
operation”. Construct a ladder diagram from the statement above
The oven is heated by an electrical heater, and in the side there are
ventilation motors to cool the oven after use.Here is a simplification of how the
cooling PLC program should work:
1.HEATING ON:
Heating element and cooling fans turn on.
2.HEATING OFF:
Heating element off and off delay timer starts counting down.
3.TIMER DONE:
Cooling fans turn off.
The electrical heater and the cooling fans should turn on simultaneously.
Why the cooling fans has to turn on too, is to circulate the hot air and
spread the heat
START1 OR MOTOR1 AND NOT STOP1 AND NOT MOTOR2
Motor 1 (active)
START2 OR MOTOR2 AND NOT STOP2 AND NOT MOTOR1
Motor 2 (active)
Paint spraying system where boxes are fed by
gravity through a feeder magazine one at a time
onto a moving conveyor belt. Upon the start
signal, boxes are pushed towards the conveyor
by valve
1.This is a cylinder which extends and retracts
which operates switches S1 and S2 respectfully.
A spraying nozzle paints each box as it passes
under the paint spray controlled by valve
2. A sensor (S3) counts each box being sprayed.
When 6 boxes have been painted the valve 2
shuts off (paint spray) and valve 1 (cylinder)
stops moving boxes onto the conveyor. Three
seconds later the conveyor stops moving and
the hopper with its load moves forward (valve 3)
where it is emptied. Ten seconds later the
hopper returns to the original position. The cycle
is then complete and waits for a start signal
again.
A normally open start and normally closed
stop pushbuttons are used to start and stop
the process. When the start button is
pressed, solenoid A energizes to start filling
the tank. As the tank fills, the empty level
sensor switch closes. When the tank is full,
the full level sensor switch closes. Solenoid
A is de-energized. Mixer motor starts and
runs for 3 minutes to mix the liquid.  When
the agitate motor stops, solenoid B is
energized to empty the tank. When the
tank is completely empty, the empty sensor
switch opens to de-energize solenoid B.
The start button is pressed to repeat the
sequence.