UNIT IV

PROGRAMMABLE LOGIC CONTROLLER

 PROGRAMMABLE LOGIC CONTROLLER
(PLC)
• Introduction
• Basic structure
• Input and output processing
• Programming
• Mnemonics
• Timers, counters and internal relays
• Data handling
• Selection of PLC.
 Introduction
• A Programmable Logic Controller (PLC) is a digital computer used for
automation of industrial electromechanical processes, such as control of
Machinery on factory assembly lines, amusement rides, or light fixtures.

• The PLCs find vast applications in the control and operation of Automated
Manufacturing Process Equipment and Machinery, Packaging and Filling
equipment,
Chemical Mixing,
Conveyor systems and
Distillation etc
 Features of PLC
The PLCs has following features and specific which distinguish from
computers.
• They are rugged and designed to withstand vibrations, temperature,
humidity and noise.
• The interfacing for inputs and outputs is inside the controller.
• They are easily programmed and have an easily understood
programming language.
• Programming is primarily concerned with logic and switching operations.
• They can be designed with communication capabilities that allow them to
interface with a computer system.
Consider a hardwired circuit used for a simple application consisting of two
independent switches and motor

• Logic-1, when the switch is

ON; Motor 1 is ON otherwise
OFF.

• Logic-2, introduce more

complex logic i.e., Motor 2
should be OFF when the
Motor I is switched ON.
• To implement such a complex logic we need use a controller circuit to control the
switches.

• Hence the switcher are not connected directly to the Motors, instead of that the
switches are connected to the input modules and logic module are connected to the
output modules.
 Basic structure of PLC
The structure of PLC is based on the principles of computer architecture, its
capable of performing other functions such as counting logistics, numerical
applications, comparing and processing of signals
PLC

PLC can be divided into four

parts.
• Input/output module (I/O)
• Central Processing unit
(CPU)
• Memory
• Programming unit
 Input/output Module
• Input/output Module are used to transfer data between external devices and
CPU.
• The input and output modules are normally incorporated into PLC in two
ways.
I) Fixed I/O
It is a small unit that comes in one piece with processor
i.e., the I/O terminals cannot be changed in fixed I/O.
ii) Modular I/O
lt is packed together
i.e., there are several compartments of I/O Modules are plugged together.
 Cont.

• Input Module ensures a usable signal is available for the CPU circuit
protection capabilities will also be necessary in the module to protect the
CPU circuitry from faults, surges or spikes in the incoming signal.

• The output module reads digital signals transmitted from the CPU, and
operates motor starters. Solenoids and status monitors.
 Cont.
• The module essentially functions as a switching device and provides on-off
signals to the associated devices.

• If the output module is incapable of handling the power needed by the

device, it sends a signal to an external relay, which connects with the actual
power circuit

• Input and Output devices are placed outside the PLC, with connecting
wires attached to the terminal strips on the PLC.
 Central Processing Unit (CPU)
• The CPU is the brain of the PLC, consisting of a microprocessor which
interprets the input signals and carries out the control actions according to
the program stored in the memory, communicating the decision as an
action signal to the outputs.

• It forms the core portion of the PLC. The microprocessor based unit
contains the logic and control algorithm for the controller.

• The CPU scans the total information package stored in the memory and the
input and output devices continuously.
 Cont.

• During the scan the CPU also executes instruction based on input data,
sends appropriate output responses to the output devices, updates data
acquisition systems, and indicates condition changes

• Smaller PLC has longer scan times than larger units and has less memory
and reduced capacity for special instructions and peripheral equipment.

• The power supply unit is needed to convert the AC voltage to the low
DC voltage necessary for the processor and to supply power to other
circuits in the input and output interface module.
 Memory Unit

• 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
input for processing and for the output.

• The memory in PLC stores the digital control logic, the process program and
the necessary instruction to operate the system. It stored in units called “byte”.

• The memory used in PLC is

I) Non-volatile Memory — The memory may retain the information even the
power is turned off.
ii) Volatile Memory - The memory may lose the information when the
electrical power is turned off.
 Cont.
According to the purpose of usage, there are two main memory types.
i) RAM (Random Access Memory) –
It is used for program and data storage. For this we need to provide a battery
backup in order to prevent loss of any data when power is removed. It is a
volatile memory.

ii) ROM (Read Only Memory) –

ROM memory cells store information permanently, and it is used to store the
operating program of the computer to permit easy startup. It is permanent
storage hence called as non-volatile memory.
 Programming Unit
• The programming unit 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.

• Programming device also enters the required program using ladder logic
into the memory of the processor.
 Cont.

• The sequence of operation and ultimate control of equipment machinery is

specified and determined by the ladder program.

• While entering the ladder program, the program device is normally

connected to the controller. Actual programming is usually achieved by
pushing keys or a keyboard and can be programmed by people without
much computer programming experience.
 Architecture of PLC
• The internal logic design of the system is known as architecture. It
determines the various operations performed by the system.
• The PLCs are programmed to sense, activate and control machines and
equipment and incorporate a large number of internal hardware and
software, normally referred as internal architecture.
Architecture of PLC
 Architecture of PLC
• The internal logic design of the system is known as architecture.

• It determines the various operations performed by the system.

• The PLCs are programmed to sense, activate and control machines and
equipment and incorporate a large number of internal hardware and
software, normally referred as internal architecture.
 PLC
• A PLC consists of the following elements.
• CPU (Central Processing Unit)
• Memory
• I/O Processing devices
 CPU (Central Processing Unit)

In general the CPU consists of,

• a) An Arithmetic and Logical Unit (ALU) which is responsible for data
manipulation and carrying out arithmetic operations like addition and
subtraction and logical operation like AND, OR, NOT and EX-OR etc.

• b) Memory termed registers, located within the processor and used to store
information involves in program execution.

• c) A control unit which is used to control the timing of operations and

control the units within the processor to ensure that operations are carried
out in the correct order
 Function of CPU
• The function of CPU is to control and process all the operations of memory and I/O
data in the system in accordance with the program.

• The CPU also holds the communication circuits and power supply.

• The CPU executes the operating system, manages memory, monitors inputs,
evaluates the user logic and turns gives appropriate outputs.

• In order to do this, the PLC is provided with a signal to sequence its internal
operations.
 Buses
The internal paths used for communication within PLC are called Buses.
These buses essentially carry the information in the digital forms.
There are four types of buses required in a PLC.
• I) Data Buses - It is used for communicating data between elements.
• ii) Address Buses - It is used to read the address of locations for accessing
stored data.
• Iii) Control buses – It is used for internal control actions carried by the
CPU. (Ex. To inform memory devices whether they are to receive data
from an input or output data.
• Iv) System Buses – It is used for communication between the input/output
ports and the input/output unit
 Memory
• Memory devices are where the program are started in the controller or
some groups of binary digits of 1s and Os stored in the form of bytes at
individual locations identified by their addressed.
• The memory of a PLC is divided into many’ Sections based Specific
functions.
• Memory elements in PLC system
• 1. RAM (Random Access Memory)
• 2. ROM (Read Only Memory)
 Input and Output Devices

• The input/output unit provides the interface between the system and the
outside world.

• I/O unit allowing connections to be made through input/output channels to

input devices such as sensors and output devices such as motors and
solenoids.

• Every input/output point has a unique address which can by the CPU.

• The input/output channels also provide isolation and signal conditioning

functions so that sensors and actuators can often by directly connect to
them without the need for other circuitry.
Programming
• The programming of PLC is based
on the “Ladder Diagram”. Ladder
diagram involves writing a
program in a similar manner to
drawing a switching circuit
• The symbols used in ladder
diagram are known as ladder
symbols. Some of basic symbols
used in ladder diagram are given
below.
 Cont.
• The Ladder diagram consists of two vertical lines representing the power
rails and circuits are connected as horizontal lines
i.e., the rungs of the ladder between these two vertical lines.

• In drawing the circuit line for a rung, input must always proceed output
and there must be at least one output on each line.

• Each rung must start with an input or a series of inputs and end with an
output.

• The inputs and outputs arc numbered, the notation used depending on the
PLL manufacturing.
Example To illustrate the concepts of ladder diagram. Consider the
following logic.

The two vertical lines are called power rails

Inputs and outputs are connected in horizontal line.

Hence the ladder diagram describes the output A occurs when the input 1 occurs.
 Cont.

The ladder diagram describes the output A occurs when both the inputs 1 and
2 occurs.
 Cont.

The ladder diagram describes the output A when input 1 or input 2 occurs.
 Logic function
• AND Function
• OR Function
• NOT Function
• NOR Function
• NAND Function
 Mnemonics
• Each horizontal rung on the ladder in a ladder program represented a line
in the program and the entire ladder gives the complete program in
“Ladder Language”.

• The programmer can enter the program into the PLC using a keyboard
with the graphic symbols for the ladder elements, and mouse is used to
select symbols and the computer translates these symbols into machine
language than can be stored in the PLC memory.
 Cont.
• There is an alternative way of entering a program and that is to translate
the ladder program into mnemonics,

• each code corresponding to ladder element, and then enter these into the
programming panel or computer.

• These are then translated into machine language.

• The mnemonics used by different PLC manufactures differs

List of Mnemonics
 Cont.
• Mnemonics forms the instruction; the list of instruction forms the program of
the specific functions.

• Instruction lists consists of a series of instruction with each instruction being

on a separate line.

• An instruction consists of an operator followed by one or more operands i.e..

the subjects of the operator

• Example: LD A
• LD is the mnemonics
• i.e., operator for loading, the operand A.
Individual rungs on a ladder are entered using the
mnemonics
Cont.
Cont.
Cont.
 Timers
• A Timer circuit is specified by starting the interval to be timed and the
conditions or events that are to start and/or stop the timer.

• They are commonly regarded as relays with coils which, when energized,
result in the closing or opening of input contacts after some preset timer.
 Counters
• Counters are used when there is a need to
count a specified number of contact operations.

• Example: Where items pass along a conveyor

into boxes, and when the specified number of
items has passed into a box and next item is
divided into another box.
•
 Counter

In most cases, the counter operates as a down counter.

This means that the counter counts down from the present values to zero. i.e., events
are subtracted from the set value. When zero is reached the counter’s contact
changes state.

An up-counter would count up to the present value, i.e., events are added until the
number reaches the set value. When the set value is reached the counter’s contact
changes state.
Sequencing
 SELECTION OF PLC
• In general, PLC are considering the size and type required for particular
tasks that need to be considered are,
• Input/output capacity required
• Types of Inputs/output required
• Size of memory required
• Speed and power of CPU
 Cont.
The following aspect considered, depending on the requirements of the specific
application.
1. System definition
2. Choosing the I/O hardware
3. I/O timing consideration
4. Analog I/O module
5. Conversion speed
6. Analog closed control
7. counters, encoders and positioning
8. Communications
9. Choosing the correct processor
10. Selecting suppliers